EN - 828D Service 0408 - 2019-03

SINUMERIK 828D
Service Documentation
Sinumerik 828D
Edition 2019.03
Training Manual
This document was produced for training purposes.

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

Turning and Milling machines
Valid for:
Sinumerik 828D Software 4.8

Start
Machine Test
Contents
Protocol
B002
B060 B061
Service &
System Menu
Commissioning
Overview Structure
Tools B021
Access Levels/
Time and Date
Settings
B041
Machine and
Setting Data
B044 B038
B007
Licensing and Network and
Electronic
Option Operator
Logbook
Management Panels
B017
Data
Management
B010
NC
Connections &
Diagnostics
B030 B051 B053
Digital Inputs & Line and Motor Axis and Drive
Outputs Modules Diagnostics
B084
Encoder
Adjustments
B008
MCP & PP72/48
PN Connec-
tions and
B033 B019 B026 Diagnostics
PLC S7-200 PLC Creating a PLC
Functions Instructions Program
B037
Alarm
Structure
B031
Alarms and
Messages
B058 B035
B009
PLC Onboard Program
Easy Extend
Diagnostics Handling
B011
Run
MyScreens
B020
Maintenance
Planner
Appendix B Appendix A B029
Technology Hardware Analogue
Settings Differences Spindle
Appendix C
PLC Interface
End
SIEMENS TEST PROTOCOL
Machine Test Protocol Sinumerik 828D
Product / Version Company:
Address:
Sinumerik 828D SW4.8
Machine Range Machine Type - Features Spindle Config. MLFB KW Axis Conf MLFB N/M
Electrical Cabinet Protocol attached
Filename of Cabinet protocol
Distribution list
Name Company / e-mail Name Company / e-mail
Department Department
Title

Document no. Date
File name:
Protocol version 1.2
Copyright © Siemens AG 2016 All Rights Reserved.

Contents
1 RESPONSIBLE PERSONS: ................................................................................................................................................................................ 4
1.1 Schedule ..................................................................................................................................................................................................................................................................................... 4
1.2 Participants carrying-out the test ............................................................................................................................................................................................................................................ 4
2 SUMMARY AND RESULT ................................................................................................................................................................................... 5
2.1 Summary .................................................................................................................................................................................................................................................................................... 5
2.2 Result ......................................................................................................................................................................................................................................................................................... 5

2.2.1 Exception List ..................................................................................................................................................................................................................................................................... 5
2.3 Release Siemens ......................................................................................................................................................................................................................................................................... 5
2.4 Release from Machine Tool Builder ........................................................................................................................................................................................................................................ 5
3 BACK UP ............................................................................................................................................................................................................. 6
3.1 Modified data ............................................................................................................................................................................................................................................................................ 6
3.2 Data Backup .............................................................................................................................................................................................................................................................................. 6
4 CHANGE LOG ..................................................................................................................................................................................................... 7
4.1 Changes to the machine. ........................................................................................................................................................................................................................................................... 7
5 SYSTEM DESCRIPTION ..................................................................................................................................................................................... 8
5.1 Machine ..................................................................................................................................................................................................................................................................................... 8
5.2 Control ....................................................................................................................................................................................................................................................................................... 8

Doc-Nr Page 2/32 Protocol version 1.2

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

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

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

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

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

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

8.6.1 Securing data areas ........................................................................................................................................................................................................................................................... 30

1 Responsible persons:
1.1 Schedule
Test carried out at (OEM Name):
From:
To:
1.2 Participants carrying-out the test
Name Company / Department

2 Summary and result

2.1 Summary
2.2 Result
Release of the machine recommended (YES/NO/Reason): ___________
2.2.1 Exception List

The machine has been released for sale with the following exceptions:
Function: Test Number Remark
2.3 Release Siemens

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

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

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

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

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

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

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

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

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

Test . Function Result / Accepted/To Do

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

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

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

T+M Additional equipment requiring

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

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

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

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

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

8.1.2 Jog → MCP
relevant
T+M If the axis is resting on the
Hardware limit switch, it should
1 be possible to JOG the axis
away in the opposite direction.
T+M It should be possible in the

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

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

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

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

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

T+M The machine builder should also

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

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

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

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

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

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

T+M WCS >><< MCS

With key not pressed (MCS)
the axis should be moved using
the Machine axis interface, and
the axis will move on an
individual basis, without active
rotations.
15
With key pressed (WCS) the
axis should be moved using the
Channel axis interface, and the
axis will move on an individual
basis, with active rotations.
T+M Repos
With interruption in Automatic, it
should be possible to switch to
Jog, move axis away from the
16
contour, subsequently return to
Automatic / Repos and Jog the
axis back to the previous
position.

8.1.3 Jog → HMI Softkeys

Technology Test Description Tested OEM Alternative / or Tested Reason for OEM Alternative To Do
No Comments / not
relevant
T+M T,S,M → T-D
Select a tool from the tool list,
using SK TOOL and IN
MANUAL. Press cycle start tool
should be transferred into the
spindle or positioned before the
work piece.
1 The tool must not rotate if
already present in the spindle or
present before the work piece.
Repeat the process with other
tools from the magazine.
Prior to changing from a driven
tool, the rotating tool should be
stopped prior to changing.
T+M Spindle →
Set a spindle speed and activate
2 "Cycle Start" (together with
spindle M function) Repeat the
procedure with further spindles.
T+M Spindle gear change→
3 Change gear, if a gear box is
available on the machine.
T+M Spindle direction →
Program M3 and M4 on all
spindles which are available on
4
the machine and ensure for the
programmed code that spindle
rotates in the correct direction.

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

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

8.1.4 MDA → Teachin

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

8.1.5 MDA → HMI Softkeys

No Comments / not
relevant
T+M Program Control →
When the PRT checkbox is set
the axis should work internally,
and not physically move the axis.
The signal should work only in
1
Automatic mode - when
changing to Jog/MDA the signal
should not be active except
when an external switch is used.

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

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

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

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

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

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

8.1.6 MDA → MDA → Teachin

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

8.1.7 AUTO
No Comments / not
relevant
T+M Move axis using Hand
wheel/Jog/Inc in the machine
1 axis interface to generate a DRF
offset
OPTION
T+M Jog in Automatic →
Jog Mode Mask is set to 0 as
standard, which means you are
not able to Jog the axis in
Automatic, with the exception of
Teach-in.
2 Jog Mode Mask is set to 1,
means you are able to Jog the
axis in Automatic. The machine
builder should explicitly set this
machine data when he requires
this functionality.
T+M AUTO →
3
Cycle start
T+M AUTO →
4
Cycle Stop
T+M AUTO →
5
Cycle single block
T+M AUTO →
6
Program reset
T+M AUTO →
7
Feed Stop in Program effect
T+M AUTO →
8
Spindle stop in Program - effect
T+M AUTO →
9
Feed override = 0

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

8.2 Parameter
8.2.1 Easy extend

No Comments / not
relevant
T+M Test the commissioning of
1 machine builder options
T+M Test the activation / deactivation

2 of machine builder options
8.2.2 Measure tool

No Comments / not
relevant
T+M Measure the length of the Tool
1
T+M Measure the Diameter / radius of

2 the tool
8.2.3 Setting data

No Comments / not
relevant
T+M Spindle data - minimum spindle
speed should be set to a value
1
not equal to 0

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

2
T+M Rename a tool

3
T+M Disable magazine locations -
4
T+M Test oversize tools

5
T+M Test tools with fixed locations
6
T+M Test interruption scenarios in tool

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

8
program
T+M L6 Optimised, Spindle Tool =
9
Pre-selected Tool

8.2.5 Tool List

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

2 Magazine

3 Buffer
T+M Delete a tool directly in Spindle

4
T+M Delete a tool from the Magazine
5
T+M Delete a tool from the buffer
6
T+M Unload the tool in the spindle

7
T+M Machine with sub-spindle should

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

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

8.3 Geometry
8.3.1 Circularity test HMI

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

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

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

8.5 Startup
8.5.1 Save data

No Comments / not
relevant
Save Data
1

8.6 Password protection
8.6.1 Securing data areas

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

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

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

4
Series machines.
T+M PLC written according to PLC
5
Design document
T+M Country specific safety
regulations included in PLC
6
program + door interlocks
etc.
T+M NCK, HMI, PLC and Drive
7
archives tested.
T+M TGZ file for series production
8
tested
T+M Axis 1 Axis utilisation value in
9
Comments column
10
Comments column
11
Comments column
12
Comments column
13
Comments column
T+M Adaptive Friction
14
compensation active

T+M
15 ESR has been commissioned
T+M
16 ELG has been commissioned

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

This module gives a graphical overview of those components and shows where each component is
connected.
A brief description of the hardware components is given.
Module Objective:
Upon completion of this module you will know the Sinumerik 828D system and the components
which make up the system.
Content:
Sinumerik
System Overview
828D & PPU Information
Machine Control Panels
Drive Components
NX Modules
Drive-CLiQ Hub & Sensor Modules
PLC Periphery Modules
Hand-held Units
SINUMERIK 828D V4.8 Page 1 This document was produced for training purposes.
B060
B060
B060 Page 2 SINUMERIK 828D

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

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

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

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

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

ports X140 Connection
kit
USB 2.0
X145
X125
Sinumerik
828D & PPU
X122
X132 } Sinamics
Digital I/O
X127
X127-Service
(Linux OS) X242
X252 } NCK Digital I/O and
Spindle analogue out
X143
Ethernet Hand-wheels
X100 X101 X102 X130
X130-Factory Ethernet
DMC20
X100 to X102 DriveCLiQ Interface DriveCLiQ
Hub
Teleservice
Modem
Filter
Sinamics S120 NX10/NX15 S120
Booksize
DMS
Scales/encoders
via SMx & DMC
modules
Reactor
Notes :

System Overview 828D Combi
PP72/48 PN PLC I/O
PN/PN USB MCP Profinet MCP
Coupler
To
other
828D
PN1 &
PN2
Profinet
+24V DC Supply Interfaces
Mini
RS232
X1 PN2 PN1 HHU
X135 Interface
Compact Flash Front
X140 Connection
ports
}
X145 Sinumerik X122 Sinamics kit
USB 2.0 828D & PPU X132 Digital I/O
X125
X127
X127-Service
(Linux OS) X242
X252 } NCK Digital I/O and
Spindle analogue out
X143
Ethernet Hand-wheels
X100 X101 X102 X130
X130-Factory Ethernet
X100 to X102 DriveCLiQ Interfaces
DMC20
DriveCLiQ
Teleservice Hub
Modem
Sinamics
Filter Combi Two additional
DMS-TTL 5V Module axes-S120
Direct to Combi (3/4 axes) single/double
compact
modules
DMS
Scales/encoders
via SMx & DMC
Max 5 circuits
Reactor
Notes :

828D & PPU Information
828D Basic (PPU24x) controller with integrated PPU (Panel Processing Unit):
PPU240:
Vertical variant.
8.4” TFT colour
screen. PPU241:
Horizontal variant.
8.4” TFT colour screen.
828D (PPu26x) and 828D (PPU28x) controllers with integrated PPU (Panel Processing Unit):
PPU260/280:
Vertical variant.
10.4” TFT colour
screen. PPU261/281:
Horizontal variant.
Notes :

828D (PPU27x) controllers with integrated PPU (Panel Processing Unit):
PPU270:
Vertical variant.
10.4” TFT colour PPU271:
screen. Horizontal variant.
Proximity
sensors for
display control
828D (PPU290.x:) controller:
PPU290.x vertical variant.

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

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

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

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

PPU Horizontal layout: 6FC5833-1GY40-4YA0 828D SW 28x
6FC5836-1GY40-4YA0 828D SW 28xA
6FC5370-3AA30-0AA1 PPU241.3 828D Basic
6FC5370-7AA30-0AA1 PPU281.3 828D
Blank Compact Flash Card 2GB:
PPU Vertical layout:
6FC5313-5AG00-0AA2
6FC5370-4AA30-0AA1 PPU240.3 828D Basic
6FC5370-8AA30-0AA1 PPU280.3 828D
6FC5370-8AA30-0BA0 PPU290.3 828D (15”)
General Information PPU2xx.4 Software- (Current system software delivered on CF card):
Hardware Part Numbers: Part Numbers for PPU270.4/271.4/290.4:
The PPU model number gives information about the control- Milling 6FC5835-2GY40-5YA0 828D SW (ME421)
ler: 6FC5834-2GY40-5YA0 828D SW (ME621)
6FC5836-2GY40-5YA0 828D SW (ME821)
PPU2xx.4
0 - Vertical Turning 6FC5835-1GY40-5YA0 828D SW (TE421)
1 - Horizontal 6FC5834-1GY40-5YA0 828D SW (TE621)
6FC5836-1GY40-5YA0 828D SW (TE821)
7 - 828D
9 - 828D OP15 Blank Compact Flash Card 2GB:
6FC5313-5AG00-0AA2
PPU Horizontal layout:
6FC5370-5AA40-0AA1 PPU271.4 828D
PPU Vertical layout:
6FC5370-6AA40-0AA1 PPU270.4 828D
6FC5370-8AA40-0BA0 PPU290.4 828D (15”)
Notes :

828D Software/Hardware Compatibility Table PPU2xx.3:
Order Number 828D Technology 828D Basic 828D

Software PPU240.3/241.3 PPU280.3/281.3/290.3
6FC5835-2GY40-4YA0 24x Milling ✓ 
6FC5834-2GY40-4YA0 26x Milling  ✓
6FC5833-2GY40-4YA0 28x Milling  ✓
6FC5836-2GY40-4YA0 28xA (Advanced) Milling  ✓
6FC5835-1GY40-4YA0 24x Turning ✓ 
6FC5834-1GY40-4YA0 26x Turning  ✓
6FC5833-1GY40-4YA0 28x Turning  ✓
6FC5836-1GY40-4YA0 28xA (Advanced) Turning  ✓
828D Software/Hardware Compatibility Table PPU2xx.4:
Order Number 828D Technology 828D 828D

Software PPU270.4/271.4 PPU280290.4
6FC5835-2GY40-5YA0 ME421 (24x) Milling ✓ ✓
6FC5835-1GY40-5YA0 TE421 (24x) Turning ✓ ✓
Notes :

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

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

functionality of the two variants is identical.
Name Colour Description
The PPU includes “Qwerty” and numerical keyboard inputs
and shortcut keys to specific machine areas. RDY Green System ready
The 828D encompasses the HMI, NC, PLC and CU logical
components. NC Orange NC ready (Flashes at approximately
1Hz)
CF Yellow CF card activity
PPU Rear interfaces and Status LEDs (All variants): Name Colour Description
X1-24V DC supply FAULT Red Fault present
X100 to X102 -DriveCLiQ interface SYNC Green Synchronisation OK

Rx/Tx Yellow Network activity (1 each for PN1,
X130-Ethernet factory network-Configurable to receive an IP PN2 & X130 interfaces)
address automatically or a manually assigned fixed address
can be used. Link Green Network connected (1 each for
Do not use addresses in the following ranges: PN1, PN2 & X130 interfaces)
192.168.214.xxx and 192.168.215.xxx. These are reserved for
the system.
X135-USB interface
X100 Fault PN
Sync
X140-RS232 interface System CF-card
X101 Fault PN
Sync
X122 & X132-Digital I/O for Sinamics X130
X102 Rx/Tx
Link
X242 & X252-Digital I/O for NCK X140 X135
X143-Hand-wheels x 2 X122
PN1 & PN2 - Profinet interfaces. (Only PN1 available for X132
PPU240/PPU241) X242
X252
X143
X1
M T1 T2 T3
Notes :

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

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

The following tables highlight the technical specifications of the 828D controller.
Key:-
 In preparation
 Delivered as standard
 Option
- Not available 828D 828D
Basic
828D Software 24x 26x 28x 28xA
Technology (Turning/Milling) T M T M T M T M
System Performance
Number of axes with standard configuration 3 4 3 4 3 4 3 4
Maximum number axes/spindles/positioning axes 5 5 6 6 8 6 10 8
Each additional axis/spindle        
Each additional positioning axis        
Maximum number of interpolating axes 4 4 4 4 4 4 4 4
Maximum number of machining channels 1 1 1 1 1 1 2 1
Minimum block cycle time 9ms 9ms 6ms 6ms 6ms 3ms 6ms 3ms
CNC user memory (buffered) 3MB 3MB 3MB 3MB 5MB 5MB 10MB 10MB
CNC Functions
Tool management with tool life monitoring and workpiece
       
count
Replacement tools        
512/ 512/ 768/ 768/
Maximum number of tools/cutting edges 128/256 128/256 256/512 256/512
1024 1024 1536 1536
Number of settable zero offsets 50 50 100 100 100 100 100 100
Safety Integrated (Safe Torque Off, Safe Brake Control)        
Asynchronous subroutines (ASUP)        
Synchronised actions and high speed auxiliary function
       
output
Acceleration with jerk limitation        
Look Ahead (Number of blocks) 1 >150 1 >300 1 >450 1 >450
Compressor for 3-axis machining -  -  -  - 
Advanced surface -  -  -  - 
A, B, C spline interpolation        
TRANSMIT and peripheral surface transformation        
Travel to fixed stop        
Travel to fixed stop with Force Control        
Inclined axis for no orthogonal Y axis - - - -  -  -
Synchronous spindle function for sub-spindle (CP Static)  -  -  -  -
Synchronous spindle function for sub-spindle (CP Basic)  -  -  -  -
Pair of synchronised gantry axes        
Temperature compensation        
Bidirectional lead-screw error compensation        
Multi-dimensional sag compensation        
Master/slave for drives        
Analysis of internal drive values        
Notes :

828D
828D
Basic
828D Software 24x 26x 28x 28xA
Technology (Turning/Milling) T M T M T M T M
CNC Programming and Operation
Programming language (DIN66025 and high level
       
language expansion)
Online ISO dialect interpreter        
Technology cycles for drilling and milling        
Technology cycles for turning  -  -  -  -
Residual material detection and machining        
Programming support for technology cycles (Program
       
GUIDE)
ShopMill/ShopTurn machining step programming        
Measuring cycles        
Simulation in plane display        
Simulation in 3-D display        
Simultaneous recording (Real-time simulation of cur-        
rent machining operation)
Extended operator functions for complex turning and
       
milling tasks.
Contour hand-wheel        
Network drive management        
Remote diagnosis function RCS host        
PLC Functions
Integrated PLC based on SIMATIC S7-200        
PLC periphery modules PP72/48D, PP72/48D 2/2A
       
PN
Ladder viewer and on board add-on editor        
PLC cycle 9ms 9ms 6ms 6ms 6ms 6ms 6ms 6ms
Maximum number of PLC ladder steps 32,000 32,000 32,000 32,000 32,000 32,000 32,000 32,000
Servo synchronous High Speed PLC Task        
Reaction time to process events (Terminal to terminal) 7,5ms 7,5ms 7,5ms 7,5ms 4,5ms 7,5ms 4,5ms 7,5ms
Maximum number of digital inputs/outputs 216/144 216/144 288/192 288/192 360/240 360/240 360/240 360/240
Maximum number of analogue inputs/outputs 6/6 6/6 8/8 8/8 10/10 10/10 10/10 10/10
PN/PN coupler        
Commissioning and Service Functions
Run MyScreens-easy creation of user screens
       
(Licence for over 5 user screens)
Service Planner for maintenance tasks        
Easy Extend management of machine components        
Easy Archive data archiving        
Notes :

Machine Control Panels
Machine Control Panel MCP310 USB
Part Number: 6FC5303-0AF33-0AA0. The MCP310 is recommended for use with the vertical style PPU.
Part Number:
6FC5303-0AF33-0AA0.
Interfaces:
X10 USB Interface (rear side)
Features:
• 39 membrane keys with LED
Indicators (22 user assignable)
• Feed override control(18 positions)
• Spindle override (15 positions)
• Dual 7-segment display for user specific func-
tions.
• 1 slot for Emergency Stop button
• 4 x Pre-drilled holes for hard wired user but-
tons/switches.
The MCP483 is recommended for use with the horizontal style PPU.
Part Number: Features:

6FC5303-0AF32-0AA0. • 40 membrane keys with LED Indicators (24 user assignable)
Interfaces:
X10 USB Interface (rear side) • Spindle override (15 positions)
• Dual 7-segment display for user specific functions.
• 1 slot for Emergency Stop button
• 2 x Pre-drilled holes for hard wired user buttons.
Notes :

The MCP416 USB 3 is a perfect fit for the SINUMERIK 828D PPU 290.3

6FC5303-0AF34-0AA0 • 40 membrane keys with LED Indicators (24 user assigna-
ble)
Interfaces:
X10 USB Interface (rear side)
• Spindle override (15 positions)
• Dual 7-segment display for user specific functions.
• 1 slot for Emergency Stop button.
• 2 x Pre-drilled holes for hard wired user buttons.
Machine Control Panel MCP310C PN
The MCP310 is recommended for use with the vertical style PPU.
Part Number:
6FC5303-0AF23-0AA1
Features:
• 49 mechanical keys with LED
Indicators (16 user assignable)
• Key switch
• Slot for Emergency stop or Spindle override
• 6 x Pre-drilled holes for hard wired user
buttons
• 1 x Hand-wheel connection
• Connections for 9 user Inputs & 6 outputs
• Connection via Profinet
Consumable items:
Interfaces:-
X10 24V DC supply 6FC5247-0AF13-1AA0-Feed override rotary switch incl. cap,
X20 Profinet Port 1 button, pointer & dials
X21 Profinet Port 2
6FC5247-0AF12-1AA0-Spindle
override rotary switch incl. cap, button, pointer & dials
Notes :

Machine Control Panel MCP483C PN

The MCP483 is recommended for use with the horizontal style PPU.

6FC5303-0AF22-0AA1 • 50 mechanical keys with LED indicators (17 user
assignable)
Consumable items:
6FC5247-0AF13-1AA0-Feed override, rotary switch incl. cap, • Spindle & feed override control.
button, pointer & dials • Key switch
• Emergency stop button
6FC5247-0AF12-1AA0-Spindle override rotary switch incl. • 2 x Pre-drilled holes for hard wired user buttons
cap, button, pointer & dials
• Connection via Ethernet
Interfaces: • 1 x Hand-wheel connection
X10 24V DC supply • Connections for 9 user Inputs & 6 outputs
X20 Profinet port 1 • Connection via Profinet
X21 Profinet port 2
Notes :

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

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

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

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

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

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

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

mined by the software version:
828D Software Maximum no. of PP72/48 modules

X222
24x 3
26x 4
28x - 28xA & 290 5
X2 X2
Port Port Interfaces:
2 1 X333 S1-Adressing switch-Default setting of 9
X1-24V DC Supply
X2-Profinet network ports 1 & 2
X111 digital inputs/outputs-ribbon connector
X1 X222 digital inputs/outputs-ribbon connector (first byte has
fast gating hardware)
X333 digital inputs/outputs- ribbon connector
Input information: The PN/PN coupler is used to link two Profinet networks so
X222, byte 1 - maximum delay time - 600μs. that data can be exchanged between them.
All other inputs, delay time - 0.5 to 3ms.
PP72/48D PN Part numbers:
One coupler is allowed per controller.
6FC5311-0AA00-0AA0 Digital only (PP72/48D PN)
6FC5311-0AA00-1AA0 Digital/analogue (PP72/48 2/2A PN) Part number:
6ES7158-3AD01-0AX0
Interfaces:
PN/PN Coupler X1 Port 1 & 2 Profinet 1 network
X2 Port 1 & 2 Profinet 2 network
PS1 & PS2 +24V DC supply
LEDs
SF1 Group fault for Profinet 1 network (Red)
SF2 Group fault for Profinet 2 network (Red)
BF1 Bus fault for Profinet 1 network (Red)
BF2 Bus fault for Profinet 2 network (Red)
MT1 Maintenance display Profinet 1 network (Yellow)
MT2 Maintenance display Profinet 2 network (Yellow)
ON Power supply +24V DC (Green)
LINK Connection on (Green) One per Profinet connection
RX/TX Data Exchange (Yellow) One per Profinet connection
PN/PN Coupler
Notes :

Drive Components General information
Line Modules Line modules are responsible for generating the DC link sup-
ply for the drive system.
They require 3-phase AC for the DC link and +24V DC for the
electronic supply.
The DC link and 24V DC voltages are distributed to other
drive modules in the system via a bus bar system.
The modules are available in several variants of size and
functionality.
Smart Line Modules (SLM)

These modules are capable of mains regeneration but the DC
link is not stabilised.
SLM modules of 5 & 10 Kw do not connect to the DriveCLiQ
network.
Modules of 16 Kw and above do connect to the DriveCLiQ.
Active Line Modules (ALM)

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

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

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

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

Motor Modules (MM) S120 Book-sized Compact
The S120 book sized compact motor modules are use to ex-
pand the number of drives the Sinamics Combi drive system
to the maximum of 6.
The modules are only available with internal cooling.
Interfaces:
Single MM
X1-Output to Motor.
X21-Enable & temperature sensor input .
X200, X201, X202-DriveCliq connections.
Double MM
X1 & X2-Output to Motors.
X200, X201, X202, X203-DriveCliq connections.
Part Numbers- Single Modules

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

6SL3420-2TE11-7AA1 2 x 1.7/5.1 Amps
6SL3420-2TE13-0AA1 2 x 3/9 Amps
6SL3420-2TE15-0AA1 2 x 5/15 Amps
Combi Drive (Combined Line and Motor Modules)
The Combi drive unit consists of a Line Module and either 3 or 4 Motor Mod-
ules, the first of which is dedicated to the Spindle.
They must always be connected to the DriveCLiQ network via controller inter-
face X100.
The number of axes can be increased by adding Sinamics S120 Book sized
Compact Motor Modules up to the maximum allowed by the system.
Part Numbers and Power ratings
Smart Line Spindle Axis 1 Axis 2 Axis 3

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

Braking Modules & Resistors
If the regenerative capability of the line module is inadequate it

can be supplemented by the inclusion of a braking module.
These modules fit neatly into the drive system.
Further braking capacity can be added in the form of braking
resistors which connect to the braking module. Braking resis-
tors require good ventilation and ideally need to be mounted
externally.
Braking modules and resistors can also facilitate the controlled

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

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

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

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

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

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

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

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

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

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

coder signals into DriveCLiQ signals.
They are available for cabinet mounting (SMC) and external
mounting (SME).
Several variants of each are available:
SMC20
For the evaluation of the following measuring systems:-
Incremental sin/cos 1v pp
Absolute EnDat encoders
SSI with incremental signals Sin/Cos 1V pp
(Temperature evaluation-KTY84-130 can also be used)
Interfaces:-
• X500 DriveCLiQ
• X520 Measuring system input (25 pin D-type connector)
• Status LED
Part Number:-
6SL3055-0AA00-5BA3
SMC30 SMC30
For the evaluation of the following measuring systems:

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

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

SMC40 SMC40
SMC40 only supports measuring systems with the EnDat 2.2

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

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

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

for connection of the mini HHU.
Part numbers:- Using the USB machine control panel:

6FX2007-1AD03 Mini HHU with coiled cable, 1.5m (4.92 ft)
stretches to 3.5m (11.5 ft). When using a MCP 483 USB or MCP 310 USB or MCP 416
USB, the mini handheld unit is either connected via the MCP
6FX2007-1AD13 Mini HHU with straight cable, 5m (16.4 ft). Interface PN or a PP72/48D PN (PP72/48D 2/2A PN) I/O mo-
dule.
6FX2006-1BG03 Non assembled connection kit with termina-
tor.
6FX2006-1BG20 Pre assembled connection kit with termina-

tor.
6FX2006-1BG70 Holding cradle
B060: END
Notes :

B060 END System Overview
Notes :

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

• Configuration Data (rescue card image, examples e.g. for Easy Extend)
• Access MyMachine allows a remote operation between the 828D controller and a computer
running windows, but is also required for certain commissioning/service procedures.
Module Objective:
Upon completion of this module the course participant will be able to do the following:
• Install the software tools from the toolbox DVD.

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

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

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

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

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

Network Settings
X127 is a DHCP server with a fixed IP address of

192.168.215.1 and subnet mask of 255.255.255.224
IP addresses from 192.168.215.2 to 192.168.215.31 are au-
tomatically issued to any PC connected to X127.
The name of the network adapter of the PC is required.
This can be found in the “Network connections” area of the
computer:
Right click the

network icon.
Select ”open Network and Sharing Centre”
Notes :

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

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

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

Online Connection-Access MyMachine
Administrator Privilege Level

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

Right click on the icon of the Access MyMachine program
and select “Properties“.
The PC has been assigned the first available IP address of

192.168.215.2 by the DHCP server of X127.
Set the privilege level to “Run the program as administrator“ When the program is opened for the first time
after the installation, it is necessary to assign
a password for encryption purposes.
Notes :

Make a connection by selecting the “icon” shown below.
A dialogue box appears where the choice of connection is

made.
A default connection is available, this is specifically for
connecting to X127 of the controller (IP address
192.168.215.1).
It is necessary to login with a password depending on the The access level determines which data can be accessed via
access level required: Access MyMachine.
The “Manufacturer” login grants the most access, the “User”
login is the most restrictive.
Select the login and enter the password.
Passwords:
Manufacturer-SUNRISE
Service-EVENING
User-CUSTOMER
Notes :

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

File --> New --> Project……..
Notes :

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

external computer including menu and soft-key functionality.
When the viewer connects, access can be restricted on the
HMI or by the PLC interface.
To configure the HMI use the following soft-key sequence:
Viewing Rights-HMI
Rights for remote access - Selected in HMI
Do not allow remote access-Prevents remote connections.
Allow remote monitoring-The remote computer can monitor
the controller.
Allow remote operation-The remote computer can access the
various screens of the controller and changes can be per-
formed.
Viewing Rights-PLC
Rights for remote access, Specified by PLC (Not settable on
screen)
The access can be restricted/blocked via the user PLC with
interface signals. These signals have priority over the
“Selected in HMI” settings. It may be necessary to Contact
the machine manufacturer if the PLC is restricting the viewer
access.
Notes :

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

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

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

same screen as the controller.
Notes :

The following keys are used to navigate the controller from

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

the remote computer, archives can also be created.
Online Connection - PLC Programming Tool Set the privilege level to “Run the program as administrator“
Administrator Privilege Level
The Toolbox programs should always be run with privileges
set to Administrator.
Setting the Administrator Privilege:

Right click on the icon of the PLC Programming Tool pro-
gram and select “Properties“
Notes :

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

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

this example.
A list of network adaptors will be displayed: The selected adapter will be shown on the right of the dia-
logue box.
The IP address of the controller should be entered in the
“Communication Parameters\Remote Address” section.
The default IP address of X127 is 192.168.215.1.
The correct
adapter should
be selected
from the list
and confirmed Network adaptor.
with the “OK”
button.
Note: Adapter types will not necessarily be the

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

X127 - 192.168.215.1
Notes :

After entering the IP address,

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

appear:
The PLC828 Programming

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

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

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

Menu Structure B061
Menu
Structure:
START
Menu Area:
Program
Menu Select
Button
Menu Area:
Program
Manager
Wide Screen
Buttons
Menu Area:
Diagnostics
Mode
Selection
Menu Area:
Setup
Menu
Selection
Short cut
keys
Menu Area:
Machine
(JOG Mode)
Menu
Structure:
END
Menu Area:
Machine
(MDA Mode)
Menu Area:
Machine
(AUTO Mode
Menu Area:
Parameter
Notes :

B061 Menu Structure
Menu Select Button
The menu system of the SINUMERIK 828D is accessed via the “Menu Select” button.
The location of the “Menu Select” button is on the operator panel.as shown:
Notes :

Menu Structure B061
Wide Screen Buttons
Shortcut softkeys
The 6 vertical soft-keys in the top right hand corner can be used as short cut softkeys to access
different functionality of the control.
Shortcut Soft-key Functionality:
Undo if selected.
Redo if selected.
Virtual keyboard displayed if selected.
Virtual calculator displayed if selected.
Help screen displayed if selected.
A screen shot is taken if selected.
Notes :

B061 Menu Structure
The 7 vertical soft-keys in the left hand of the main window can be used as short cut softkeys to
access the areas of the control.
Displays the Machine area menu
Displays the Tool List area menu
Displays the Workpiece offset area menu
Displays the Program area menu
Displays the Program Manager area menu
Displays the alarm List area menu
Displays the Setup area menu
Notes :

Menu Structure B061
The side screen displays 6 areas, workpiece offsets, active alarms, axis loads, active tool, tool
management of the active too, and program runtime.
Displays any active “ZERO_POINT” including coarse, fine, rotations etc etc.
Displays any active “ALARMS” only, NO “messages” will be shown.
Displays the active “AXISLOAD” for all axis in the system.
Displays the active loaded “TOOL” including “Geometry and Wear”.
Displays the active loaded “TOOL” along with “Tool management Data”.
Displays the “PROGRAMRUNTIME” of the active program.
Notes :

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

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

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

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

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

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

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

B061 Menu Structure
Menu Area: Machine (JOG Mode) Milling
Menu Area: Machine (JOG Mode) Turning
Notes :

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

B061 Menu Structure
Menu Area: Parameter Milling
Menu Area: Parameter Turning
Notes :

Menu Structure B061
Menu Area: Program Milling
Menu Area: Program Turning
Notes :

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

Menu Structure B061
Menu Area: Setup
Notes :

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

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

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

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

+ selection of directories and program blocks.
Notes :

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

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

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

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

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

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

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

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

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

+ + C (USB-FlashDrive).
Note: For diagnostics purposes only.
Backs up the log files on the USB-FlashDrive. If a USB-FlashDrive is not

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

+ M
Feed over ride is increased in Simulation

+
Feed over ride to decreased in Simulation

+
Opens the Editor to enter Asian characters.

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

+ Navigation - Deletes all characters
B061: END
Notes :

B021 Access levels / Time and Date settings
Sinumerik
Operate
Module Description:
The data of 828D sl controller is protected by using one of seven access levels, four of which are set
via a key-switch and three by password.
This module explains the different access levels, how to set these levels and how to protect
individual files.
It is also important that the system date and time are correct.
This is necessary for checking when an alarm occurred or when a file (Part program, archive etc)
was created or edited.
If at the time of installation, the time and date is not set correctly, the Guarantee period of the control-
ler could be effected.
Before the date and time displays can be edited, the password for the “User” or higher must be en-
tered.
Module Objective:
Upon completion of this module you will be able to set the different protection levels using a pass-
word or key switch, you will also be able to change the protection levels of individual NC programmes
and set the time and date for the system.
Content:
Sinumerik
Password and key-switch information
Setting and Deleting the Password
Protection of files
Customising Soft-key Access Levels
Setting the Date and Time
B021
B021

Access Levels / Time and Date Settings B021
Access Levels /
Time & Date:
START
Password
and
key-switch
information
Setting and
Deleting the
Password
Protection of
files
Customising
Soft-key
Access
Levels
Time and
Date
Setting
Access Levels /
Time & Date:
END
Notes :

B021 Access Levels / Time and Date Settings
Password and key-switch information
The following table shows the password/key-switch positions.

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

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

Black 0&1 6-7
3 User Password: CUSTOMER
Green 0, 1 & 2 5-7
4 Programmer, Setter Key-switch position 3
Orange 0, 1, 2 & 3 4-7
5 Qualified operator Key-switch position 2
It is the responsibility of the OEM to ensure that the key-switch
signals are transferred to the PLC interface.
6 Trained operator Key-switch position 1
DB2600.DBB0 is used for the transfer of the key-switch signals.
7 Untrained operator Key-switch position 0
The key switch is located to the bottom right of the MCP and DB2600 Key-switch signals to NC (PLC → NC)
has four positions. Three colour coded keys are available,
each of which allow a different access level. This is from a Bit7 Bit6 Bit5 Bit4 Bit3 Bit2 Bit1 Bit0
standard Siemens machine control panel. It is possible that a
manufacturer may use a different method to set the interface DBB0 Key- Key- Key- Key-
signal. switch switch switch switch
Pos.3 Pos.2 Pos.1 Pos. 0
Setting and Deleting the Password
Setting the password:

The screen for entering the password is reached via the fol- A dialogue box is opened, this box shows the current access
lowing key presses: level and allows a password to be entered using the key-
board.
After typing the password it is confirmed by pressing the “OK”

soft key.
Notes :

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

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

default values)
• Read-in an archive. (To return the machine to a run-
ning condition)
Deleting the password:
The Delete password soft-key removes the entered pass-

word. The protection level is then set by the key switch.
Note: The password remains active after power off/on.
Module B033 explains how password deletion can be auto-
mated.
Example: TEST.MPF file has been selected in the Part Pro-

grams directory.
The properties of the file are found by paging right and select-
ing the properties Soft-key.
Protection of files A dialogue box allows four properties to be changed.

Certain files such as important cycles, programmes etc can be In the following example, the program:
individually protected against accidental editing, deletion or
execution. They can also be hidden from view. • Can only be executed if the “Service” password or
higher is active
The file to be protected has to be located before the properties
can be edited. In this example, the part programme • Can only be written to (Edited) if the “Manufacturer”
“Example.MPF” is to have it’s properties changed. password or higher is active
The “Part program” directory is located by selecting the
“Program manager” key.
• Will only be listed if the key switch position 2 or higher
is active
• Can only be read if the key switch position 3 or higher
is active
Notes :

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

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

nect a mouse into the USB socket of the controller.
Place the mouse pointer over the relevant soft-key and select
the Right click button.
Example: Changing the access level of the System data soft-

key to Manufacturer.
Place the mouse pointer over

the soft-key and Right click.
Notes :

Setting the Date and Time (TCU)
A summary of any changes to access levels can be seen in Before the date and time displays can be edited, the password
the Customize softkeys area for the User or higher must be entered.
The date/Time screen is reached with the following soft key

sequence:
The Original setting soft-key can be used to return the

access levels of all the soft-keys to their default state. Use the cursor keys to move between the data fields.
The format can be changed by highlighting the required input
field and using the Select key.
If the date or time is changed, each element has to

be confirmed using the Input key.
Automatic Time & Date Adjustment Manual Time & Date Adjustment
If the controller is connected to the internet, the option, Use To manually adjust the settings, ensure that the Use time
time server, can be set. server option is not selected.
The address/name of the time server needs to be entered and
the relevant time zone selected from the time zone drop down
menu.
The date and time format also needs to be selected.
Example - Date & time set via the Time server option:
Once all elements of the time & date are correct

press the OK soft key. The current date/time will
then be updated with the new values.
B021: END
Notes :

B021 END Access Levels / Time and Date Settings

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

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

Machine & Setting Data Overview Note:-

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

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

controller
Machine Data Components:

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

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

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

(Compensations, reference points etc.). An archive of the
The 828D controller uses machine data which is divided into Individual type could typically be made prior to a software
data classes. update.
Data classes can be used to create archives which contain
only specific data of the controller, data according to its clas- User (U) - The user data is user specific (Part programs, tool
sification. Upgrades etc. can therefore be carried out while data, zero points etc.). An archive of the user type could be
leaving any existing unrelated data of the controller intact. used to transfer data to an identical machine cutting the
same component or in the case of a software update.
Types of Data Classes:-
The Data Classes are split into four categories:
System (S) - This data belongs to the system and cannot be

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

throughout a particular machine series. No individual or user
data is included.
Notes :

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

machine data.
Control Unit parameter.
Supply MD (ALM/SLM-only DriveCLiQ types).
Drive parameter (Motor Modules)
Notes :

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

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

page/cursor keys or the search function.
The search function is activated with the “Search” soft key. If

the Machine Data number is known this can be typed into
the dialogue box. It is also possible to enter part or all of the
MD name in text format.
The correct machine data has to be highlighted. The number REMEMBER:- Create a data backup !
1 is entered and confirmed with the “Input” key.
On pressing the “Input” key the text of the machine data

changes immediately (see below).
Notes :

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

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

machine data list.
The “SELECT” button can be to show the Setup_Turning
view. Create new machine data list.
The machine data list will be displayed in the machine data

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

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

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

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

The uploaded files can be seen in the upper window by us-

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

Choose the required “Data Classes”
This will open the file within "Create MyConfig Diff".

Select the menu , "Selective"
Notes :

B041 END Machine and Setting Data
Two archives can be opened and the data compared with Choose the required “Data Classes”
each other.
Tick two Archive files and click the "Compare"
This will open the two files within "Create MyConfig Diff".
Select the menu , "Selective", then open and tick the same areas within each file.
Data that is different will be highlighted in RED text.
B041: END
Notes :

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

Network & Operator Panels B038
Network & Operator

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

Panels:
END
Notes :

Licensing:
In order for the required function to be achieved on your ma-

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

Order Nr. 6FC5800-0AP01-0YB0
Access MyMachine connected via X130
Computer Network Settings
When using X130 in a manual set-up, the IP address and

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

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

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

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

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

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

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

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

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

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

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

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

Controller IP address
The new connection is now listed in the Saved connections

list:
User name:
user
Authentication:
CUSTOMER
Set the Trans-

mission rate The new connection can now be tested
to High
A connection can also be made from the toolbar: A few moments later the connection will be made and the fold-
er structure of the controller will be displayed in the lower half
of the Access MyMachine program
From the drop down menu select the connection to be used

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Paste soft-keys.
Notes :

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

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

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

B038 END Network & Operator Panels
Notes :

B044 License and Option Management
Sinumerik
Operate
Module Description:
When a CF card with options is purchased, a software License key is required.
The license key is unique to the CF card supplied with the controller.
This module explains the licensing procedure and how to activate options.
Module Objective:
Upon completion of this module you can manage the licence key using the Sinumerik HMI.
Content:
Sinumerik
Licence and Option overview
Test Licences
Saving and Restoring the Licence Key
Retrieving a Lost Licence
Assigning New Licenses
CNC Lock
B044
B044

License and Option Management B044
License and Option

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

Management:
END
Notes :

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

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

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

8081 Control Period 1: Periods 2 to 6:
828D 150 hours 150 hours
Test Licence use and philosophy:
Test licence 1
Example: An unlicensed option and alarm 8081
• OEMs can freely activate and test options during the
commissioning stage. Once satisfied which options are
required, these can be officially purchased and licensed.
Test licenses 2- 6
• Dealers/End users can demonstrate/test options.
Alarm active due to unlicensed option being set:
• Service engineers can activate a test licence in the
event of a faulty system CF card. This eliminates any
production delays while awaiting the delivery of a new
licence from the Siemens Hotline.
Note: Cycle start is blocked if the licence key is not suffi-
cient.
In the event of an unlicensed option being set it is possible to

activate a Test licence.
Up to six time monitored test licences are available should a

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

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

have full functionality of the option.
Notes :

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

easily be restored.
A valid licence key must be already active.
Choose the destination for the License key. The new folder now appears. Select OK to save the licence
key to this folder.
Create a new directory/workpiece if required:
A confirmation message is displayed, momentarily, above Restoring the License Key:

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

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

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

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

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

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

found in the left hand column.
From the Please select menu, choose Hardware serial num-
ber.
This is the serial number of the internal CF card taken from
the License screen shown on the controller.
Example: A hardware serial number has

been entered :
Enter any one of the following:

• Hardware Serial Number
• License Number
• Machine identifier.
Select Display license key
Notes :

The license key will be displayed:
Click on the Save the license key in keys.txt. Link.
Save the file to a suitable location.
Entering the saved licence key:
Unlike the alm type files, the txt file cannot be read in to the controller.
The licence number can be typed directly to the licence screen.
Alternatively, the keys.txt file can be opened, on the controller, and the licence key copied/pasted into the licence screen.
Copy/paste from keys.txt:

Mark and copy the licence number section of the opened keys.txt file:
Locate the licence screen and paste the licence number using the Ctrl + v key combination.
Notes :

Assigning New Licenses Each purchased option has a licence certificate. The certifi-
cate contains the License and dispatch note numbers.
Activating an unlicensed option without a test licence being
active results in alarm number 8081. Example licence certificate:
If a new option is required it can be licensed via the Web Li-
cence Manager website.
Example of an unlicensed option:
The assignment of a new Licence key is via the Siemens Web

Licence Manager website:
www.siemens.com/automation/license
Sequence:
The licensing is achieved by a series of 5 steps via the Siemens Web License Manager website.
The hardware serial number (System CF card serial number) and the hardware type are required. These can be seen on the
licensing screen.
Example:
Select the Direct access button.
Notes :

Step1 - login: Example:

Enter the license and delivery note numbers taken from the
relevant certificate:
Continue to step 2 with the Next button.
Step 2 - Identify Product:
Enter the hardware serial number and select the product.

If saved license file is available, this can be loaded as an al-
ternative to manually entering the information.
An alternative method of identifying the product is by selecting a license file via the Browse button and submitting it with the
Submit button.
A list of licenses that are already

assigned to the card is displayed
Notes :

Step 3 - Select Licences:
Deselecting Unterdrücke un-

geeignete Lizenzen results in the
screen being refreshed and the li-
cences appearing.
Note: it is possible that multiple

licences have been assigned to one
dispatch note.
Set the tick-box and then se-

lect the Next button:
Step 4 - Assign Licences:
The option is now ready to be assigned:
The new license key is displayed
The newly assigned option will

now appear along with the ex-
isting options.
Notes :

Step 5 - Generate License Key:
A license key file can now be generated in order to load it to the controller.
The file can be generated in .alm format which can be loaded directly to the controller via the licensing area.
It is also possible to generate the file in .txt format. This cannot be loaded directly to the controller.
A license report, in .pdf format, can also be made.
To generate the file in .pdf format, click the link and save the file to a suitable location e.g. a USB memory device.
Click on the above link and save the file.
The license file can now be read directly into the controller:
The option is now licensed and can be set.
Notes :

CNC Lock CNC Lock Option:
Requirements:
• Option number 6FC5800-0AP76-0YB0.
• Access MyMachine version 4.7 SP1 or above.
Description:
The CNC Lock feature is used to block the Cycle Start func-
tion of a machine after a specifiable time period has elapsed. Note: the CNC Lock option cannot be activated with a test
The feature is intended for use by the OEM, for example, in license.
the event of withheld payments by the end user.
CNC Lock activation
Important Notes:
• The Option is currently only released for specific Open the Access MyMachine program. (No online connection
markets. is required)
• It is neither released nor intended for the Japanese Open the Tools menu and select CNC lock function:
market.
• The functionality may be unsuitable due to tech-
nical, legal or other issues.
• Any sale to, delivery to or use in such markets oc-
curs at the sole risk of customer and Siemens
takes no responsibility whatsoever for the func-
tionality in relation to such markets.
• Siemens recommends not to sell the functionality
to such markets and not to bring it there in any
other way.
The CNC lock function parameterising window will open. A lockset file needs be created to activate the CNC lock func-
tion.
The following information is required:

• Software version of the control to be locked
• CF Card number
• Hardware series number
• OEM pin
• Locking date
• Comment
The Software version is displayed in the diagnostics area:
Example: V04.08 + SP 02 + HF 00
Notes :

The Hardware series number is also found in the diagnostics

area.
Highlight the Hardware entry followed by the Details soft-key:
Example Hardware series number: SZJ4Y0H000416
The CF Card number can be found in the Licenses area.

Highlight the Hardware entry followed by the Details soft-key:
Example CF Card number: SPG2016071901699
The OEM Pin is defined by the OEM.
The pin must contain a minimum of 8 characters (up to a maximum of 32) including at least one upper case, one lower case, one
number and one special character.
Important:
• The OEM Pin should be noted and kept safe.
• Forgetting/losing the pin will result in the loc
being permanently active.
• Extending the locking date or Deactivating the CNC Lock will not be possible !
The Locking date is defined by the OEM. This is the date when the CNC Lock will become active.
Deactivating the CNC Lock or extending the locking date will require the OEM Pin (see above)
Comments can be added if required.
Enter the data:
Notes :

Create the Lockset file:
The file now needs to be loaded to the controller.
Important! - Set the correct date on the controller !
Assign a file name and save the to a suitable destination e.g.

USB storage device.
The file is to loaded via the licensing area:
Select the relevant Lockset file:
The licensing screen shows that CNC lock option is enabled,

but it is not yet in operation.
Notes :

The CNC lock date will now be displayed: Message 8063 will periodically appear.
Saving the CNC Locking Data:
The CNC locking data can be saved:
The data saved is unencrypted. This should be taken into • Select the Extend button:
consideration for security reasons
• Enter the new locking date:
• Create a new Lockset file:

Loading the CNC Locking Data:
The previously saved CNC locking data can also be loaded.

This is ideal for extending/deactivating the CNC lock
• Load to the controller:
Extending the CNC Locking date:
The CNC lock date can be extended. • Observe the new CNC lock date:
The correct information for the controller in question needs to

be present e.g. by loading a saved CNC lock data file (.ucls
extension)
Notes :

B044 END License and Option Management
Deactivating the CNC Lock: • Create a new Lockset file:

The correct information for the controller in question needs to
be present e.g. by loading a saved CNC lock data file (.ucls
extension)
• Select the Deactivate button • Load to the controller:
• Observe the deactivated CNC lock date:
Expiry of the CNC Lock Date:
Alarm number 8064 is displayed when the CNC lock date is

reached. As a result, NC start is inhibited.
B044: END
Notes :

B044 END License and Option Management

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

• Make logbook entries
• Save and load the log file using the GSP iBase database via the identSNAPSHOT software.
Content:
Sinumerik
Logbook information
Importing/Entering Logbook data
1st Commissioning-Start-up Complete
2nd Commissioning-Machine Installed
Recording a Service Visit
Saving the Logbook data - identSNAPSHOT
Uploading to GSP iBase
B007
B007

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

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

life of the machine:
- Manufacturer information at OEM

- Dealer information at delivery and installation of machine
- End user information at delivery and installation of machine
- 1st Commissioning - End of start-up at Manufacturer
- 2nd Commissioning Machine installed - End of start-up at
end user
- All service visits
Importing/Entering the Logbook Data File Function
The OEM and Dealer information can be imported to the con- oem.xml Manufacturer information
troller in three ways:
oemsubs.xml Manufacturer subsidiary information
• Import the XML file via the “Import” soft-key. dealer.xml Dealer information
(Preferred method)
user.xml End user information
• Copy/paste the XML file in the “System data” area. ma_types.xml List of available machine types
• Type the information directly on the controller. The files are imported using the “Import” soft-key.
If the files are not available they can be created directly on
(When the files are not available.)
the controller or offline on a computer.
Machine Identity File (identity.xml)

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

Data 17400. This is individual to the machine and needs to
be entered here.
Notes :

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

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

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

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

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

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

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

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

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

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

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

include three machine types.
Once the choice of machine type is made it cannot be un-

done unless the “identity.xml” file is deleted.
When the file is imported, the machine types will appear in

the drop down list.
Copy and Paste function Locate the destination folder (Machine identity).
It is also possible to copy the files from USB/networked PC

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

Subsidiary files The default screen displays the manufacturer data.
Subsidiary files are used to define the details of manufactur-

er regional offices.
Example: A machine manufacturer has its head office in Ger-

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

described previously.
Select the “Manufacturer” soft-key to view the “oem

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

been made. This is the name of the branch, i.e. the subsidi-
ary.
To return to the manufacturer details, select the “Reg. office

of manufact.” soft-key.
This the original manufacturer soft-key with different text.
The text of the soft-key changes depending on the current
selected screen.
Select the branch/subsidiary name; Templates for xml Files

in this case “Test Subsidiary 1”
Templates for the various xml files are available in the
“HMI data\Templates\Examples\Machine identity” folder.
The subsidiary details will be displayed.
Notes :

The templates can be used if the files cannot be obtained

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

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

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

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

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

turer the “Start-up Complete” soft-key is selected. This auto-
matically logs the current time and date.
2nd Commissioning-Machine Installed
When the machine has been installed at the end-user (2nd

commissioning) the “Machine Installed” soft-key is pressed
This automatically logs the current time and date.
To confirm that 1st Commissioning is complete.

The information will appear on the main logbook page.
To confirm that 2nd Commissioning is complete. The name and company/department of the engineer should
be entered followed by a detailed description of the fault and
work carried out.
The information is now added to the main logbook page.
Recording a Service Visit
Whenever an engineer visits the machine to carry out

maintenance etc., a record of the visit and information about
the work carried out should be entered into the Logbook.
To do this select the “New Entry” soft key.
Notes :

The details of the service visit are now shown on the Log- The save procedure should be carried out after each data
book page. entry in the logbook.
To save the data to a file first locate and select the “Save”
soft-key.
The file should be saved to the default “Version data” folder

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

via an external PC, therefore it should also be saved to an
external USB device.
Saving the Logbook data
The following procedure shows how to save the newly

entered data to a file.
The file contains all information about the system (Controller,
drives, software and hardware etc) as well as the information
entered on the logbook pages.
The file is given a default name using details from the

machine information page. This can be changed. A comment
can also be added.
Two files are created by default, Version data and
Configuration data.
The “Version data (.TXT)” file is a text file and contains
details regarding the versions of the controller, drives etc.
The “Configuration data (XML)” file is an xml file and con-
tains more information about the whole system including the
logbook entries. It is this file which needs to be uploaded to In this example, the files are saved in the “version” folder.
the database via the internet.
PPU: System CF card\user\sinumerik\hmi\ data\version
The information will now be saved.
Notes :

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

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

A new log file needs to be created when anything new is
added to the logbook.
The file must then be uploaded to the GSP iBase. This is
done using identSNAPSHOT software, which can be
downloaded via:
www.siemens.com/sinumerik/register
Once identSNAPSHOT has been downloaded, and the zip

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

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

As response, you receive an e-mail from the

identSNAPSHOT registration with your user ID in the form of
a graphic.
Select "New" The numerical sequence 82489503 is shown here as

example
These digits must be entered in this sequence into the input

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

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

memory stick
Notes :

This will populate all relevant fields within identSNAPSHOT,

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

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

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

will appear.
B007: END
Notes :

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

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

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

Data Management Concept

Change necessary to
Bug with Reproduce Machine at Manufacturer
customers and change in
Update change log in or Individual level - PLC or
found Prototype
Protokoll NC update necessary
Prototype Serial machines become

1st TGZ File of Serial Maschine Individual Machines
Save Data (1……..x)
Commissioning Prototype (1………..x)
Individual data (class)
OEM Logbook Time and Date
Individual Machines
Regular (1……..x)
development TGZ File from Prototype into Data save
works Serial machines Local Archives
OEM TGZ with machine
and local to server
Data Classes Changes to

E-Mail Inkremental Machine at
Archive machine with
Update Update updates Customer
archive
Updates von OEM Customer
Notes :

Data Classes
The 828D controller uses machine data which is divided into data classes.
Data classes can be used to create archives which contain only specific data's of the controller, data according to it´s classifica-
tion. Upgrades etc. can therefore be carried out while leaving any existing unrelated data of the controller intact.
Types of Data Classes:
The Data Classes are split into four categories:
System - This data belongs to the system and cannot be edited. The values are determined by the controller type and standard
data. Data belonging to this class is not saved in any archive type.
Manufacturer - The manufacturer data is common throughout a particular machine series. No individual or user data is included.
Individual - The individual data is machine specific (Compensations, reference points etc.). An archive of the Individual type
could typically be made prior to a software update.
User - The user data is user specific (Part programs, tool data, zero points etc.). An archive of the user type could be used to
transfer data to an identical machine
cutting the same component or in the case of a software update.
Data Classes for Machine Data Data Classes for PLC Data Blocks
When looking at the machine data area of the controller it is It is also possible to select the Data Class of certain Data
possible to see which machine data belongs to which Data Blocks in the User PLC program. When a Data Block is first
Class. created, the properties box is displayed.
Example: Axis specific machine data screen showing data The Data Class can be changed via the drop down menu. If
class identifiers: the Data Block already exists, the properties can be viewed by
right clicking on the Data Block and selecting properties.
Selection of the
Data Class.
Data Class Identifier
Notes :

Easy Archive Creating Non-Data Class Setup Archives:

Creating Setup Archives: A number of choices are available with regards to the type of
To create a Setup Archive, locate the correct area by using the data to be included in the archive you are about to create.
following key sequence. The “All” option does not take into account the Data Classes.
Data from all data classes will be included.
Individual control components can be selected/deselected to
make a full or partial back-up of the controller.
Ensure that the option “Create Setup Archive” is selected and

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

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

The list comprises of:-
Cycle storage
Texts
Templates
Applications
Configurations
Help
Version data
Logs
User views
Dictionaries
Notes :

The example below shows the “All” option selected with the Information about the archive can be entered in the Comments
four control components also selected. This would create a section.
full backup of the controller.
The destination of the archive needs to be selected next. This

can be on the controller itself in the “Archive” directory or ex-
ternally to a USB or CF device.
A new directory can be created if necessary.
The archive is now created and stored in the specified destina-

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

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

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

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

User Data Class archive containing user data from the NC
only.
Note that the Drive data option is not available for selection,
Drive data always belongs to the “Manufacturer”
data Class type.
The destination of the archive is selected next. This can be on

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

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

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

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

Before reading in an archive it is recommended that the
controller is loaded with default data. The basic “Start-up” menu will be displayed, to display the
advanced “Start-up” menu press the key combination
Restart the controller, press the “select” key within 3 seconds "8" → "2" → "8".
of the following screen appearing.
Press SELECT key to enter startup menu
Notes :

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

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

be loaded, the “Factory settings” option would be chosen.
Depending upon which option has been selected, a series of

dialogue boxes may appear, acknowledge these as required.
Allow the control to boot. This is indicated by the permanently
illuminated top green LED and the flashing orange middle LED
directly above the CF and USB sockets.
Alarms will be present (Alarm numbers 4060 & 400006, alarm
120402 will be present if the default drive data was loaded)
These alarms can be ignored.
Set the password to “service” or higher. Select the archive to be read-in, example- Milling Machine 123
Selecting the archive to be read-in
Use the following key combination to reach the area for read-
ing in archives:-
Information about the archive is displayed. It is possible to read

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

When the archive has been successfully read-in the following

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

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

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

Part Programs
The “Save Data” function is used to automatically save the NC User Data
data stored in the static ram memory (SRAM) of the 828D con-
troller to the system CF card. Performing the Save Data Function:
The “Save data” function stores an image of the data to the
internal CF card of the controller (the image is not accessible
via HMI explorer).
Only one copy of the image is stored, the previous image is
overwritten each time the save data function is performed.
The image cannot be retrieved from the CF card.
The saved data can be used in one of two ways:-
• Creation of series machines. Series machines are

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

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

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

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

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

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

ods.
Creation of series machines:

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

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

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

minutes.
When the process is complete a message is displayed warning

that the backup data has been loaded.
This message is cleared with the “Reset” key, however it
should be noted that the data that has been restored will possi-
bly be old data and may contain incorrect tool data etc.
The operator should be warned of this fact and be prepared to
check program data, offsets, tools etc. before operating the
machine.
Cursor to the “Yes” button and press the “Input” key.
Notes :

Creating Archive with Shortcut keys
The screen of the 828D controller is integrated into the PPU

and cannot be changed. In the event of a screen failure it is
not possible to create an archive in the usual
manner prior to replacing the controller.
For this reason it is possible to create a complete archive by
simultaneously pressing three keys together.
The keys to be pressed are “CTRL” + “ALT” + “S”.
This procedure will automatically create an archive to an exter-
nal USB or CF memory device.
Select the following keys simultaneously to produce the ar-

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

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

card contains the system software from which the controller
operates. The card also contains other important data which is
essential for the machine to function.
The following procedure shows how to create an image of the

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

Empty storage device Storage device containing
cards:
(CF card/USB stick) system image (TGZ)
Notes :

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

function.
Insert a FAT formatted CF card or USB stick of at least 1GB

into the front of the controller (X125-USB, X145-CF card). To display the advanced “Start-up” menu press the key combi-
nation "8" → "2" → "8".
Restart the controller, within 3 seconds of the following screen
appearing, press the “select” key.
The advanced menu will be shown, select the option “Create

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

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

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

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

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

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

When the controller reboots, the alarm “4062 Back-up data Machine Functionality:
loaded” will be displayed. This data is the data saved in the
“Save data” procedure. Clear with the “Reset” key The machine functionality should now be checked. The opera-
tor should ensure that tool data, offsets etc. are correct.
If alarms numbers 4060 & 400006, 120402 are present, this

indicates that the “Save data” procedure was not carried out
before the system image was created.
In this case an archive will need to be loaded to get the
machine to an operational condition.
Time and Date Settings:
The 828D controller uses the GSP iBase system for register-
ing the machine.
The registration is very important with respect to the start of
the 2 year warranty period.
For this reason it is essential that the time and date be set
correctly.
System CF Card Replacement The software package “Access MyMachine” is required plus a
recovery file called “minsys.img”. This file is installed as part of
In the event of the internal CF card becoming damaged it is the toolbox and is found within the folder named “Recoverysys”
possible to write a previously saved system image to a new CF in the toolbox directory.
card.
It is necessary to obtain a replacement blank CF card from Start the “Access MyMachine” software:
Siemens. Part number for replacement 2GB card:
6FC5313-5AG00-0AA2.
The card will need to be licensed, this can only be done via the
Siemens Hotline.
The serial numbers of the faulty and replacement cards are
required by the Hotline before a new licence number can be
issued.
Preparing the replacement System CF card:
This card needs to be made bootable using the following

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

using a suitable adaptor.
Notes :

You select the “SINIMERIK 828D boot system”” from the Highlight the drive letter of the CF card. Example “G:\”
"extras" list.
Browse for the CF card:
Start the write procedure with the “Write” button. Writing the Image to the Replacement CF Card
The “Minsys” recovery file to the CF card makes the card boot-
able. The card needs to placed in the rear CF card slot of the
controller in place of the “damaged” card.
The following procedure will flash the backup image saved
earlier to the new system CF card.
Insert the replacement bootable system CF card in the rear

slot of the controller.
Switch the controller on and allow to start-up, the following

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

Insert the USB/CF device which contains the backup image

and select “Yes”.
The data backup is now written to the internal card. Allow the
process to finish.
Select the backup image and press the “Input” key. It is possi-
ble that more than one image is present on the card/USB stick,
ensure that the correct one is chosen.
When the procedure is finished the controller needs to be pow- If alarms numbers 4060 & 400006, 120402 are present, this
ered off to allow the USB/CF device to be removed. indicates that the “Save data” procedure was not carried out
before the system image was created.
In this case an archive will need to be loaded to return the
machine to a running condition.
Licensing
The licence key number is matched to the System CF card

serial number, using a new CF card means that the numbers
Switch off the controller, remove the front CF card/USB stick do not now correspond.
and then switch the controller on. Alarm number 8081 is generated because of this. The number
When the controller reboots, the alarm “4062 Back-up data of options not licensed will differ between machines.
loaded” will be displayed, this data is the data saved in the
“Save data” procedure. Clear with the “Reset” key.
The new licence number obtained from the Siemens Hotline

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

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

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

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

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

can then be used for new topologies!
Notes :

The saved data is in the

following directory.
Use drive data modularly:

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

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

B017 END Data Management
B017: END
Notes :

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

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

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

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

memory devices.
Compact Flash port for custom-

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

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

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

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

Name Colour Description
X122 & X132: BiCos are used to assign Sinamics inputs/
FAULT Red Fault present (Profinet interface) outputs to a specific function e.g. enabling of drives, BERO’s,
automatic line contactor control etc.
SYNC Green Synchronisation OK (Profinet interface)
Certain terminals are automatically assigned to a function by
Rx/Tx Yellow Network activity (X130 interface) default, these are the OFF1 and OFF3 drive enable signals
and the input for probe 1.
Link Green Network connected (X130 interface) The remaining terminals can be assigned to a function via
machine data.
The status of the terminals is transferred to CU parameter
r0722 which is referred to when assigning a function.
X242 & X252: Functionality for digital NCK inputs/outputs and

one analogue spindle.
Notes :

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

enabled (SLM <16Kw)
Pin 2 Sinamics DI1 OFF3 drive enable-Fast Stop

Pin 3 Sinamics DI2 Safety Integrated SH/SBC 1 Group 1
input
Pin 4 Sinamics DI3 Safety Integrated SH/SBC 1 Group 2

input
Pin 5 Sinamics DI16 DI 16 Free to assign

Pin 7 MEXT2 Ground (M) Ground for pins 1 to 6
Pin 8 P24EXT1+24V DC (P) +24V DC common
Pin 9 Sinamics DI/DO8 Safety Integrated SH/SBC 1 Group 1
output
Pin 10 Sinamics DI/DO9 Safety Integrated SH/SBC 1 Group 2

output
Pin 11 MEXT1 Ground (M) P Ground for pins 9, 10, 12, 13

Pin 12 Sinamics DI/DO10 Bero 1 reference mark input
Pin 13 Sinamics DI/DO11 Probe 1 de-centralised input
Pin 14 MEXT1 Ground (M) Ground for pins 9, 10, 12, 13
X132-Sinamics I/O X132 Signal Function/Default Setting

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

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

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

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

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

Pin 1 5V DC (P5) +5V DC common
Pin 2 0V DC (M) Ground
Pin 3 1A Hand-wheel 1 signal A
Pin 4 –1A Hand-wheel 1 signal –A
Pin 5 1B Hand-wheel 1 signal B
Pin 6 –1B Hand-wheel 1 signal –B
B010: END
Notes :

B030 Digital I/O, Hand-wheels and Probes
Sinumerik
Operate
Module Description:
The 828D has interfaces for the connection of Digital I/O (Sinamics & NCK), Probes & Hand-wheels.
The hand-wheel connections (X143) are pre-assigned, while the digital I/O and probes can be as-
signed to any suitable connection by the user.
Connections used within the drive group components are known as BICOs (Binary Connectors)
Certain connections can be configured as an output or an input.
X252 has the possibility of analogue spindle functionality, this is described in Module B029
X122-Sinamics Digital I/O

X132-Sinamics Digital I/O
X252-NCK Digital I/O / Analogue Spindle Functionality
X143-Hand-wheel Functionality
This module shows the pin assignment of each connector and shows several examples of how a
connector is assigned to a function, including probes and line contactors.
Module Objective:
Upon completion of this module you will be able to locate the interface connectors and configure
individual connections to perform certain functions.
Content:
Sinumerik
PPU Digital I/O Interfaces.
Digital Input/Output Terminal Description
BICO Technology
BICO Assignment
NCK Inputs and Outputs
B030
B030

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

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

X122 X122 Digital I/O for Sinamics
X132 Digital I/O for Sinamics
X242 Digital I/O for NC
X132
X252 Digital I/O for NC / Analogue I/O for analogue spindle
X143 Handwheel Interface
X242
X252
X143
Notes :

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

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

1 DI 4 +/- 10V AO Spindle 1
2 DI 5 AM Spindle 2
3 DI 6 IN9 3
4 DI 7 IN10 4
5 DI 20 IN11 5
6 DI 21 IN12 6
7 MEXT2 MEXT4 7
8 P24EXT1 P24EXT3 8
9 DI/DO 12 1* OUT9 9
10 DI/DO 13 1* OUT10 10
11 MEXT1 MEXT3 11
12 DI/DO 14 1* OUT11 / Analog Spindle 12
14 MEXT1 MEXT3 14
Analogue spindle option

Enable / direction
Enable / direction
1* Fast inputs/outputs (Must be shielded). Can be parameterised as Inputs or outputs.
Functionality of X252 pins 12 & 13:
The functionality of X252 pins 12 & 13 changes depending on whether an analogue spindle is declared
X252 Analogue spindle is declared Analogue spindle is not declared

Pin 12 Controller enable/positive direction for Digital Output $A_OUT[11]
analogue spindle option
Pin 13 Controller enable/negative direction for Digital Output $A_OUT[12]
analogue spindle option
Notes :

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

Source Destination
ON/OFF1 for DriveCLiQ line

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

X132-Sinamics I/O

Source Destination

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

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


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

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

X143-Hand-wheel connections

Notes :

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

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

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

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

connection of OFF3 to several drives

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

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

Telegramm 136 Telegramm 136

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

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

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

Example: How the OFF3 signal is assigned to X axis p0849 CU parameter r722.1
Physical connection of the OFF3 signal:

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

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

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

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

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

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

Assigning the Probes to the Drives: Assigning probe 2 to X132.13
The system needs to know which terminal the probe input is Probe 2 is not assigned by default.
connected to, this is set with drive parameter p488. Drive parameter p489 needs to be parameterised in order for
probe 2 to function
All the drives that use the probe functions will need to be set.
Select the correct drive and cursor to the parameter p489[0]
There are two parameters, one for each probe, each with 3 then press the “Select” key
indexes (Indices).
p488 Measuring probe1 input terminal: Encoder 1..3
p489 Measuring probe2 input terminal: Encoder 1..3
Assigning probe 1 to X122.13:
The 1st probe is connected to X122.13 of the CU.

By default, probe 1 is already assigned to X122.13
A list of permissible inputs is displayed, cursor to the correct

one i.e [6] DI/DO 15 (X132.13) and press the “Input“ key to
confirm.
Saving the Changes:
The changed data needs to be saved to the system CF card

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

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

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

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

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

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

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

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

The position of the axis when the probe is triggered is read Assigning the Spindle BERO Connector:
into variables:
The training equipment has a proximity switch connected to
$AA_MM[x] - machine coordinate position. X122.12, this is for the spindle BERO (External zero mark)
$AA_MW[x] - workpiece coordinate position. signal.
To make this active the relevant Drive Machine Data, p495[0]
[x] = Axis name. or [1] has to be set.
Ensure that the correct drive is selected, i.e. Spindle.
Select the input terminal to which the BERO switch is

connected (X122.12).
Configuring the automatic line contactor.
The automatic line contactor function is used to ensure correct

switching of the line supply to the line modules (DriveCLiQ
versions only)
The following example shows how to configure the line con-

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

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

For identification purposes, the LED of the module can be

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

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

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

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

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

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

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

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

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

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

Optional stop active.
$A_OUT[9] = 1 Set NCK output 9 to 1
M00 Optional program stop, program will

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

The status of the PLC variable can now be checked. Example: Using NCK inputs in a part program
The NCK inputs can also be used in the part program. The
following program checks the status of NCK input 9 and dis-
plays a relevant message.
Type the following into the MDA screen (Blue text):

For the purpose of this exercise it is necessary to link X252 Setting NCK output 9 to 1
$A_OUT[9] = 1
pin 3 to pin 9. will also set NCK input 9
Type in the variables to be checked. IF $A_IN[9] == 1 GOTOF LABEL1 If NCK input 9 = 1

When output 9 is set input 9 will also be set because of the jump forward to LABEL1
MSG (“NCK INPUT 9 IS LOW”) Message line showing that

the input is low
Digital NCK output 9 M00 M00 Program stops until

DB2900.DBX1004.1 cycle start is pressed
M30
M30 Program end
LABEL1:
LABEL1 used for the
jump command (GOTOF)
MSG (“NCK INPUT 9 IS
Digital NCK input 9 Message line for showing
HIGH”)
Mirrors the status of that the input is high.
NCK output 9
M00 M00 Program stops until
cycle start is pressed
M30 M30 Program end
To test the run/test the program select the Cycle Start button. Edit the program so that NCK output 9 is set to 0.
Program message display
The Jump command is ignored and the message,

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

Hand-Wheels, Mini-HHU
Connection via PPU:
Handwheels directly connected to terminal X143 of the PPU are parameterized using the following NCK machine data:
1st handwheel
MD11350 $MN_HANDWHEEL_SEGMENT[ 0 ] 2 Hardware segment: 8xxD_HW
MD11351 $MN_HANDWHEEL_MODULE[ 0 ] 1 ---
MD11352 $MN_HANDWHEEL_INPUT[ 0 ] 1 PPU, 1st handwheel in the handwheel slot (X143)
2st handwheel
MD11350 $MN_HANDWHEEL_SEGMENT[ 1 ] 2 Hardware segment: 8xxD_HW
MD11351 $MN_HANDWHEEL_MODULE[ 1 ] 1 ---
MD11352 $MN_HANDWHEEL_INPUT[ 1 ] 2 PPU, 2st handwheel in the handwheel slot (X143)
Conenection via PROFINET:

For the SINUMERIK 828D, in addition to the connection of two handwheels to the PPU interface, terminal X143, a third hand-
wheel can also be connected via a machine control panel, e.g. MCP 483C PN, interface X60.
The parameter assignment of the third handwheel is performed in the following NCK machinedata:
3st handwheel
MD11350 $MN_HANDWHEEL_SEGMENT[ 2 ] 5 Hardware segment: PROFINET
Reference to logical base address of the hand-
MD11351 $MN_HANDWHEEL_MODULE[ 2 ] 1
wheel slot of the MCP
MD11352 $MN_HANDWHEEL_INPUT[ 2 ] 1 MCP. 1st handwheel in the handwheel slot (X60)
Indication for the PLC:

In the PLC toolbox examples the 3rd handwheel is not included!
Using the USB machine control panel:

When using a MCP 483 USB or MCP 310 USB or MCP 416 USB, the mini handheld unit is either connected via the MCP
Interface PN or a PP72/48D PN (PP72/48D 2/2A PN) I/O module.
Notes :

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

and jog signals
Standard addresses for X51, X52 & X55

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

Hand-held Units
B030
Mini Hand Held Unit Colour Codes
bk - Black
B030 END
Emergency Stop Enabling Button Axis Selection Function/jog/rapid Keys Hand- br - Brown
wheel rd - Red
ye - Yellow
gn - Green
bu - Blue
vt - Violet
gy - Grey
wh - White
pk - Pink
wh bn gn ye gy pk bu rd bl vt ye/ gy/ rd/ wh/ bn/ wh/ wh/ gy/ wh/ pk/ wh/ bn/ wh/
bn pk bu gn gn ye gy bn pk bn bu bu rd
Page 24
1 2 3 4 5 6 7 8 9 10 16 11 12 13 14 15 17 24 18 19 20 21 22 23 HHU plug/flange socket
Digital I/O, hand-wheels and probes
Connection kit
6FX2006-1BG20
wh br gn ye gy pk bu wh br vt rd bu pk gy ye gn bk br wh bu pk ye gn
1 2 3 4 5 6 7 1 2 3 4 1 2 3 1 2 3 2 1 6 5 4 3
X51 X52 X55 X143
Connector block MCP310/483PN PPU
B030: END
SINUMERIK 828D
B051 Line and Motor Modules
Sinumerik
Operate
Module Description:
The Sinumerik 828D uses Sinamics drive components, these components must be powered on/off in
a certain sequence in order to operate correctly. This module shows how these components are
connected to the system and the required power on/off enabling sequence.
Module Objective:
Upon completion of this module you will know how the drive components of the Sinumerik 828D
system are integrated and how the power to these components should be applied and removed.
Content:
Sinumerik
Topology Drive Object Numbering
General Information
Drive Module power Supply
Smart Line Module (SLM)
Active Line Module (ALM)
Motor Module (MM)
Combi Drive Module
Supply and Enabling Examples
B051
B051

Line and Motor Modules B051
Line and Motor

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

abling
Examples
Line and Motor

Modules:
END
Notes :

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

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

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

Components are numbered in purple.
PPU Motor Motor Motor

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

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

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

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

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

1 2 3
X203
X102 X202
X101 X201 B C X500

Motor Motor SMC
SMI- 7 SMI- 4 SMI- 10
X100 X200 ENC- 8 ENC- 5 ENC- 11
MOT– 9 MOT– 6
(2) (3)
Notes :

Topology
The Combi drive can only be connected to X100.

Additional axes are facilitated by the addition of Book-sized Compact Modules. These must always be connected to X101.
X102 is reserved for the connection of a Terminal Module (TM54) which is used for Safety Integrated functionality.
Example – 5 axis system with Combi Drive:
Drive Device 1: CU (PPU)
4 Axis Combi Drive Booksize Compact

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

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

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

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

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

supply which is used to drive the servo motors.
By regulating the frequency and voltage of the AC supply to
the servo motors it is possible to precisely control the move-
ment of motors.
Line and motor modules are available in different variants

depending on the machine requirements.
Each module requires a +24V DC control voltage, this is sup-

plied by the user to the line module and then distributed to the
motor modules via a bus system.
Example, Line module with two motor modules:- Line-Modul Motor-Modul

(LM) (MM)
Drive Module power Supply X24– Electronic Supply 24V DC
Power Requirements
The drive modules require two power supplies in order to op- “M” Terminal: Electronics ground
erate.
A 3 phase AC supply (380V to 480V +10% (-15% < 1 min) to “+” Terminal: +24V DC
the bottom of the line module is used to produce the 600V DC (20.4V to 28.8V)
link. The DC link is distributed to the motor modules via a bus
bar system on the front of the drive modules beneath a flip Location of the electronics supply and DC link bus bars:-
down cover
The +24V DC electronics supply is obtained externally from 24V DC Electronics supply (X24) Bridging device for
the user on connector X24. This is also distributed by a bus continuity of the
bar system along the front of the drive modules. bus between drive
The electronic supply is used internally by the drive modules modules.
for powering of the electronic circuitry etc. Externally it is used
for supplying the Drive-CLiQ encoders and fault, ready and
enable signals.
+24V DC Bus-bar
0V DC Bus-bar
+ DC Link Bus-bar
- DC Link Bus-bar
LM MM1 MM2
Notes :

Smart Line Modules (SLM) X22:

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

terminal locations etc.
X1: Mains supply

Protective earth (3-Phase AC)
connections
X22 Terminal description and functionality

Connector locations X21, X22 & X24
Terminal Function Description

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

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

(Output)
• Over-temperature threshold reached.
• I²t threshold reached.
• Mains fault making regenerative feedback impossible. If feedback is intentionally deactivated (X22.2 is
high) this warning is disabled.
This signal is for use by the manufacturer to set a user alarm and alert the operator to a problem.
3 Enable Puls- Applying +24V DC will cause the pulses to be enabled. (Current consumption:10mA)
es This signal must be removed at least 10ms prior to the 3-phase mains supply being removed.
(Input) Failure to do this can lead to damaged drive modules. This is especially important when the axes/spindles are
decelerating and causing regenerative currents. if the mains circuit is opened these regenerative
currents remain within the drive system causing damage to the modules.
It is recommended that this terminal is connected via an early break contact on the machine isolator switch and
the line contactor (If used).
If the terminal is used by the manufacturer it must be ensured that it is controlled in the suggested manner.
When used in this way the transistors will be switched off and mains regeneration halted, the motors will then
coast to a halt. This is not suitable for an emergency stop situation.
4 Enable Puls- Must be connected to the 0V of the enable pulses supply.

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

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

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

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

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

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

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

Pulses supply.
(Ground)
Notes :

LED Status Display

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

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

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

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


Location of ALM connectors X21, X24, X200, X201 & X202
X21:
Enable and Terminal Function Description
Temperature sensor 1 + Temp Temperature sensor input from Active Interface
Connections (Input) Module (Observe the polarity)
2 - Temp Temperature sensor input from Active Interface
(Input) Module (Observe the polarity)
X203:
Drive-CLiQ connect- 3 Enable Applying +24V DC enables the pulses.
or Pulses (Current consumption:10mA)
(Input) This signal must be removed at least 10ms prior to
the 3-phase mains supply being removed.
X202: Failure to do this can lead to damaged drive mod-
Drive-CLiQ connect- ules. This is especially important when the axes/
or spindles are regenerating. If the mains circuit is
opened in this state, regenerative currents remain
X201: within the drive system causing damage to the mod-
Drive-CLiQ connect- ules.
or It is recommended that this terminal is connected via
an early break contact on the machine isolator
switch and the line contactor (If used).
X200: If the terminal is used by the manufacturer it must be
Drive-CLiQ connect- ensured that it is controlled in the suggested man-
or ner.
X24: switched off and mains regeneration halted; the
24V DC Electronics motors will then coast to a halt. This is not suitable
supply for an emergency stop situation.
4 Enable Must be connected to the 0V of the enable pulses

Pulses supply.
(Ground)
LED Status Display

Off Electronics power supply outside permitted Check 24V supply to X24.
range.
Green On Module configured and ready, DriveCLiQ

communication is active.
READY Orange On DriveCLiQ communication is being estab- Check alarms on controller.

(Top) lished/module not configured.

2Hz
Red Flashing Firmware download procedure is complete Power off/on.

8Hz

Orange 2 Hz
or Red/
Orange
Off Electronics power supply outside permitted Check 24V supply to X24.
range.
DC
LINK Orange On DC link voltage within tolerance-Only if unit is
(Botto configured and ready.
m)
Red On DC link voltage outside tolerance-Only if unit Check the mains input.
is configured and ready.
Notes :

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

Available in the following rated current output sizes:-3, 5, 9 & Enables etc. Enables etc.
18A
Example:-A double axis MM showing connector locations. X200/X201/X202/ Electronics/DC

These units will have two identical Motor/Brake connectors X203: link bus bars
DriveCLiQ (below flip down
(X1 & X2) and two cover)
connectors
identical enable connectors (X21 & X22).
LED Status
Indicators
X1 & X2 Output
to Motor,
including the
brake output for
MM less than
45A
Protective
earth X11: Brake out-
connections put for MM of
45A and above
Notes :

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

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

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

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

Connection Positive Con-
nection
Locating key Locating key
Motor: Motor: Motor:

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

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

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

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

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

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

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

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

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

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

Integrated shield concept
Motor plug connectors

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

clip when fabricating cables from 7mm to 19mm (up to 23mm
yourself Single Motor Modules)
Plug connectorwith latching
mechanism
PE is integrated
Fan can be replaced in the installed state
Fast, simple wiring
Can be removed
towards the front
Motor plug connectors that customers can fabricate/assemble
themselves from 1.5mm² (AWG16) to 6mm²
Prefabricated MOTION-CONNET power-cables to 10mm²
(AWG 8)
Push-in plug connector Plug connector screw Fan model Fan with
connection monitoring.-
supported from SINAMICS
firmware V4.8
6SL3162-2MB00-0AC0 6SL3162-2MA00-0AC0
Notes :

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

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

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

brake (Underneath)
Notes :

Detailed Terminal Description X21 Terminal description and functionality
Top view of Combi Drive Unit:
X21/X22 X12/X13 Terminal Function Description

Enables and tem- Fan supply and monitoring 1 Not used Not used
perature sensor. X224 +24V DC
auxiliary supply 2 Not used Not used
3 Enable Applying +24V DC enables the pulses.
Pulses (Current consumption:10mA)
(Input) This signal must be removed at least 10ms
prior to the 3-phase mains supply being re-
moved.
Failure to do this can lead to damaged drive
modules. This is especially important when the
axes/spindles are regenerating. If the mains
circuit is opened in this state, regenerative
currents remain within the drive system caus-
ing damage to the modules.
It is recommended that this terminal is connect-
ed via an early break contact on the machine
isolator switch and the line contactor (If used).
If the terminal is used by the manufacturer it
must be ensured that it is controlled in the
suggested manner.
switched off and mains regeneration halted,
the motors will then coast to a halt. This is not
suitable for an emergency stop situation.
4 Enable Must be connected to the 0V of the enable

Pulses pulses supply.
(Ground)
X22 Terminal description and functionality X12/X13 Terminal description and functionality

Terminal Function Description Ground Ground connection for fan monitoring
1 + Temp Positive temperature sensor input from non- 1 circuit.
(Input) DriveCLiQ temperature sensor.
Type:- KTY84-1C130/PTC Fan Fan monitoring signal, input from fan.
2 - Temp Negative temperature sensor input from non 2 Monitoring.
(Input) DriveCLiQ temperature sensor. (Input)
Type:- KTY84-1C130/PTC
+24 V DC +24V DC supply to fan.
3 Safety Applying +24V DC will cause the pulses of the 3 (Output) Maximum 2 A. (1 x 2 A or 2 x 1A)
Integrated. individual axis to be enabled. (Current consump-
Enable tion:10mA) 4 Ground Ground for fan supply.
Pulses When the signal is low, “Safe pulse suppres-
EP +24 V sion” is activated.
(Input) Note:-No electrical isolation occurs between the External Fan module
Motor module and the motor.
This enable signal is only operational if the Safe-
ty Integrated function “Safe Standstill (SH)” is
enabled.
This is a dual channel monitoring system of the
Control Unit and Motor Module. The status of
the Enable Pulses input is cross checked
against the corresponding CU input, an error is
reported if they do not match.
4 Safety Must be connected to the 0V of the enable puls-

Integrated. es supply. Non Siemens fans may be used without the monitoring. In
Enable this case terminals 1& 2 must be linked.
Pulses
EP M1
(Ground)
Notes :

X224 Terminal Description and functionality

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

+ M
X203 - Y axis motor feedback.

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

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

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

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

Combi Drive LED Status:
Off Electronics power supply outside permitted Check +24V supply (X24).
range.
READY Orange On DriveCLiQ communication is being Check alarms on controller.

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

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

Mains Supply and Enabling Examples

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

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


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

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


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


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

B051 END Line and Motor Modules

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

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

Axis and Drive Diagnostics B053
Axis and Drive

Diagnostics:
START
Service
Overview
Screen
Axis
Diagnostics
Drive
Diagnostics
Axis and Drive

Diagnostics:
END
Notes :

Service Overview Screen The indicators change appearance depending on the condition
of the signal.
To navigate to the relevant diagnostics page please use the
following key presses. The signal is healthy, in the case of an enable, the
signal is high. For a monitoring signal there is no fault
present.
The signal is missing i.e. low (Enable signals only).
The signal is indicating a fault (Monitoring signals

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

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

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

new displayed.
Give the name for the displayed

and for the file
Notes :

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

This detailed information can be very useful when a problem is done with the “Axis +” and “Axis -” soft keys.
occurs on the machine.
or
An alternative method of selecting the required axis is via the
“Axis selection” soft key.
This the quickest method on a machine with many axes.
Useful information about the axis in question ranging from

positional data to current and torque readings is available.
Further information can be seen by using the page/cursor
keys.
Notes :

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

select the “Service drive” soft key.
More diagnostics information is revealed by

using the page/cursor keys
Drive System.
Further drive diagnostic information, specifically Sinamics re-

lated, can be found by selecting the “Drive system” soft key.
The status of the Drive-CLiQ drive objects can be seen. The CU is the only drive object displayed, to view the other
drive objects press the “Input” key.
A healthy drive object, fully enabled ready for
operation.
A drive object with a warning e.g. enable missing.
A drive object with a fault.
Notes :

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

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

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

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

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

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

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

“SINAMICS_ALARM_MASK”.
Notes :

Many alarms are generated when the system detects a com-

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

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

will be displayed in red or grey.
Notes :

Display options Automatic Firmware Update:

When replacement drive hardware is fitted it is important that
The topology display can be changed via the “Display op- the firmware version is correct. In normal circumstances the
tions” soft-key: system automatically loads the firmware to any modules not
at the correct firmware level. If the firmware is not automati-
cally updated the “Load firmware” soft-key can be used.
Firmware:
Firmware is a software that is written to the internal flash
memory of the Drive-CLiQ components. Firmware updates
are used to keep the components up to date with the latest
technological advances. The firmware version is dependant
upon the current system software version.
Graphic Toplogydisplay
Set/act comparison NCU
The topology is displayed by the

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

To the alarms diagnosis the fields with Actual topology NCU

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

system is displayed!
Notes :

Configuration
The configuration shows the allocati-

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

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

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

Useful information is displayed when the “Details” soft-key is
selected.
These are known as the ”Electronic Rating Plates”.
Example: Details of component MM_SP1 single motor module
Comparison Levels To the right of the screen, a column named “C.level” can be
seen.
This is used to set the comparison level for the Drive-CLiQ
components.
The system compares the stored details of the electronic rat-
ing plate of each object with the actual components connect-
ed to the Drive-CLiQ bus.
Once the drive system is configured it is continually moni-
tored. Alarms will be displayed if a fault occurs or an unknown
Comparison Levels: object is detected.
High-compares the complete electronic rating plate.
Medium– compares the component type and order number.
Low– compares the component type.
Minimum– compares the component class.
Service case 1: If a new component is to be fitted to a system

to replace a faulty one it is not necessary to change the com-
parison level. The system should automatically load the cor-
rect firmware to the new component.
Service case 2: If two existing components are to be inter-

changed to prove a fault e.g. Motor Module 1 & Motor Module
2, the system will detect this and issue alarms depending on
the setting of the comparison level.
In this case setting the comparison level to low would allow
the modules to be interchanged without alarms occurring.
Notes :

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

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

B084 Encoder Adjustment
Sinumerik
Operate
Module Description:
All positioning axes require referencing in order for the controller to position them. The procedures for the
referencing of incremental and absolute encoders is described along with the most important machine
data.
Module Objective:
Upon completion of this module you will be able to synchronise/adjust the measuring system for the
Sinumerik 828D controller.
Content:
Sinumerik
Referencing Incremental Encoders
Referencing Absolute Encoders
Machine Data Information
Automatic Referencing
828D SINUMERIK Operate V4.8 Page 1 This document was produced for training purposes. B084
B084 Page 2 828D SINUMERIK Operate

Encoder Adjustment B084
Encoder
Adjustment
START
Referencing
Incremental
Encoders
Referencing
Absolute
Encoders
Machine
Data
Information
Automatic
Referencing
Encoder
Adjustment
END
Notes:
828D SINUMERIK Operate V4.8 Page 3 B084

Referencing Incremental Encoders :
General Information
Axes equipped with incremental encoders require referencing
each time that the NCK is powered off/on or reset.
This usually entails traversing the axis to a switch which then
initiates the referencing procedure. Certain machine data's
are available to influence this procedure and adjust it to indi-
vidual requirements.
Some axes have a second encoder fitted for positioning oper-
ations. It needs to be checked which measuring system is
active, as that will be the one which requires referencing.
To check which measuring system is active we can look at the
“Axis diagnostics” area.
Look for the “Measuring system 1 active” and “Measuring sys- If it is uncertain whether an axis has an incremental or abso-
tem 2 active”. A green tick symbol indicates which measuring
lute encoder fitted, this can be checked via axis machine data
system is active for each axis., typically the motor encoder. A
30240.
2nd measuring circuit is typically a linear scale on an axis or a
To check the machine data use the following soft key se-
2nd encoder for a spindle. quence.
Some manufacturers may also switch between measuring
systems. If there is uncertainty about this please contact the
manufacturer for information.
Machine data 30240[0] & [1] should be checked.
If the active measuring circuit is 1, machine data 30240[0]

should be used to identify the encoder type.
Ensure that the correct axis is selected. If the active measuring circuit is 2, machine data 30240[1]
or
Incremental encoder = 1
Absolute encoder =4
To reference an axis fitted with an incremental encoder, an

interface signal needs to be switched high in the user PLC
program. This is usually done with a switch positioned at a
suitable place on the axis slide way.
During the reference procedure the axis will traverse towards
the switch, on activation of the switch the interface signal will
be set.
A sequence of axis moves will then take place which are con-
trolled by the NC and influenced by machine data.
(Further details are shown on the following pages)
Example of an axis reference switch input activating a refer-

ence point approach interface bit.
Notes:

Before referencing can be initiated the controller needs to be

placed into Reference Mode by selecting the “REF.POINT”
button on the machine control panel. The LED should Illumi-
nate, the “JOG” mode LED remains illuminated.
Variable DB380x.DBX1000.7 “Delay Ref. Pt approach” inter-

face signal needs to be set to high to initiate the referencing
procedure.
Each axis has its own variable which is identified by changing Confirmation that the correct mode is selected can be seen at
the x for a numerical value which represents the axis, see the top of the screen.
below-
1st axis - DB3800.1000.7

2nd axis - DB3801.1000.7
3rd axis - DB3802.1000.7
etc.
The axis must now be moved in the direction of the reference

switch. This can be done manually via the axis jog keys or
automatically if automatic referencing is set-up.
The direction of movement is set via machine data.
The axis should move uninterrupted towards the reference
switch. Some systems require that the jog direction button is
continually depressed throughout the reference cycle, howev-
er it is more common to find that the axis will continue to
move even when the jog direction button is released.
Each axis can be referenced individually. It is also possible to
reference the axes automatically. This is usually set up by the
machine builder and will be explained in more detail later in
the module.
To reference an individual axis select the correct axis via the

machine control panel.
Notes:

Referencing sequence diagram for incremental encoder
In the event of the values of machine data 34080 & 34090 equalling less than the stopping distance of the axis, the controller will
automatically readjust to the correct position.
34040 $MA_REFP_VELO_SEARCH_MARKER = 0
34080 $MA_REFP_MOVE_DIST + 34090 $MA_REFP_MOVE_DIST_CORR = > 0
Velocity
Reference point cam
switch activated
0 1
MD34020 Ref. point approach velocity
34070 Ref. point position velocity
MD34040 Ref. point search marker velocity
Position
Cam switch 1 0
Axis referenced. Marker pulse detected Reverse direction
The control receives a reference axis command, the axis accelerates to the feed-rate in machine data
34020 $MA_REFP_VELO_SEARCH_CAM then searches for the reference switch input to become high.
The reference switch is operated and the axis decelerates.
The axis reverses direction at the feed-rate set in machine data.

34040 $MA_REFP_VELO_SEARCH_MARKER.
Feed-rate as machine data 34040 $MA_REFP_VELO_SEARCH_MARKER.

Search for next reference marker
Reference marker is detected. The axis accelerates to the feed-rate set in

machine data 34070 $MA_REFP_VELO_POS to a position which is the sum of machine data
34080 $MA_REFP_MOVE_DIST and 34090 $MA_REFP_MOVE_DIST_CORR
Notes:

Once the axis is referenced the controller issues interface Referencing Absolute Encoders :
signals.
1st axis - DB3900.DBX0.4 1st measuring circuit is referenced General information
1st axis - DB3900 DBX0.5 2nd measuring circuit is refer- Absolute encoders need referencing on first commissioning
enced and remain referenced until a problem occurs with the encod-
2nd axis - DB3901 DBX0.4 1st measuring circuit is referenced er or the NCK. Re loading of an archive will also necessitate
2nd axis - DB3901 DBX0.5 2nd measuring circuit is refer- the referencing of the encoder.
enced Procedure:
etc. First it must be ascertained that the encoder is of the absolute
type. This can be done by checking the motor data rating
plate (In the case of an integrated motor encoder)
The position display will indicate the axis is referenced and Checking with the supplier of the encoder is another method
display any values stored in machine data: of determining the correct type.
34100 $MA_REFP_SET_POS
Machine data 30240[0] & [1] can also be checked.
Symbol indicating the axis is referenced. If the active measuring circuit is number 1, then the value of
machine data 30240[0] should be used to identify the encoder
type.
If the active measuring circuit is 2, machine data 30240[1]

The following values determine the encoder type:
Incremental encoder =1
Absolute encoder =4
Value from Axis MD 34100
Check that machine data 34200 ENC_REFP_MODE is set to

0 This enables the control to take over the value in machine
data 34100 $MA_REFP_SET_POS.
Check that machine data 34210 ENC_REFP_STATE is set to
1. This is to enable encoder calibration to take place.
Check whether machine data

34010 REFP_CAM_DIR_IS_MINUS is set to 0 OR 1.
The procedure requires that the axis be moved to a known
mechanical position e.g. 150mm. Locate machine data 34100
$MA_REFP_SET_POS and enter 150.
Notes:

The axis to be referenced should be moved to the known me-

chanical position using “Jog” mode in the direction determined
by the value of machine data:
34010 REFP_CAM_DIR_IS_MINUS.
A value of 0 and the approach will be in the positive direction,

a value of 1 will make the approach negative.
The feed rate when approaching this position should be re-
duced to avoid inaccuracies caused by backlash.
Before referencing can be initiated the controller needs to be

placed into Reference Mode by selecting the “REF.POINT”
button on the machine control panel. The LED should Illumi-
nate, the “JOG” mode LED remains illuminated.
Confirmation that the correct mode is selected can be seen at

the top of the screen.
The A axis of the training equipment is fitted with an absolute
encoder and therefore the following procedure can be used to
reference it.
Select the A axis and then press the same direction key used
to position the axis earlier.
The axis will not physically move but the position display will
change to show the axis is referenced symbol and the refer-
ence point set position will be shown as the position of the
axis (150 mm).
Machine data 34210 will have changed to 2 to indicate a
successful procedure.
Notes:

Machine Data Information :

If the axis fails to reach the reference cam it is probably due to
If a machine does not have reference switch cam it is possible machine data-34030 $MA_REFP_MAX_CAM_DIST (Default
to reference from the zero mark by changing machine data- value 10000 mm) This is the maximum distance to the refer-
34000 $MA_REFP_CAM_IS_ACTIVE (Default value 1) ence cam.
A value of 0 will deactivate the cam. The controller will issue alarm:-20000 Channel %1 axis %2
This is used for example on axes that have only one reference reference cam not reached.
mark along the entire traversing range and rotary axes that
have only one reference mark per revolution. When the reference switch is activated the axis reverses di-
rection in search of the reference marker. This search speed
The direction that the axis approaches the reference switch is determined by machine data- 34040
can be changed by machine data- $MA_REFP_VELO_SEARCH_MARKER (Default value
34010 $MA_REFP_CAM_DIR_IS_MINUS (Default value 0) 300.0 mm/min).
The default value will result in the reference point approach in
a positive direction. To reverse the direction a value of 1 has The direction for the reference marker search is changed by
to be entered. machine data-
34050 $MA_REFP_SEARCH_MARKER_REVERSE (Default
The initial approach speed for referencing is determined by value 0)
machine data- 34020 $MA_REFP_VELO_SEARCH_CAM The default value causes the axis to search for the reference
(Default value 5000.0 mm/min) cam in the opposite direction to the direction specified in ma-
chine data 34010 $MA_REFP_CAM_DIR_IS_MINUS.
Entering a value of 1 in machine data 34050 will reverse the
cam search direction.
If the axis fails to reach the reference marker it is probably

due to machine data- 34090 $MA_REFP_MOVE_DIST_CORR (Default value 0.0
34060 $MA_REFP_MAX_MARKER_DIST (Default value 20 mm) This machine data is used to accurately set the position
mm) This is the maximum distance the axis can travel without and correct discrepancies caused by an encoder exchange or
finding the marker.. mechanical work.
The controller will issue alarm:-20002 Channel %1 axis %2 The values in machine data 34080 & 34090 are added togeth-
zero mark missing. er to determine the distance the axis moves.
When the marker is detected the axis will either stop or move Usually the position display shows zero after an axis has
to a position determined by the values of two machine data been referenced. This can be changed by machine data
(34080 & 34090 see below for further explanation) 34100 $MA_REFP_SET_POS (Default value 0.0 mm)
The speed at which this position sought is determined by ma- The value entered in here will be displayed on the screen as
chine data- soon as referencing is complete.
34070 $MA_REFP_VELO_POS (Default value 10000.0 mm/ This is used when the reference position is not the mechani-
min). cal zero of the machine. The machine data does not result in
the axis physically moving.
34080 $MA_REFP_MOVE_DIST (Default value -2.0 mm).
Once the marker has been detected it is advisable to move
the axis away from the marker (Into the machining area). This
is achieved by putting a value in machine data 34080.
If the axis was asked to reference again while still on the
marker this could result in the axis going toward the end of the
slide.
Notes:

B084 End Encoder Adjustment
Automatic Referencing (Incremental Encoders):
Automatic referencing cycle Example: Y Axis set as number 2 in the reference procedure.
To set the automatic referencing function it has to be decided
in what order you want the axes to reference. It is common for
example that on a milling machine the Z axis needs to be ref-
erenced first, this helps eliminate the chance of a collision.
The order is set by axis machine data
$MA_REFP_CYCLE_NR (Default 1)
Possible entries:-
0 = no referencing cycle participation.
1 to 15 = allowable range for setting the sequence.
-1 = no reference required for Cycle start.
Up to five axes can be referenced at the same time.
To initiate the automatic cycle the necessary interface bit has

to be set (DB3200.DBX1.0).
Example of how the automatic referencing cycle can be initiat-

ed.
Ref Mode active NC start request Activate

referencing
Interface signal DB3300.DBX1.0 (NC to PLC) changes to 1

while the referencing cycle is active.
B084: END
Notes:

B008 MCP & PP72/48 PN Connections and
Sinumerik Diagnostics
Operate
Module Description:
The PLC periphery components of the 828D controller are connected to the Profinet network.
Periphery components are used to interface between the controller and the physical inputs and out-
puts of the machine.
Machine control panels (MCPs) :

MCPs handle signals such as axis selection, jog commands, cycle start etc.
There are two possibilities for connecting an MCP to the 828D controller; one is via USB, the second
is via Profinet.
It is possible to have a maximum of two MCPs per controller - one must be via USB & one must be
via Profinet.
There are three sizes of MCP supplied by Siemens:
MCP483 is 483mm in length and is recommended for use with the horizontal variant of 828D.
MCP310 is 310mm in length and is recommended for use with the vertical variant of the 828D.
MCP416 is 416mm length and is a perfect fit for the SINUMERIK 828D PPU 290.3
A 4rd variant is the OEM version (supplied/manufactured by OEM).
PP72/48:
The 828D controller uses up to five PP72/48 PN input/output modules for example, to handle signals
to coils and lamps, and signals from pressure switches, over-travel switches etc.
Module Objective:
Upon completion of this module the course participant will know how to configure and install
Siemens machine control panels (MCPs) and PP72/48 periphery I/O modules.
Content:
Sinumerik
USB MCP: Description and Interface Signals
Profinet MCP: Description and Interface Signals
Profinet PP72/48: Description and Interface Signals
Profinet Configuration: MCP & PP72/48
Configuration of two MCPs
B008
B008

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

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

They are available in three formats:
MCP483 USB - 483mm wide.
The MCPs have pre-determined buttons and switches (Cycle start, Jog selection, feed override etc.) for standard machine con-
trol as well as freely assignable custom keys and a twin 7-segment display.
A single USB interface is found on the rear side for connecting to the 828D.
Two 16mm diameter blanked holes are available on the MCP483 USB, MCP416 USB and four on the MCP310 USB.
Setup is achieved by a single machine data. No addressing is required.
MCP483 USB
MCP483 USB: Front Layout with Custom Key Identification (S10 - 24 & S31 - 39)
JOG REFP 88 S10 S11 S12 S31 S32 S33
Emergency Teach MCS Spindle Feed

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

RESET
block Stop Start S49 S7 S21 S22 S23 S24 stop start stop start
Notes :

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

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

RESET
Stop Start block stop start
Spindle
override
Notes :

MCP416 USB
MCP416 USB: Front Layout with Custom Key Identification (S10 - 24 & S31 - 39)
Notes :

MCP xxx USB: Key assignment
Milling: Turning:
(S31) (S32) (S33) (S31) (S32) (S33)

X Y Z +Y +X +C
(S34) (S35) (S36) (S34) (S35) (S36)

4. Axis 5. Axis 6. Axis -Z +Z
(S37) (S38) (S39) (S37) (S38) (S39)

7. Axis 8. Axis 9. Axis -C -X -Y
(S22) (S23) (S24)

- +
• Keys S22 to S24 are only preassigned for milling applications.

• You can freely assign keys S22 to S24 for turning applications.
Notes :

Input images (DB1000 & DB1001) for MCP483, MCP310 and MCP416
1st MCP = DB1000

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

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

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

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

2) MCP310 USB: Preassigned as Coolant. MCP483 USB and MCP416 USB: Freely assignable customer key.
3) Not available for MCP310 USB, for MCP483 USB and MCP416 USB: Freely assignable customer key.
Notes :

Ouput images (DB1100 & DB1101) for MCP483, MP310 and MCP416
1st MCP = DB1100

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

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

0003 mand in
MCS/WCS
0004
S18 *S40 2) *S7 1) S21 - - - S32
0005
S10 S11 S12 S13 S14 S15 S16 S17
0006 - - - - - - Reset S23
0007 - - - - - - - -
0008 7-segment display LED 1
0010 - - - - - - - -
0011 - - - - - - - -
DP
0012
- - - - - - DP2 DP1
0013
0014 User data
0015 User data
1) MCP310 USB: Preassigned as Coolant. MCP483 USB and MCP416 USB: Freely assignable customer key.
2) Not available for MCP310 USB, for MCP483 USB and MCP416 USB: Freely assignable customer key.
Notes :

Control 7-segment display:
The MCP USB has a 2-position 7-segment display. To output a character, write the ASCII code as hexadecimal value of the
character to the output image. For the signs q, b, r, d, t, y, n, o, only the code works for the capital letters
Example: To display the number “2“, you must write hexadecimal value 32 and for "p" the hexadecimal value 50 write to
the output image.
The representable signs are yellow marked.
DB1100.DBB8 7-segment-display left

DB1100.DBB9 7-segment-display right
ASCII-character table
MCP USB Initialisation:
On machines where a single MCP of the USB type is to be

used, set the Machine Data:
MCP 1 12950[0] $MN_PLC_MCP_CONNECT = 1

MCP 2 12950[1] $MN_PLC_MCP_CONNECT = -1
Value = -1 no MCP
Value = 0 MCP PROFINET
Value = 1 MCP USB
.
The MCP USB LEDs will no longer flash following the NCK
reset.
Note: To configure a machine with two MCPs please refer

to the last section of this module.
Notes :

Profinet MCP: Description and Interface Signals:
Profinet MCPs have extra functionality for advanced applications.

They are available in two formats:
MCP483 PN - 483mm wide.
MCP310 PN - 310mm wide.
The MCPs have pre-determined buttons and switches (Cycle start, Jog selection, feed override etc.) for standard machine con-
trol as well as freely assignable custom keys.
Various interfaces are found on the rear side.
Two 16mm diameter blanked holes are available on the MCP483 USB and six on the MCP310 USB.
Setup is achieved by machine data and dip switches.
MCP483 PN
S1
MCP483 PN: Front Layout with Custom Key Identification (T1 - T16)
Note:- Cycle stop, Feed stop & Spindle stop signals are inverted i.e. Normally closed.
Buttons T1 to T16 are free for use by the manufacturer.
Notes :

MCP483 PN: Rear Layout
X10
X53
X54 X60 X61
X31 X51
X52
X55
X20
H3
X30 H2
H1 X21
X5
S2
X51 Digital inputs X60 Hand-wheel

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

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

IB112
D C B A
IB113 REPOS REF INC var. 10000 INC INC 1000 INC 100 INC 10 INC 1
Key- Key- Spindle start Spindle stop Feed Feed NC Start NC Stop
IB114 switch switch posi- start stop
position 0 tion 2
Reset Key- Single block Feedrate override

IB115 switch posi-
tion 1 E D C B A
Direction keys Key switch Axis selection keys
position 3
IB116 + - Rapid trav- X 4th axis 7th axis
R15 R13 erse R1 R4 R7
R14
Axis selection keys
IB117 Y Z 5th axis MCS/WCS R9 8th axis 6th axis
R2 R3 R5 R12 R8 R6
Unassigned customer keys
IB118
T9 T10 T11 T12 T13 T14 T15
IB119
T1 T2 T3 T4 T5 T6 T7 T8
IB122 KT8 KT7 KT6 KT5 KT4 KT3 KT2 KT1
IB123 KT9
Spindle override
IB125
E (16) D (8) C (4) B (2) A (1)
MCP483 PN Output signals to machine control panel (LEDs)

Machine function Operating mode

QB112
INC 1000 INC 100 INC 10 INC 1 JOG TEACH IN MDA AUTO
Feed Feed NC Start NC Stop REPOS REF INC var. INC 10000
QB113
start stop
Direction X 4th axis 7th axis Single block Spindle start Spindle stop
QB114 Minus R1 R4 R7 R10
R13
Z 5th axis MCS/WCS 8th axis 6th axis Direction Plus
QB115 R3 R5 R11 R9 R8 R6 R15
Unassigned customer keys Y
QB116
T9 T10 T11 T12 T13 T14 T15 R2
QB117
T1 T2 T3 T4 T5 T6 T7 T8
QB118 Reset Rapid
QB119 KT6 KT5 KT4 KT3 KT2 KT1
Signals marked with * are inverse signals.
Notes :
SINUMERIK 828D Page 13

MCP310 PN
MCP310 PN: Front Layout with Custom Key Identification (T1 - T16)
Note:- Cycle stop, Feed stop & Spindle stop-signals are inverted i.e. Normally closed.
Buttons T1 to T16 are free for use by the manufacturer.
Notes :

MCP310 PN Rear Layout
X10
X53
X54 X60 X61
X31 X51
X52
X55
X20
H3
H2
X30 H1 X21
X5
S2
Interface Description:- X51 Digital inputs X60 Hand-wheel

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

Machine Control Panel Interface Signals
The following tables show the interface signals for an MCP310 PN with the recommended start address of 112.
MCP310 PN Input signals from machine control panel (keys)
IB112 *NC Stop Spindle - Spindle Spindle + Single block JOG MDA AUTO
100%
NC Start Spindle right *Spindle Spindle left Key-switch REF REPOS Teach IN
IB113 stop position 3
Feed start *Feed stop INC var. Key-switch

IB114 position 0 INC 1000 INC 100 INC 10 INC 1
Feedrate override
IB115 Reset Key-switch Key-switch E (16) D (8) C (4) B (2) A (1)
Direction keys Rapid

traverse KT5 (X52.2) KT4 (X52.1) KT3 (X51.3) KT2 (X51.2) KT1
IB116
+ - (X51.1)
Axis selection
IB117
T16 KT6(X52.3) 6th axis 5th axis 4th axis Z Y X
IB118 T9 T10 T11 T12 WCS MCS T13 T14 T15
IB119 T1 T2 T3 T4 T5 T6 T7 T8
IB123 KT9
Spindle override
IB125
E (16) D (8) C (4) B (2) A (1)
MCP 310 PN Output Signals to machine control panel (LEDs)
QB112 NC Stop Spindle Dec. Spindle Spindle Inc. Single Block JOG MDA AUTO
100%
NC Spindle Spindle RESET REF REPOS Teach In
QB113 Spindle left
start right Stop
QB114 Feed Start Feed Stop INC var. INC 1000 INC 100 INC 10 INC 1
QB115
QB116 Minus Plus Rapid trav- KT5 KT4 KT3 KT2 KT1
Direction Direction erse
QB117 T16 KT6 6th axis 5th axis 4th axis Z Y X
T9 T10 T11 T12 MCS/WCS T13 T14 T15
QB118
QB119 T1 T2 T3 T4 T5 T6 T7 T8
Notes :
B008 Page 16 SINUMERIK

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

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

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

PP72/48 PN Description and Interface Signals

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

In total 72 digital inputs and 48 digital outputs are available on
each of the two variants.
The analogue module has an additional two analogue inputs
and two analogue outputs.
X222
828D Software Max. number of PP72/48 modules
24x 3
26x 4
28x & 28xA 5
X2 X2
Port Port
Part numbers: 6FC5311-0AA00-0AA0 Digital only 2 1 X333
(PP72/48D PN)
6FC5311-0AA00-1AA0 Digital/analogue
(PP72/48 2/2A PN)
X1
Interfaces:
S1: Addressing switches.

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

H1 Power Green On: Power OK
Off: One of the generated logic voltages is low.
H2 PNSync Green ON: Bus cycle clock is synchronised.
Off: Bus cycle clock is not synchronised
Flashing @ 0.5 Hz: Bus clock cycle is synchronised and cycli data exchange is running.
H3 PNFault Red Off: No errors present, data exchange with all configured
I/O devices is running.
On: Serious bus fault due to one the following:
• No physical connection to a subnet/switch.
• Incorrect transmission rate.
• Full duplex transmission is not activated.
H4 DIAG1 Green Reserved
H5 DIAG2 Green reserved
H6 OVTemp Red Over temperature Indication.
Notes :

Ribbon cable connections.
The following Tables show the pins and I/O addresses for ribbon connectors X111, X222, X333. This is assuming the PP72/48
PN is configured with a start address of 0 (Input bytes 0, 1, & 2 and output bytes 0 & 1).
Pin assignment X111 Pin assignment X222

Pin Signal Pin Signal Pin Signal Pin Signal Pin Signal Pin Signal
1 0V DC 19 I2.0 37 Q0.6 1 0V DC 19 I5.0 37 Q2.6
2 +24VDC O/P 20 I2.1 38 Q0.7 2 +24V DC O/P 20 I5.1 38 Q2.7
3 I0.0 21 I2.2 39 Q1.0 3 I3.0* 21 I5.2 39 Q3.0
4 I0.1 22 I2.3 40 Q1.1 4 I3.1* 22 I5.3 40 Q3.1
5 I0.2 23 I2.4 41 Q1.2 5 I3.2* 23 I5.4 41 Q3.2
6 I0.3 24 I2.5 42 Q1.3 6 I3.3* 24 I5.5 42 Q3.3
7 I0.4 25 I2.6 43 Q1.4 7 I3.4* 25 I5.6 43 Q3.4
8 I0.5 26 I2.7 44 Q1.5 8 I3.5* 26 I5.7 44 Q3.5
9 I0.6 27 Not used 45 Q1.6 9 I3.6* 27 Not used 45 Q3.6
10 I0.7 28 Not used 46 Q1.7 10 I3.7* 28 Not used 46 Q3.7
11 I1.0 29 Not used 47 +24V DC I/P 11 I4.0 29 Not used 47 +24V DC I/P
12 I1.1 30 Not used 48 +24V DC I/P 12 I4.1 30 Not used 48 +24V DC I/P
13 I1.2 31 Q0.0 49 +24V DC I/P 13 I4.2 31 Q2.0 49 +24V DC I/P
14 I1.3 32 Q0.1 50 +24V DC I/P 14 I4.3 32 Q2.1 50 +24V DC I/P
15 I1.4 33 Q0.2 15 I4.4 33 Q2.2
16 I1.5 34 Q0.3 16 I4.5 34 Q2.3
17 I1.6 35 Q0.4 17 I4.6 35 Q2.4
18 I1.7 36 Q0.5 18 I4.7 36 Q2.5
*Note: The first input byte of X222 has FAST gating hardware.
Input information:
X222, byte 1 - maximum delay time - 600μs.
All other inputs, delay time - 0.5 to 3ms.
Pin assignment X333

Pin Signal Pin Signal Pin Signal
1 0V DC 19 I8.0 37 Q4.6
2 +24V DC O/P 20 I8.1 38 Q4.7
3 I6.0 21 I8.2 39 Q5.0
4 I6.1 22 I8.3 40 Q5.1
5 I6.2 23 I8.4 41 Q5.2
6 I6.3 24 I8.5 42 Q5.3
7 I6.4 25 I8.6 43 Q5.4
8 I6.5 26 I8.7 44 Q5.5
9 I6.6 27 Not used 45 Q5.6
10 I6.7 28 Not used 46 Q5.7
11 I7.0 29 Not used 47 +24V DC I/P
12 I7.1 30 Not used 48 +24V DC I/P
13 I7.2 31 Q4.0 49 +24V DC I/P
14 I7.3 32 Q4.1 50 +24V DC I/P
15 I7.4 33 Q4.2
16 I7.5 34 Q4.3
17 I7.6 35 Q4.4
18 I7.7 36 Q4.5
Notes :

Profinet Configuration - MCP & PP72/48

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

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

MD Profinet Input Output IP address
S1/S2
12986[x] Device Range Range 192.168.214.xxx
Setting
0 1&4
1. PP72/48 0 to 8 0 to 5 9
on
1 4
2. PP72/48 9 to 17 6 to 11 8
on
2 1, 2 & 3
3. PP72/48 18 to 26 12 to 17 7
on
3 2&3
4. PP72/48 27 to 35 18 to 23 6
on
4 1&3 Compatibility
5. PP72/48 36 to 44 24 to 29 5
on
PN/PN To achieve compatibility between machines using the 828D
5 96 to 111 96 to 111 - 20 *)
Coupler
Controller, it is necessary to assign individual hardware with
7 the same I/O address range.
6 MCP 112 to 125 112 to 121 64
on The 1st PP72/48 module should always start with I/O address
7 n/a n/a n/a n/a n/a 0 (MD12986[0] = -1). Further modules should be addressed in
numerical order i.e
Sentron 2nd PP72/48 (MD12986[1] = -1) I/O start address = 9
8 132 to 143 132 to 143 - 21 *)
PAC 4200
3rd PP72/48 (MD12986[2] = -1) I/O start address = 18
Sentron
9
PAC 3200
144 to 155 144 to 155 - 22 *) 4th PP72/48 (MD12986[3] = -1) I/O start address = 27
5th PP72/48 (MD12986[4] = -1) I/O start address = 36
10...15 n/a n/a n/a n/a n/a
The MCP should always be assigned the start address of 112
*) The IP address of these components is configured by direct- (MD12986[6] = -1).
ly connecting to them using a PC and the relevant software.
Notes :

Recommended MD12986 use: Example: MD12986 for use with MCP and one PP72/48
module.
Machine data Device Start Address/ Activation
Default Setting Setting
12986[0] 1st PP72/48 0 -1
12986[1] 2nd PP72/48 9 -1
12986[2] 3rd PP72/48 18 -1
12986[3] 4th PP72/48 27 -1
12986[4] 5th PP72/48 36 -1
12986[5] PN/PN Coupler 96 -1
12986[6] MCP 112 -1
12986[7] Reserved
12986[8] Sentron PAC 132 -1 The machine data is activated by an NCK power off/on.
4200
12986[9] Sentron PAC 144 -1
3200
12986[10]... Reserved
[15]
Configuration of two MCPs Profinet MCP via Data Blocks
When two MCPs are to be connected, observe the following: It is possible to use the MCP Data Block interface for the
Profinet MCP rather than the PLC I/O interface.
• USB MCP always uses the DB interface.
Machine data to be set:
• Profinet MCP can use either PLC I/O or DB interface.
• If two MCPs are used, one must be the USB type and 19720 $MN_PLC_FUNCTION_MASK
one must be Profinet type. Bit 0 : Profinet MCP via DB = 1
12986[6] $MN_PLC_DEACT_IMAGE_LADDR_IN = -1
Machine data is used to achieve the required configuration.
MCP 1 12950[0] $MN_PLC_MCP_CONNECT = 1 The PLC user program needs to be edited to ensure the cor-
MCP 2 12950[1] $MN_PLC_MCP_CONNECT = 0 rect transfer of signals between MCPs and the user interface.
More information is found in Module B026.
Value = -1 no MCP
Value = 0 MCP PROFINET
Value = 1 MCP USB
PLC Interface DBs for USB/Profinet MCPs
There are four PLC interface DBs to handle the two MCPs:
MD Inputs Outputs
MCP1 DB1000 DB1100
MCP2 DB1001 DB1101 B008: END
Notes :

B008 END MCP & PP72/48 PN Connections and Diagnostics

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

To maintain compatibility between machines fitted with the Sinumerik 828D controller it is essential
that the design criteria, described in the PLC Design document, is adhered to.
These requirements have been created so that the PLC program is easy to understand. This simpli-
fies the fault finding procedure, leading to minimal downtime in the event of a breakdown.
This module describes the PLC design requirements and shows how to use the PLC828
programming tool, including uploading/downloading procedures.
Module Objective:
Upon completion of this module you will know how to use the PLC828 programming tool to:
• Create a PLC program
• Upload a PLC project from the controller to a computer
• Download a PLC project to the controller from a computer
• Use the diagnostic functions of the Programming Tool
You will also know the recommended PLC design requirements.
Content: PLC Design

Sinumerik
S7-200 PLC Cyclic Operation

General PLC Interface Description
Creating a PLC Project (PLC Part1)
Uploading & Downloading PLC Projects
Editing PLC Programmes (PLC Part 2)
Symbol Tables
Cross Referencing
Data Blocks
Comparing PLC Programs
Importing & Exporting PLC Archives.
B026
B026

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

Downloading Exporting
PLC PLC
Projects Archives
Editing PLC Creating a PLC

Programs Program:
(PLC Part 2) END
Notes :

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

• Program blocks using transfer variables are difficult to understand for the customer and
the dealer.
2 Organisational block OB1 should perform organisational tasks only.
• Conditional subroutine calls
• Unconditional subroutine calls
3 The logic programmed should not exceed the width of the displayable area of the controller.
• The complete logic network should be displayable on the control.
4 Only use complex instructions when there is no alternative.

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

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

Subroutine
Subroutine
Subroutine Subroutines are processed in the

order they appear in OB1.
Subroutine
Subroutine
Interrupt INT_101 The INT_101 interrupt block can be used to influ-

ence the Process Image Table (Outputs).
Process Image Table At the end of the scan the status of the outputs is
(Outputs) transferred to the Process Image Table.
End of Scan
Interrupt INT_0 The INT_0 interrupt block runs independently of

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

General PLC Interface Description
Operand identifiers Description Area

DB Data Blocks DB1000 to DB7999 System DBs
DB9000 to DB9063 User DBs
DB9900 to DB9999 Special DBs
T Timers T0 - T15 = 100ms
T16 - T127 = 10ms
C Counters C0 to C63
I Digital Inputs I0.0 to I256.3
Q Digital Outputs Q0.0 to Q256.3
M Marker M0.0 to M999.7
SM Special Marker SM0.0 to SM0.6 (see below)
A ACCU AC0 to AC3 (DWord)
Structure of Data Blocks

The 8-Digit Data Block made up of different sections.
DB3801.DBX1000.7
Bit Number (0 to 7)
Offset (000 to 999)
Section (0 to 9)
Area Number (00 to 99)
User Area (10 to 99)
The format of the Data Block can be written in different ways.
Type Format No. of bits

Bit DB3801.DBX1000.7 1
Byte DB3801.DBB0 8
Word DB3801.DBW2 16
Double Word DB3801.DBD3004 32
Special Markers
The interface structure also consists of “Special Markers” (Flags) which are a set of operands to be used at the convenience of
the user throughout the PLC program
SM bits Description
SM0.0 Flag with defined ONE signal
SM0.1 Initial setting: first PLC cycle ’1’, following cycles ’0’
SM0.2 Buffered data lost - only valid in first PLC cycle (’0’ data ok, ’1’ data lost)
SM0.3 Power On: first PLC cycle ’1’, following cycles ’0’
SM0.4 60 s cycle (alternating ’0’ for 30 s, then ’1’ for 30 s)
SM0.5 1 s cycle (alternating ’0’ for 0.5 s, then ’1’ for 0.5 s
SM0.6 PLC cycle (alternating one cycle ’0’, then one cycle ’1’)
General
Variables that can only be read are identified with [r]
Variables that can be read and written to are identified with [r/w]
Notes :

The PLC interface Data Blocks are used for interfacing between the PLC, HMI, NC & Drives.
The following Table shows a brief description of the interface Data Blocks. For a more detailed description please refer to Ap-
pendix C.
DB1000/DB1001 User data (Area 1) /MCP USB

DB1100/DB1101 User data (Area 2) /MCP USB
DB1200...DB1207 PLC functions and PI services
DB1400 Retentive data area
DB1600 PLC user alarms
DB1700/DB1701 Program control (HMI to PLC) & SMS Messenger
DB1800 Mode signals (HMI to PLC), date/time (from PLC) & Maintenance Planner
DB1900 General status/selection signals to/from Operator Panel, RCS viewer inhibit
DB2500/DB2501 Auxiliary functions M, T, S, D & H functions
DB2600 General signals to NCK
DB2700 General signals from NCK
DB2800 Signals to fast I/O
DB2900 Signals from fast I/O
DB3000/DB3001 Operating mode signals (PLC to NCK)
DB3100/DB3101 Operating mode signals (NCK to PLC)
DB3200/DB3201 Signals to NCK channel, Signals to geometry axis
DB3300/DB3301 Signals from NCK channel, Signals from geometry axis
DB3400/DB3401 Signals for Asynchronous sub routines
DB3500/DB3501 G Functions from NCK channel
DB3700...DB3711 M/S Functions from axis/spindle
DB3800...DB3811 Signals to axis/spindle/drive/PLC axis & technology functions
DB3900...DB3911 Signals from axis/spindle/drive/PLC axis & technology functions
DB4000...DB4301 Signals to/from tool management
DB4500 PLC machine data and PLC user alarm configuration
DB4600...DB4700 Synchronised actions
DB4900 Reading/writing PLC variables
DB5300/DB5301 Tool management signals from NCK
DB5700...DB5711 Reading actual values/distance to go
DB6000...DB6011 Safety Integrated signals to axis
DB6100...DB6111 Safety Integrated signals from axis
DB9900...DB9902 Tool management-user interface
DB9903...DB9904 Maintenance planner user interface
DB9905 Easy Extend user interface
DB9906, DB9907 Control Energy function.
DB9908 Spindle temperature monitoring
DB9910...DB9912 NCvar selector
DB9913 Extended alarm messages
The Machine Control Panel is allocated to a certain Input/Output area.

IB112...IB125 Reserved for MCP 310/483 input signals
QB112...QB119 Reserved for MCP 310/483 output signals
Notes :

Creating a PLC Project (PLC Part1)
Toolbox Examples
The PLC program is created using the PLC828 Programming

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

the library:
The sample programs are freeware. Any user can use,

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

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

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

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

Part one is intended to get the machine control panel and
hand-wheels functioning using example projects from the Milling machine with (MCP483).
toolbox.
PLC Project with Profinet MCP:

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

Example for the training equipment using an MCP483 PN:
Select and open the MCP_483_M project.
It is advisable that the project is saved under a different name.

This will keep the example intact so that it can be used again
in the future.
To save the project select “Save as” from the drop down
menu.
The right hand window of the PLC828 programming tool con-

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

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

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

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

Deleting networks 1 & 2: Spindle assignment
In order for the MCP to correctly process the spindle specific

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

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

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

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

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

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

The properties dialogue box of the Subroutine is opened auto- Calling the subroutines.
matically.
The properties can be edited, however, the block number The newly added subroutines have to be called in Organisa-
should not changed. tion Block OB1.
OB1 should only be used for the calling of subroutines.
Below: OB1 containing calls to the MC P subroutines. Special

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

paste mouse functions.
This should be pasted to an unused network e.g. Network 3 This subroutines are located in the Subroutines folder
Notes :

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

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

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

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

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

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

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

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

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

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

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

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

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

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

gards to the types of blocks to be downloaded to the control-
ler.
Blocks of the Manufacturer/individual data class can be in-
cluded or excluded as well as the actual values of Data
Blocks.
Note- Actual values:
This is an important selection depending on the reason

for downloading the project in the first place.
Example: If an old PLC project containing actual values is

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

data blocks for storing data. This data is continually
changing which is why careful consideration should tak-
en when deciding whether to include the actual values of
the data blocks.
In the case of the PLC part 1, there will be no actual values

present.
Notes :

The option to download the project in stop or run mode is of- To start the PLC, select the Run button on the toolbar.
fered along with a warning about the dangers of downloaded
in run mode.
If in doubt always use the option “Place the PLC in STOP

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

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

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

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

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

of each PLC instruction.
Notes :

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

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

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

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

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

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

Training equipment Pulse Enable signal requirement:
Axis Interface signal

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

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

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

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

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

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

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

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

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

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

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

Symbole (SYS2) symbol tables belong to the system and are
read-only. Further symbol tables can be selected via the tabs.
Editing the symbol tables
The symbol tables for the inputs and outputs, (PP_1, PP_2,
PP_3, PP_4, PP_5) should be edited to assist with the fault
finding process.
The symbols used should match those of the electrical dia-
grams.
Double click the Symbol Tables to open them.
Example: Modified PP_1 symbol table
To see the effect of the symbol table, the options “Symbolic

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

With both the Symbolic Information Table and the Symbolic New Symbol Tables
Addressing selected:
New Symbol Tables can be added by right clicking on the
Symbol Table folder and selecting Insert Symbol Table:
Symbolic
Addressing
Symbolic
Information
Table
Right click Insert Symbol table
A new symbol Table ready for editing:
Cross Referencing
Right click in the Symbol table to rename, if required:
A Cross Reference table can be created, this lists information
about individual operands such as which blocks they are used
in and can greatly assist maintenance personnel with the fault
finding process.
It may be necessary to compile the project before a cross

reference list can be displayed.
Compile
button
Notes :

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

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

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

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

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

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

Editing Data Blocks:
• The Address is automatically set, depending on the Data Type.
• The Name is entered by the user and must be unique. Underscores are automatically added in place of spaces.
• Data Types are selected via a drop down menu.
• Formats are selected via a drop down menu. (Available Formats are determined by the selected Data Type)
• An Initial Value can be set. This value can be transferred to the controller during the download procedure.
• Additional information can be added in the Comment column.
Various Data Types can be used in various Formats Data Types Format Drop Down Menu:
(Depending on the Data Type): Drop Down Menu: (Depends on the Data Type):
Data Type Format

Boolean Bit
Byte Unsigned, Hexadecimal, Binary, Ascii
Word Unsigned, Hexadecimal, Binary, Ascii
Double word Unsigned, Hexadecimal, Binary, Ascii
Integer Signed
Double Integer Signed
Real Floating point, Hexadecimal, Binary, Ascii
An example of a Data Block containing information, including Initial Values:
Initial Values:
If the Data Block requires Initial Values the values have to be

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

From the Edit menu select Accept Initial Values.
Notes :

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

B026 END Creating a PLC program

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

Compare Functions
Convert Functions
Counter Functions
Floating Point Number Functions
Integer Functions
Interrupt Functions
Invert Functions
And Functions
Or Functions
Move Functions
Program Control Functions
Shift/Rotate Functions
Timer Functions
Libraries
B021
B019

S7-200 PLC Instructions B019
S7-200 PLC
Instructions:
START
Bit Logic And

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

B019 S7-200 PLC Instructions
General Information A Word can only be addressed as 0 or an even number (IW0,

Address Formats: IW2, IW4 etc) odd numbers are not allowed.
Bit- This refers to a single element of logic e.g. I6.0, Q5.5, As with the Byte format the numbering starts from the right.
M100.6, DB3804.DBX2.1. Example IW4
The Bit part is the number after the decimal point. The value of IB5 IB4
a bit is either 1 or 0. Bit no 7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0
Value 1 0 1 0 0 1 0 1 0 1 1 1 0 0 1 1
Byte- A Byte is a collective of 8 bits of logic in the same group.
e.g. In this example I4.0, I4.1, I4.4, I4.5, I4.6, I5.1, I5.2, I5.5, I5.7.
Input Byte 4 (IB4) contains the bits I4.0, I4.1, I4.2, I4.3, I4.4, are equal to 1.
I4.5, I4.6, I4,7. Output Words (QW) and Marker Words (MB) can also be used
When working with bytes it must be remembered that the num- in the same way.
bering counts up from the right as shown below.
IB4 Double Word- A Double Word is a collective of 32 bits of logic
Bit no 7 6 5 4 3 2 1 0 which encompasses two consecutive Words (Four consecu-
Value 1 0 1 0 0 1 0 1 tive Bytes).
In this example I4.0, I4.2, I4.5 & I4.7 are equal to 1. Another A Double Word can only be addressed as 0 or an even num-
term for being equal to 1 is that these bits are High. ber which is a multiple of four, (ID0, ID4, ID8, ID12 etc) odd
The bits equal to 0 are termed as being Low. numbers are not allowed.
Output Bytes (QB) and Marker Bytes (MB) can also be used in Example ID4
the same way. IB7 IB6 IB5 IB4
Bit no 7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0
Word- A Word is a collective of 16 bits of logic which encom- Value 1 0 1 0 0 1 0 1 0 1 1 1 0 0 1 1 1 0 1 0 0 1 0 1 0 1 1 1 0 0 1 1
passes two consecutive Bytes.
Output Double Words (QD) and Marker Double Words (MD)
can also be used in the same way.
Bit Logic Function The PLC program is built up of a series of blocks called sub-
Instruction Tree:- routines. The blocks contain networks, the user PLC is written
The instructions are found in the menu tree to the left of the into these networks.
main programming area.
The first instruction category in the list is Bit Logic. This group
is the simplest of the instructions.
The individual items in the Bit Logic area are referred to as
Operands.
These operands need to be addressed, the type of address
depends upon the
operand.
Terminology
Inputs:- Typically they are represent the physical state of the

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

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

Program Status Contacts:
The status of an operand can be checked by selecting the
“Program status” Icon.
The most commonly used operands are “contacts”. Combina-
The centre of the operand becomes highlighted with a colour tions of contacts are used to achieve the end result of activat-
when it is true. ing an output.
These contacts can be assigned to system/user variables,
markers, physical outputs or inputs and can be of the normally
open or normally closed types.
Normally open contacts.
Program Q4.0 = 0 or Q4.0 = 1 or When the operand is high (Equal to one) the contact will be
Status Icon Low High closed and the logic will be true.
When the logic is true the centre of the contact will be col-
oured.
In the terms of an electrical device the contact will be closed
Coils: and current can flow.
As the names suggests, “Coils” are switched on/off by

“Contacts”.
Typical coil operands are Outputs, Markers, Variables, Data
Blocks, Timer & Counters. It is also possible to have an input
as a coil but this can be deemed as bad
practice.
I6.0 = 0 or Low I6.0 = 1 or High
Output Q4.0 as a coil
Normally Closed Contacts. Immediate Contacts.

These operands are effective immediately upon activation,
In this situation when the status of the operand is high (Equal they are not subject to the Process Image Table (Inputs). They
to one) the logic will be false. are identified by the letter “I”.
In terms of an electrical circuit, the contact will be open and
current cannot flow through to the next operand.
This is the opposite of the Normally Open operand.
Normally Open Immediate Normally Closed Immediate
Not operands.
The Not operand is used to reverse the state of the logic. i.e.
A status of one will become a status of zero while a status of
zero will become a status of one.
I6.0 = 0 (Low) I6.0 = 1 or (High)
Set and Reset example:-
I6.2 = 1 but Q4.2 remains low because the not operand inverts
the signal.
I6.5= 0, however Q4.5 I6.6 = 1, this has the ef-

remains high because it is fect of resetting Q4.5 to 0.
a “Set” output.
I6.2 = 0 but Q4.2 is high because the not operand inverts the
signal.
Notes :

Positive Transition operands. No Operation Operand (NOP):-

The Positive Transition operand monitors the preced- A network cannot be left in an unfinished state, this leads to
ing operand status for a rising edge (Signal state change from errors when the program is compiled and prevents the pro-
0 to 1) on seeing a rising edge the logic will become true for gram from being loaded.
one scan of the PLC.
An unfinished network.
If the program is in the development stages then a “No Oper-
When I6.3 changes from 0 to 1, Q4.3 will become high for one ation” operand can be inserted, this prevents the network
scan of the PLC cycle from being operational and allows the program to be compiled
and loaded to the controller.
Negative Transition operands.
The Negative Transition operand monitors the preceding oper-

and status for a falling edge (Signal state change from 1 to 0)
on seeing a falling edge the logic will become true for one
scan of the PLC.
An unfinished network with a NOP operand.
When a NOP operand is inserted it has to be given an numeri-

cal identifier.
This identifier can be selected from the range of 0-255.
When I6.3 changes from 1 to 0, Q4.4 will become high for one
scan of the PLC cycle.
Immediate Outputs.
These operands are effective immediately upon activation.
The status is passed to both the physical output and the Pro-
cess Image Table (Outputs).
They are identified by the letter “I”.
IB6 = 14 and IB7 = 15, they IB6 = 14 and IB7 = 14,
are not equal so the status they are equal so the
is low. Q5.0 = 0. status is high. Q5.0 = 1.
Output Immediate Set Immediate Reset Immediate Compare bytes for not being equal.
Compare functions are used to compare two values. The com-

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

compare Input
bytes 6 & 7.
IB6 = 15 and IB7 = 14, IB6 is

IB6 = 14 and IB7 = 15, IB6 greater than IB7 so the status
Compare Functions is less than IB7 so the sta-
Compare bytes for being equal is high. Q5.2 = 1.
tus is low. Q5.2 = 0
This would also be the case if
the values were equal.
Notes :

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

When I6.0 is true the integer value in MD0 will be converted Permitted ranges:
into a real number and the result placed into MD4.
It is also possible to extend the network via the “ENO” output BCD Decimal Hex
to other operands. The “ENO” output will be high if the convert Minimum 0000 0000 0000 0000 0 0
function was successful. Maximum 1001 1001 1001 1001 9999 9999
Truncate (Converts 32-bit real to 32 bit signed integer). Example:- When input I6.2 is true the value in MW0
(0000000001010100 = 54) will be converted into an integer
and the result placed in MW12. Output Q4.6 will become high
provided that the value in MW0 is within the ranges specified
above and I6.2 remains true.
The Truncate Function takes a 32 bit Real number and cov-
erts it into a 32 bit Double Integer which is signed. In other
words only the whole number portion of the real number is
transferred. The fraction is discarded.
Example:-
When input I6.1 is true the value of –1.1 in MD0 was trans-
ferred to MD8 as a value of –1. Output Q4.5 was set high by
the ENO output.
Notes :

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

Below:-The reset input has been switched from low to high Prior to using the countdown counter a value has to be en-
resulting in the count value being reset to zero and the C1 tered into the Preset Value PV input field.
operand becoming false. No further counting can take place This value has is then transferred into the counter when the
until the reset signal is set to low. LD input (I7.1) changes from low to high.
The count value can be reloaded at any time by setting the LD
input from low to high.
When the counter is first selected in the user program it needs
to be given a unique name (Available range C0 to C63).
Below:-Count down counter C2 with a PV of two, this PV value

Preset value (PV) = 10
will be entered into the counter when the LD input I7.1 switch-
es from low to high.
This count value will decrease by one on each positive edge
detection of the CD input I7.0.
C1 count value = 0
Countdown counters
Countdown counters are used to monitor the rising edge of a

signal, each time a rising edge is detected on the CD input
the count value will decrement by one.
When the count value reaches zero the counter operand be-
comes high.
Below:-Countdown counter C2 showing a count value of 4.

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

high as a result of
countdown counter
C2 reaching zero.
Below:-Countdown counter C2 showing a count value of 0.
This means that the CD input has detected a rising edge from
I7.0 on 10 occasions since the preset value of 10 was entered.
The result of this is that the C2 operand is now true as shown
in network 22. In this case output Q5.6 is now high.
Notes :

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

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

value of 9 which is less than of 11 which is more than the pre-
the preset value. set value.

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

Floating Point Number Functions When input I9.0 goes high, the value in MD100 (IN1) in this
case 16, will be added to the value in MD104 (IN2) in this case
Addition of real numbers 2. The result will be placed in MD108 (OUT)
Below:- The function requires parameterisation on first selec-

tion.
Values to be added:
IN1 32 bit real number
IN2 32 bit real number added to IN1
Result:-
OUT 32 bit real number
MD100 has been assigned to IN1 and has a value of 16.0
Confirmation:- MD104 has been assigned to IN2 and has a value of 2.0
ENO Bit goes high if operation successful
Below:- Input I9.0 is high and the ADD function has been per-
Below:- The ADD function prior to parameterisation. formed. The result is placed in MD108. The ENO output is
high which sets output Q6.0 high, this indicates that the ADD
function was a success.
MD108 = 18 Result of the ADD func-
Below:- Example of a parameterised ADD function before

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

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

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

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

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

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

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

tion.
It is also possible to add/subtract/multiply/divide integers in MD200 + MD202 = MD204

the same way as real numbers. The inputs and outputs act in Adding Double Integers (9000) + (3000) = (12000)
the same way, only the number format changes.
IN1 16 bit integer or 32 bit double integer

IN2 16 bit integer or 32 bit double integer
MW200 - MW202 = MW204
Result:- (100) - (25) = (75)
Subtracting Integers
OUT 16 bit integer or 32 bit double integer.
Confirmation:-
ENO Bit goes high if the operation was successful. MD100 has been
assigned to IN1 and
Below:-Examples of adding/subtracting Integers and double has a value of 16.0 MD208 - MD212 = MD240
integers. Subtracting Double Inte- (9000) - (3000) = (6000)
Notes :

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

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

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

result to a double word.
The result is in two parts, the high word section of the double Increment and Decrement Functions.
word represents the whole number while the low word repre-
sents the remainder. The format is hexadecimal. These functions allow a number to be incremented or decre-
In the example below the result of 100 ÷ 8 shows a value of mented by a value of one.
000C in hex format which is equal to 12 as an integer. The The formats can be Byte, Word or Double Word.
remainder is 0004 which is equal to 4 as an integer. This is a once only occurrence, further switching of the control
bit does not result in further increments/decrements.
Below:- Examples of increment and decrement functions.
The value in MB200

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

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

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

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

Interrupt Functions Invert Functions

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

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

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

dress column and the format set to binary. And Double Word
In the example below it can be seen that the status of the
inputs is the exact opposite of the output status.
This is better seen in the Chart Status area.
And Functions I7.0 and I9.0 are high

which sets M238.0
The AND function compares two bytes, words or double
words. If two corresponding bits are high the relevant output This equivalent operation when written in ladder is seen be-
bit will be set. low:-
And Byte
Notes :

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

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

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

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

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

Move Byte Immediate Write
Move Real Number

The Swap function takes the lower byte data and places it in
the higher byte and vice versa. The swap is initialised via the
EN input. The swapping continues every PLC cycle as long as
the input is high. A positive edge instruction can be used to
control the swapping of data more effectively.
Swap Function Example of how a Jump/Label might be used.
Jump Instruction to Label 1 is not active.
MW68 prior to running the Swap function.

I7.2 switches Q8.7 in the expected manner.
MW68 after running the Swap function.
Program Control
Jump Instruction to Label 1 is active.
Jump Instruction & Labels
I7.2 does not switch Q8.7 because the
The Jump Instructions and labels are used together. When program jumps to Label 1.
the Jump is activated the program will skip to the Label spec-
ified by the Jump.
The Jump Instruction needs to be parameterised with the
number of the label to be jumped to. The available range is
from 0 to 255.
The jump instruction has to be used in the same program-
ming block.
Notes :

Jump Instruction to Label 1 is active. The Conditional Return Instruction is not

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

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

Jump Instruction to Label 1 is active.
has been terminated by the Conditional
Return.
Q8.7 remains high despite I7.2 being low

this because I7.2 was set low after the
program Jump Instruction was activated. The Conditional Return Instruction is active.
Q9.3 remains high despite I7.7 being low.

This is
Conditional Return Instruction. because I7.7 was set low after the program
Conditional Return was activated.
The Conditional Return Instruction is used to terminate a sub-
routine.
Example of how a Conditional Return Instruction might be

used:-
The Conditional Return Instruction is active.
Q9.3 remains low despite I7.7 being high. The Conditional End Instruction is active.
This is
because I7.7 was set high after the Condi-
tional Return was activated.
I6.2 is high which but Q4.1 remains low. This
is because program end is now in the previ-
ous network.
Conditional End Instruction.
The Conditional End Instruction is used only in OB1 and re- When the Conditional End Instruction is active, no further pro-
sults in the program scan restarting at the beginning of OB1. cessing takes place.
No further operations after the Conditional End will be pro- Outputs, markers etc which were already high will remain so
cessed. until influenced from elsewhere in the program.
Example of how the Conditional End Instruction might be Shift Left Byte.
used.
The shift Left Byte function allows the bits within a byte to be
moved to the left by up to 8 places. In the example below the
contents of IB9(IN) will be shifted left by 4 places (N). The
result will be placed in MB100 (OUT) The maximum number of
places that can be moved is eight. If a larger number is en-
tered the value will default to eight.
The Conditional End Instruction is not active.
I6.2 is high which switches Q4.1 high.
Notes :

The example below shows the result when viewed in ladder

status, a better idea of this is seen in Chart Status.
Byte to be shifted (IB9) The result of the Shift

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

Shift/Rotate Functions
shifted left by four places and the result placed in MB100.
Shift Left Word & Shift Right Word.
Below:-The Chart Status shows that status of IB9 has been The contents of a Word can be shifted left or right in the same
shifted left by four places and the result placed in MB100. way that the contents of a Byte can be shifted. The maximum
number of moves is 16.
Shift Right Byte. Below:-Examples of shifting words.
The Shift Right Byte function operates in the same way as the
Shift Left Byte, except that the move is to the right. Shift Left:
Below:-Example of a Shift Right Byte by 2 places operation.
Shift Right: Shift Left:
The Results:
Shift Right:
The Results:
Shift Left Double Word & Shift Right Double Word
The contents of a Double Word can be shifted left or right in

the same way that the contents of a Byte or Word can be Timer Functions
shifted. The maximum number of moves is 32.
Timer are used to delay the effects of a signal when it switch-
Below: Examples of shifting Double Words. es. There are a total of 128 timers available (T0 to T127).
T0 to T15 have an input resolution of 100ms with a maximum
preset time (PT) value of 327.67 seconds.
T16 to T127 have an input resolution of 10ms with a maximum
preset time (PT) value of 3276.7 seconds.
Notes :

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

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

operand in network 8 is still low as the PT value of 50 has not
been reached.
Below: On-Delay timer T1 has been a PT value of 50 this
equates to a delay of 5 seconds (50 x 100ms).When Input
T1 value has
I7.0 becomes high, T1 will start to count, when the PT value is
reached 20
reached the T1 operand will switch high. As a result Q5.0 will
be come high (Network 8) as long as I7.0 remains high T1 will
continue to count and the T1 operand will remain high. When
I7.0 becomes low, the count value of T1 will reset to zero and
the T1 operand will go low.
Below:- The time value of T1 has gone beyond the PT value. Retentive On-Delay Timer
As a result the T1 operand in network 8 is high and has
switched output Q5.0 high.
The Retentive On-Delay Timer works in the same way as the
ON-Delay Timer except that when the IN signal is removed the
Timer operand remains high. The Timer operand will need to
T1 value be reset by the user which also resets the time value to zero.
has
surpassed Below:- Retentive On-Delay timer T2 has been triggered by
the PT I7.1 and the time value has passed the 10 second PT value
value of 50 (100 x 100ms = 10 seconds). The T2 operand is high and has
switched Q5.1 high.
T1 operand is now
high, Q5.0 is also
high as result
Below: Input I7.0 has gone low and the T1 time value is reset
to zero. The T1 operand also goes low as a result.
Notes :

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

Timer operand remains high
The timer is reset using the Reset function which can be seen
in network 8 below.
Timer reset by I7.2 Timer operand T3 is high
Timer count value

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

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

Libraries Data Blocks
The Library contains system blocks for executing specific TM_CTS (DB9900 Constant transfer step table for tool
tasks. These blocks consist of Interrupt Routines and Data change
Blocks.
TM_VTS (DB9901) Variable transfer step table for tool
change
TM_ACK (DB9902) Acknowledgement step table for tool
change
SP_INI (DB9903) Start data for service planner
SP_ACT (DB9904) Actual data for service planner
EE_IFC (DB9905) Interface for Easy Extend options.
CTRL_E (DB9906) Interface for energy saving.
SENTRON (DB9907) Interface for energy monitoring
ISM_TS (DB9908) Interface for spindle temperature
monitoring
ALARM_INI (DB9913) Extended alarm messages function
Interrupt Routines
INT_0 Executed synchronously with the servo cycle The various data blocks are explained in the relevant mod-
INT_100 Executed immediately prior to the MAIN routine ules.
(OB1)
INT_101 Executed immediately after to the MAIN routine
(OB1)
B019: END
Notes :

B019 END S7-200 PLC Instructions

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

PLC Functions B033
PLC
Functions:
START
PI Services
(Program
Invocation
Services)
Reading
Axis
Positions
Reading
and Writing
of NC Data
Data
Exchange
between
NC & PLC
PLC
controlled
axis
PLC
Functions:
END
Notes :

B033 PLC Functions
PI Services (Program Invocation Services)

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

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

PI Services Start Bit Function
PI Address Function Permitted
DB1200.DBX4000.0 Start PI Service Parameter Values
PI Service: LOGOUT - Password Reset 1 DB1200.DBW4004 Tool Number 1 to 31999
PI Index (DB1200.DBB4001) Function 2 DB1200.DBW4006 Source Location 1 to 31999

Number
3 Password Reset
3 DB1200.DBW4008 Source Maga- 1 to 9999
zine Number
PI Services Start Bit Function
DB1200.DBX4000.0 Start PI Service 4 DB1200.DBW4010 Target Location 1 to 31999
Number
There are no PI parameters required for LOGOUT. 5 DB1200.DBW4012 Target Maga- 1 to 9999
zine Number
PI Service: _N_DASAVE - Saving of Data
PI Index (DB1200.DBB4001) Function PI Services Start Bit Function
4 Save data automatically DB1200.DBX4000.0 Start PI Service
Notes :

PLC Functions B033
Interface signals for PI services
The following interface signals are reserved for use with the PI Services function.
DB1200 PLC NCK [r/w]
4000 Start
4001 PI-Index
4002
4003
4004 PI-Parameter 1
4006 PI-Parameter 2
to
4022 PI-Parameter 10
DB1200 NCK PLC [r]
5000 Fault Finished

5001
5002
DB3400-
PLC NCK [r/w]
3401
0000 Asup 1
start
0001 Asup 2
start
0002 Asup 3
Start
0003 Asup 4
start
DB3400-
NCK PLC [r]
3401
Asup 1 Asup 1 Asup 1 Asup 1

1000 start not number not running finished
possible possible

possible possible

1002 start not number not Running Finished
possible Possible

possible possible
Notes :

B033 PLC Functions
Example: Initialise and start an ASUP
The ASUP has to be created either offline and loaded to the

controller or it can be created directly on the controller. To
create on the controller use the following soft-key sequence.
Path = NC data\Cycles\Manufacturer cycles.
The file will open automatically to allow the program com-

mands to be entered. In this example a 10 second dwell is
used with an operator message.
A subroutine should be created in which to write the PLC code to initialise and start the ASUP.
Select PI Service no. 1 (ASUP1) by putting a value

of 1 into DB1200.DBB4001.
Initialise the ASUP with the “Start PI Service signal”.

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

PLC Functions B033
Start ASUP1 with the “ASUP1 Start sig-

nal” (DB3400.DBX0.0 high).
Reset the “ASUP1 Start signal.
LED to indicate ASUP1 is running.
The ASUP will run in all modes. Any program running in automatic mode will be interrupted while the ASUP runs, this program
will then continue when the ASUP has finished.
Notes :

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

into B1200.DBB4001.
Start the PI service by switching

DB1200.DBX4000.0 high.
Reset the PI service start signal.
The active password will be deleted and the access level will be determined by the key-switch position.
Example: _N_DASAVE - Saving data
The following example can be used for automatically backing-up the RAM on the internal flash card. There is no screen display
showing that a data back-up is being carried out. Interface signals are used to show a successful PI Service.
Select PI Service no. 4 by entering a value

of 4 into DB1200.DBB4001.
Initialize the PI Service by setting

DB1200.DBX4000.0 to 1.
Reset the PI Service start signal.
Notes :

PLC Functions B033
PI Service complete signal used to set Q1.1.
MCP Reset key used to reset Q1.1.
Reading Axis Positions
Reading axis actual positions and distances to go
The actual position and distance to go of an axis can be read in the PLC.
The following PLC interface areas are reserved for this function.
DB5700- NCK PLC [r]

5711
0000 Axis actual value (Real)
0004 Axis distance to go (Real)
DB2600 PLC NCK [r/w]

Request axis Request axis

0001 distances to actual values
go
Notes :

B033 PLC Functions
Example: Reading axis actual position and distance to go
Moving the 1st axis actual position into MD100

using the MOV_R instruction. The value is read,
only when DB2600.DBX1.1 is high.
Moving the 1st axis distance to go into MD200

using the MOV_R instruction. The value is read,
only when DB2600.DBX1.2 is high
The result of the example can be seen below:
Reading and Writing of NC Data The parameter values which are obtained from the NC Varia-
ble Editor point to the storage location within the NC which
During the manufacturing process it may be necessary to are required as destination or as source, determined by a
have data available to the NC program from the automation READ or WRITE function.
system in order to optimize the NC machining process.
This could take the form of a numerical value being trans- The NC Variable Editor is part of the 828D PLC Program-
ferred to an R Parameter or a machine setting data receiving ming Tool.
from the automation system an optimised value.
In the opposite direction it may be necessary to influence the
automation system dependent upon the current NC machining
process, positional data available in the automation system is
an example of this.
A user interface is available for the function of:
Reading NC data - DB1200-DB1207

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

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

PLC Functions B033
NCK/Drive PLC user interface NC variables list
DB1200 Global Part DB9912 List 3

DBX0.0 Start Bit
DBX0.1 Read/Write DB9911 List 2
DBB1 Number of variables
DB9910 List 1
Reading NC Data - Var 1 Index 100
- Var 2 Index 101
DB1207 Var 8 …
- Var 42 Index 141
etc.
DB1201 Var 2
Variable from
DB1200 Var 1 DB9910-9912
- Index DBB1000
- Data from NC
3016...3027.0
NC Data
Writing NC Data
Drive
parameters DB1207 Var 8
etc.
DB1201 Var 2
Variable from
DB1200 Var 1 DB9910-9912
- Index DBB1000
- Data to NC
1016...1027.0
Reading and Writing of NC Data Addressing of variables:
Each variable that is to be processed in a job, must be speci- Up to eight variables can be addressed at any one time, iden-
fied in the variable-specific job interface via its parameters. tified by substituting a number (0 to 7) in place of the 4th digit
of the DB number. Example:
Operable variables: DB1200.DBB1000 - 1st variable
DB1201.DBB1000 - 2nd variable
The selected NC variables are specified via the DB9910 data DB1202.DBB1000 - 3rd variable etc.
block (selected NC variable). The length of the data block
depends on the number of NC variables selected in the varia- Note:
bles list. The variables list can contain maximum 42 selected
NC variables. Channel-specific variables:
When reading/writing channel-specific variables, only the
Up to three variable lists, with in each case maximum 42 se- variables of exactly one channel may be addressed in a job.
lected NC variables (DB9910-9912), are possible.
Drive-specific variables:
When reading/writing drive-specific variables, only the varia-
bles of exactly one SERVO drive object may be addressed in
a job. The SERVO drive object must be assigned to a ma-
chine axis of the NC. The line index corresponds to the logical
drive number.
Error case:
In the event of an error, reading/writing variables from differ-
ent drive objects, or simultaneously from a channel and a
drive object, an error message is output:
DB1200.DBX3000.1 == 1 (error occurred)
Notes :

B033 PLC Functions
Interface signals for read/write NC Data

The following interface signals are reserved for use with reading and writing NC data.
DB1200 PLC  NCK [r/w]
Read:0
0000 Start
Write:1
0001 Number of variables to be read/written
0002
0003
DB1200- PLC  NCK [r/w]

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

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

PLC Functions B033

1207
3000 Fault Valid Variable
3001 Access result

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

from NC varia-
ble x (BOOL)
*2)
*1) Only for predefined variables of the "Read/write NC variable" user interface (available owing to compatibility)
*2) Only for variables from DB9910-9912 NC_DATA
Special data block (DB9910-9912) with selected NC data
DB9910-9912 Selected NC data [r]

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

B033 PLC Functions
Generate Special data block (DB9910-9912) By compiling the PLC Project the suitable data blocks are
generated from the variable lists.
The Selected NC Variables folder contains all selected NC
Variables. A new list can be inserted via Right click on the
Selected NC Variables folder. Up to three lists are possible.
Compile PLC
project to gen-
erate DBs
Allocation of the DBs:

- Variables list 1 -> DB9910 (Index 100-141)
Note: - Variables list 2 -> DB9911 (Index 142-183)
- Variables list 3 -> DB9912 (Index 184-225)
Every variables list can contain maximum 42 selected NC
variables, restricted by the maximum DB size of 512 bytes.
Variable from DB9910-9912 NC_DATA
Type 100 - 225: Variable from DB9910-9912 NC_DATA - The value of a variable can be read/written.
Selected NC data (Read/write)
DB120x.DBB1000 100 - 141: Variable 1 to 42 from DB9910 NC_DATA1

142 - 183: Variable 1 to 42 from DB9911 NC_DATA2
184 - 225: Variable 1 to 42 from DB9912 NC_DATA3
DB120x.DBB1001 Area Number of variable x *1)
DB120x.DBW1002 Line index of variable x *2)
DB120x.DBW1004 Column index of variable x *3)
DB120x.DBD1016 … Writing data to NC variable x (REAL, ...)

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

PLC Functions B033
Example: Reading and writing data from/to an R parameter
1. Variable from DB9910 NC_DATA 2. Variable from DB9910 NC_DATA
fixed addressing variable addressing
(Example: Reading R parameter 10) (Example: Writing R parameter 11)
DB1200 PLC  NCK [r/w] DB1200 PLC  NCK [r/w]
0000 Read: 0 Bit1=0 0000 Write: 1 Bit1=1
0001 Number of variables 1 0001 Number of variables 1
Variable declaration Variable declaration
1000 Variablenindex 100 1000 Variablenindex 101
1001 Bereichsnummer -
Not used 1001 Bereichsnummer -
when DB9910
1002 Line index - - DBB3>0 1002 Line index 12 12=R11
- DBW4>0 =12th RP
1004 Column index - - DBW6>0 1004 Column index -
Result Result
1016 Writing NC variable - 1016 Writing NC variable 25.4

(REAL) (REAL)
3016 Reading NC variable 25.4 3016 Reading NC variable -
(REAL) (REAL)
DB9910 Selected NC data [r] DB9910 Selected NC data [r]
NC Variable 1 NC Variable 2
0000 Variable index 100 0012 Variable index 101
0001 Syntax ID 16#82 0013 Syntax ID 16#82
0002 Area 2 This case 0014 Area 2

1=Chan 1
0003 Unit 1 0015 Unit 1
0004 Column index 1 0016 Column index 1
0006 Line index 11 11=R10 0018 Line index 0 0=Value

=11th RP in User
0008 Block 16#15 0020 Block 16#15
Interface
0009 Number of lines 1 0021 Number of lines 1 not DB
0010 Type 15 0022 Type 15
0011 Length 8 0023 Length 8
NC variables selection via 828D PLC Programming Tool
Notes :

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

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

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

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

PLC Functions B033
Compile now the PLC project. Content of the DB9910 (NC_DATA):
The data block DB9910 (NC_DATA) is generated.
The data block DB9910 (NC_DATA) contains the selected

NC variables. Example:-
Variable 1 - Index 100

Variable 2 - Index 101
Notes :

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

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

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

Read. (0 = Read).
Reset Start signal.
Reset Read signal.
Value of DB1200.DBD3016 written to

MD300.
Notes :

PLC Functions B033
To locate the R Parameter screen use the following key selection:
R parameter 10 is used in the example, Cursor to R10 and When the start signal is set to high, the value in R10 will be
enter a value, confirm with the “Input” key. Example R10 = 25. transferred to DB1200.DBD3016.
Below: Status of target variable prior to the start signal.
The value from R10 will now appear in DB1200.DBD3016.
Example: Writing data to an R parameter

To write data to the NC variable it is necessary to first enter a value in the area reserved for this function. This area is
DB1200.DBD1016. Network 4 below shows how this can be done.
Selection of the number of data sets to

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

(= 2nd variable defined in DB9910 = R
parameter [x]).
Selection of the Variable number + 1

(R parameter 11 + 1 = 12).
Value of MD300 written to

DB1200.DBD1016.
Notes :

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

Write. (1 = Write).
Reset Start signal.
Reset Write signal.
The value from DB1200.DBD1016 now appears in R11.
Data exchange between NC and PLC
The 828D controller has a 4095 byte memory area for use
with data exchange between the NC program and PLC.
The function is also available with SYNACT.
The memory available is from DB4900.DBB0 to

DB4900.DBB4095, allowing data to be exchanged directly
between the user PLC and for example a part program.
It is possible to use Byte, Word, Double Word and floating

point numbers to be used as shown below:
$A_DBB[n] Byte format

$A_DBW[n] Word format
$A_DBD[n] Double Word format
$A_DBR[n] Real number
[n] should be substituted for the byte number.
To test the function, the value stored in R10 will be written

into $A_DBR[4] (the 4th double word of DB4900, i.e.
DB4900.DBD4).
The following program code has to be typed into the MDA

area of the Controller: $A_DBR[4]=R10. When the cycle start button is pressed the value be copied
from R10 to the destination variable.
Notes :

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

In the MDA area type the line: R11=$A_DBR[4].
This will copy the contents of $A_DBR[4] into R11.
Notes:
1. The data structure in the data area is defined by the

user.
2. Data reading by the NC can activate a pre-read stop
(internal STOPRE).
3. A maximum of 3 sets of data can be written by the NC
in the same program block.
PLC controlled axis
It is possible to control a servo axis using the PLC interface. Various interface signals are available for this task.
A tool magazine is an example of when a PLC controlled axis could be used.
There are 3 possibilities for positioning a PLC axis:
• Variable positioning using the PLC interface

• Pre-defined positioning from a table in the “General Machine Data” area.
• Equidistant positioning determined via “Axis Machine Data”
Interface signals are used to facilitate the movement of a PLC axis.
PLC interface signals:
DB3800- PLC NCK [r/w]

DB3811
0008 Request PLC Activation Request NC

axis/spindle signal for NC/ axis/spindle
PLC axis
changeover
Notes :

B033 PLC Functions
Start posi-
3000 tioning axis
Traversing Path Path

3002 dimension condition: condition:
Inch Shortest path Incremental
(DC) (IC)
Abs. path Abs. path

3003 Indexing condition: condition:
position Positive di- Negative
rection direction
(ACP) (ACN)
3004 Position (Real number for variable positioning, double word when using fixed index positions)
3008 Feedrate (Real number)

If = 0 value is taken from axis machine data POS_AX_VELO

DB3911
PLC axis/
0008 spindle
Positioning Position Error Axis

3000 axis active reached during travers- cannot be
ing started
3002
3003 Error number
Prior to commissioning a PLC axis it is necessary to declare the axis as a PLC axis.
It is possible to do this permanently via Axis machine data 30460 or using interface signals to switch between PLC/NC control.
A geometry axis cannot be assigned as a PLC axis.
Firmly assigning the axis to the PLC via machine data:
Variable positioning using the PLC interface
The following example shows how to position a PLC axis using a variable from the PLC interface.
Notes :

PLC Functions B033
Reset Initiation bit.
Initiate the PLC axis.
Select the axis as a PLC axis.
Select incremental moves.
Command position of the axis (“real”

value).
Start the positioning procedure.
Reset Start signal.
Notes :

B033 PLC Functions
The PLC axis will now move to the position entered in

DB3804.DBD3004.
By the changing the value of DB3804.DBD3004 it is possible to

move the axis to varying positions, For example, the value en-
tered here could be taken from the Tool Management interface
and used to position a tool carousel in preparation for a tool
change.
Positioning using an index table General MD: 10910 $MN_INDEX_AX_POS_TAB_1

10930 $MN_INDEX_AX_POS_TAB_2
The number of indexing positions is entered via machine data:
The index array to be used is selected via Axis machine
General MD: 10900 $MN_INDEX_AX_LENGTH_POS_TAB_1 data:
10920 $MN_INDEX_AX_LENGTH_POS_TAB_2
Axis MD: 30500 $MN_INDEX_AX_ASSIGN_POS TAB
There are two index tables (Machine data arrays) available
where index positions can be entered: The following example shows how to position a PLC axis
using the positions entered in an index table found in the
“General Machine Data” area.
The 10 positions are divided equally into 36 degree incre-

ments.
Notes :

PLC Functions B033
Reset Initiation bit.
Initiate the PLC axis.
Select the axis as a PLC axis.
Select positioning by index table.
Selecting the index position e.g. 5.
Start the positioning procedure.
Reset Start signal.
The axis will now move the position entered into the 5th value (Index 4) of General Machine data 10910
$MN_INDEX_AX_POS_TAB_1.
B033: END
Notes :

B033 END PLC Functions

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

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

Alarm Structure B037
NCK Alarms and

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

Messages:
END
Notes

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

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

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

of the controller display.
More than Brief alarm description.

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

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

ues of 500 to 10000 (milliseconds) set the time that each
alarm/message is displayed for.
The machine data is activated with an NC reset.
A full list of alarms can be seen in the “Diagnostics” area. To see extra information, highlight an alarm and select the
“Help” key.
Notes

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

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

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

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

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

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

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

Alarm Log
A log of alarms that have occurred can be seen by selecting

the “Alarm protocol” soft key.
This shows the time when the alarm occurred and when it
was cleared.
The “Display new” soft key is used to refresh the list and
display any alarms that have recently occurred.
There are a number of options which can be selected by

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

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

B037 END Alarm Structure
Write mode file: Time controlled:

The log will be saved at the interval entered in the Write
interval area (max. 32000 seconds).
This will cause less wear and tear of the CF card but still
carries similar risk of damage to the CF card.
The HMI will require restarting for the changes to become ef-
fective
Suppress Alarm Function
Certain alarms can be suppressed via General Machine Data

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

B031 Alarms and Messages
Sinumerik
Operate
Module Description:
Alarms and messages are essential to inform operators, maintenance personnel etc. of the state of
the machine.
Alarms and messages can be configured to have different behaviour on the operation of the ma-
chine.
User help files can be created to give a more detailed description of each alarm/message.
This module describes how the alarms and messages are activated.
The effect an alarm has on the system is described and how to acknowledge an alarm.
Module Objective:
Upon completion of this module you can configure, activate and set the attributes of messages and
alarms and create user help files.
Content:
Sinumerik
General Information
Alarm and Message Screens
PLC Alarm Configuration
Entering the Alarm Text
User Help Files
Alarm Log
Extended Alarm Configuration
Cycle Alarm Configuration
Program Messages Configuration
Text and Colour Configuration files
B031
B031

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

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

700000 - 700247 PLC alarms/messages Customer 2 Acknowlegement of alarm
Extended PLC alarms/messages Custo-
701000 - 701999 3
mer Alarm text
As soon as a fault occurs on the machine, an alarm together A description of the system alarms, their cause and remedy
with the alarm number, alarm text and the acknowledgement/ is documented in the Online Help of the controller and in the
clearance will be shown on the screen. diagnosis manual on DOConCD.
Alarms and Message Screen When alarms and messages are triggered they are separat-
ed and displayed on different screens. The time and date of
The 828D controller allows 248 user PLC alarms/messages the alarm/message occurrence is given.
to be configured (numbered 700000 to 700247).
A configurable alarm log is available to show past alarms/
Each alarm/message has an interface bit for activation messages including when they occurred and when they
(DB1600.DBX0.0 to DB1600.DBX30.7). were cleared. The log can be saved and forwarded to tech-
nical personnel if necessary.
The alarms/messages can be displayed in red or black. Red
is traditionally used to indicate a more serious alarm and Select the following keys to locate the screen where the
black is used for a message type situation. active alarms and messages are displayed.
The effect an alarm/message has on the machine is configu-

rable via general machine data 14516. The same machine
data is used to determine how the alarm/message is
acknowledged.
The 828D controller allows 5000 Customer CYCLE alarms to Depending on the configuration, there are two areas where
be configured (numbered 650000 to 69999). an active alarm might be displayed.
The 828D controller allows the customer to create Program
messages, and assign text.
The “Alarm list” screen displays serious alarms
The alarm/message text can be input via the controller or which result in the machining process being halted.
created offline.
The extended alarm function allows the same alarm/

message number to be used for different situations by substi- The “Messages” screen displays less serious
tuting part of the text for a numerical variable. The following alarms which may not necessarily result in the ma-
shows information required for setting and configuring chining process being halted.
alarms.
Notes :

Below is an example of two alarms in the Alarm list. The alarms can be made scroll in turn after a set time.
This is controlled by Display Machine Data 9056.
With values of less than 500 there is no rotation cycle. Val-

ues of 500 to 10000 set the time that each alarm/message is
displayed for.
The units are milliseconds.
The machine data is activated with an NC reset.

Alarms/messages are also displayed on the top line of the
screen. When more than one alarm/message is present a
downwards pointing arrow appears to the right of the alarm/
message number.
PLC Alarm Configuration Below: An example of how Alarm 700000 is activated via
input I8.0.
The table below shows the alarm numbers and their associ-
ated interface signals and configuration machine data.
Alarm Activation bit Configuration Variable for

No. Machine Data Alarm text
function
700000 DB1600.DBX0.0 14516[0] DB1600.DBD1000
700001 DB1600.DBX0.1 14516[1] DB1600.DBD1004
700002 DB1600.DBX0.2 14516[2] DB1600.DBD1008
700003 DB1600.DBX0.3 14516[3] DB1600.DBD1012
700004 DB1600.DBX0.4 14516[4] DB1600.DBD1016
700005 DB1600.DBX0.5 14516[5] DB1600.DBD1020
700006 DB1600.DBX0.6 14516[6] DB1600.DBD1024
700007 DB1600.DBX0.7 14516[7] DB1600.DBD1028
700008 DB1600.DBX1.0 14516[8] DB1600.DBD1032
700009 DB1600.DBX1.1 14516[9] DB1600.DBD1036
700010 DB1600.DBX1.2 14516[10] DB1600.DBD1040

... ... ... ...
700247 DB1600.DBX30.7 14516[247] DB1600.DBD1998
Notes :

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

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

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

quires no acknowledgement and will clear as soon as the
activation bit becomes zero.
The alarm/message will appear on the message page.
If bits 6 & 7 are used then the alarm/message appears on

the alarm page and an acknowledgement is required.
14516[xx] Effect/Acknowledgement Entering the Alarm Text

Bit 0 NC start inhibit Entering the Alarm Text with HMI
Bit 1 Read in disable
The PLC alarm text or existing text from AMM can be creat-
Bit 2 Feed disable ed or edited directly on the controller, the details are then
saved automatically to an XML file.
Bit 3 Emergency stop It is also possible to edit the xml file off the machine.
Bit 4 PLC stop
The alarm file determines the text that is displayed when a
Bit 5 Alarm log particular alarm is activated.
Bit 6 Acknowledged by DB1600.DBX3000.0 Creating the text on the controller
Bit 7 Acknowledged by Power off/on Locate the Alarm texts screen with the following key se-
quence.
The machine data is activated with via the “Reset (po)” soft
key.
In this window:
Manufacturer PLC alarm tex.
Manufacturer cycle alarm text.
Manufacturer part program message text.
Can be selected.
Notes :

Use the cursor key to highlight the User PLC alarm texts The colour of the alarm text can be either black or red. This
option alarm type and select “OK”. is selected at the right of the text input field.
When an alarm text entry is complete press the “Input” key

to confirm the entry.
Add further alarms in the same way. Select “OK” when all
Up to 248 alarm numbers with text can now be typed in using the alarms have been entered then reboot the HMI.
the key board. Existing alarms can also be edited here.
Allow the HMI to reboot.
The data is now saved to an xml file in the following location:

SystemCF card\oem\sinumerik\hmi\lng
The file name is dependant on the active language when the

file was created:
oem_alarms_plc_eng.ts. The “eng” part of the name is the
language identifier.
Language identifier examples:
eng = English
deu = German The alarm text entered earlier can be seen within the file.
fra = French
ita = Italian
esp = Spanish
chs = Chinese (Simplified)
cht = Chinese (Traditional)
kor = Korean
ptb = Portuguese (Brazil)
Viewing the oem_alarms_plc_eng.ts file:
Notes :

Creating additional language files using AMM-Project. Language files can be uploaded from the controller into the
project.
Access MyMachine can be used to the create language spe- To upload the language files, tick all boxes in the bottom
cific files. Start the Access MyMachine program and make an window.
online connection to the controller.

Example- Adding additional language specific files for the

alarm texts:
To add additional language files for the alarm texts, highlight
the "Alarm texts" menu, followed by "New target language"
Notes :

Select the file "oem_alarms_plc_deu.ts. and open it using

the "Edit" key.
Note:
Target lang: select from the remaining 8 standard

languages
Master copy: select the master language from the

control.
All languages: Allows you to pick the full remaining 21

languages.
In the Edit window, change the alarm number and required

text

text
Enter the required text for the second language.
Notes :


text
Select, with a tick, all the required boxes....

Download the two alarm text files, as shown, using the
"transfer" button.
German translation:
700000 Sicherheitstür geöffnet
700001 Hydrauliköldruck niedrig
700002 Hydraulikölstand niedrig
Note:
Export: Allows a CSV to be generated on PC/
PG, so that language text can be easily translated.
Import: Allows the translated CSV file to be im-

ported back into the AMM project.
Once all the alarms have been transferred using AMM then
reboot the HMI.
English:
The respective files will

be transferred to the
controller
Notes :

German: Entering the Alarm Text with AMM-Editor.
Access MyMachine can be used for entering and editing

alarm text files, this is usually the better option when a large
number of alarms are to be used.
Start the Access MyMachine program and make an online
connection to the controller.
Locate the storage location of the alarm text files:
System CF card\oem\sinumerik\hmi\lng
Right click on the alarm text file oem_alarms_plc_eng.ts Any alarms present in the alarm text file will be displayed.
and select “Open with AMM editor”
The text of the alarms can be easily edited, this is useful for
any translation requirements.
New alarms can also be added
Notes :

Variable Alarm text Function: In the Variable DB1600.DBD1012 the value of 2 is entered.
This is done by a move command.
It is possible to define a variable within the alarm text string. This variable is a Double Word and as such it has to use the
“MOVE_DW” instruction (Move Double Word).
Each alarm is assigned a Double Word variable for this pur-
pose. By selecting one of the following identifiers and enter- Below is an example of how a value 2 is moved into the vari-
ing it into the alarm text, the contents of the Double Word will able DB1600.DBD1012 when input I8.3 is equal to one. This
appear in place of the identifier when the alarm is triggered. would display the number 2 in place of the “%d” and activate
alarm 700003.
%d Decimal value
%x Hexadecimal
%b Binary
%o Octal
%u Unsigned integer
%f Floating point number
Example:
The alarm number 700003 is to be used to signal that sever-
al axes are in the parked position.
The bit to activate this alarm is DB1600.DBX0.3 and that the
extended function variable is DB1600.DBD1012.
In the alarm text, “Axis %d in parked position” has been Below is the alarm 700003 as displayed on the controller.
typed.
By moving different values into DB1600.DBD1012 it is pos-

sible to use the same alarm number to display slightly dif-
ferent messages.
Notes :

User Help Files
General Information
To further enhance the fault finding procedure it is possible to create a “Help” file.
When the HELP key is pressed the details of the selected alarm will be displayed on the screen.
Help file information and Rules:

The help file is of the type HTML (HyperText Markup Language) and needs to be stored in a specific directory.
The HTML file name is fixed: sinumerik_alarm_oem_plc_pmc.html
File location for English language: System CF-Card\oem\sinumerik\hmi\hlp\eng\sinumerik_alarm_plc_pmc
The blue text indicates the folders that require creating. Separate folders are required for each language where the Help files are
a requirement.
Examples:
English - eng\sinumerik_alarm_plc_pmc
German - deu\sinumerik_alarm_plc_pmc
Chinese (Simplified) - chs\sinumerik_alarm_plc_pmc
Chinese (Traditional) - cht\sinumerik_alarm_plc_pmc
Portuguese - ptb\sinumerik_alarm_plc_pmc
Korean - kor\sinumerik_alarm_plc_pmc
A separate file needs to be created and stored in each of the language folders.
HTML script language

Once the file is created the HTML code can be entered. HTML uses tags, each tag has a specific function.
Tags have to be opened and closed in the correct manner, example :
<html> Opening the “html” tag

Information/more tags entered here
etc.
</html> Closing the “html” tag
Common HTML Tag Descriptions:
TAG Description
html Root element-Main tag for the help file, contains all other tags, first to be opened and last to be
closed.
head Contains document information, opened immediately after the HTML tag, closed directly before the
BODY tag is opened.
body The main body of the HTML document, determines what will be displayed on the screen. Opened
immediately after the closing the HEAD tag. Closed immediately before the HTML tag.
table Creates a table for the help file information.
tr Table row, creates a row within the table.
td Table data cell. Used within the tr tag, contains the text that is to be displayed on the help screen.
The tag is used with the width attribute to determine the width of the cell and the valign attribute
to align the text within a cell.
p Used to begin a new paragraph.

b Text will be written in bold type.
i Text will be written in italic type.
br Starts a new line.
Notes :

Creating the help files/directories on the controller

The folders can be created directly on the controller.
Locate the directory where the folders are to be created.

System CF-Card\oem\sinumerik\hmi\hlp Select the “Directory” soft-key, this is usually already select-
Or ed by default.
System CF-Card\user\sinumerik\hmi\hlp
Enter the directory name, this is the language directory.

Several will have to be created help files are to be available
for more than one language. See previous page for
language specific folder names.
Below: Creating a folder for user help in the English

language.
Highlight the new folder and select the “New” soft-key.
The new directory has to be named

“sinumerik_alarm_plc_pmc”
Type in the help file name:
“sinumerik_alarm_oem_plc_pmc.html“.
The file will automatically open in readiness for the HTML

code to be entered,
The file is closed with the following soft-keys:
Creating the help file:
Cursor to “sinumerik_alarm_plc_pmc” directory and select
the “New” soft-key followed by the “Any” soft-key.
Notes :

Example help file
Below is an example help file “sinumerik_alarm_oem_plc_pmc.html” for alarm 700001. The text is in different colours to assist with
understanding the contents.
It is important that the lines begin and end with a Tag open or Tag close instruction (< or />).
<html>
<head><meta http-equiv="Content-Type" content="text/html; charset="UTF-8"/><title></title></head>
<body>
<table>
<tr>
<td width="15%"><b><a name="700001">700001</a></b></td>
<td width="85%"><b>Hydraulic Oil Pressure Low</b></td>
</tr>
<tr>
<td valign="top" width="15%"><b>Parameter:</b></td>
<td width="85%">N/A</td>
</tr>
<tr>
<td valign="top" width="15%"><b>Explanation:</b></td>
<td width="85%">I8.1 is low.</td>
</tr>
<tr>
<td valign="top" width="15%"><b>Reaction:</b></td>
<td width="85%">Emergency Stop Initiated</td>
</tr>
<tr>
<td valign="top" width="15%"><b>Remedy:</b></td>
<td width="85%">The hydraulic unit has indicated a fault. Check oil level. Check pressure switch. <br />Clean filter if necessary.</td>
</tr>
<tr>
<td valign="top" width="15%"><b>Part number:</b></td>
<td width="85%">Hydraulic oil type: AAA. Pressure switch type: BBB <br /> Filter type CCC</td>
</tr>
<tr>
<td valign="top" width="15%"><b>Program continuation:</b></td>
<td width="85%">Machine restart required</td>
</tr>
</table>
<p></p>
</body>
</html>
The system is able to cross reference the highlighted alarm with the entry under the “a” tag.
<td width="15%"><b><a name="700001">700001</a></b></td>
The contents of the table containing the correct anchor are now displayed.
Adding further alarms to the HTML file is simply a case of copying/pasting the existing ”table” tag and its contents and editing to suit
the individual alarm.
The contents of the “head” tag should be left as it is. This determines the content type and text format.
Notes :

Creating the help files/directories on an external PC: The alarm will appear in either the “Alarm list” or “Messages”
It is possible to create the directories/help files offline using screen depending how it has been configured.
an HTML or ASCII editor (e.g. Notepad®).
These files have to be transferred to the controller and placed
in the correct folders.
This can be done via the USB /CF Interfaces or with the Ac-
cess MyMachine software. If several alarms exist cursor to the alarm correct one.
The “sinumerik_alarm_oem_plc_pmc.html” needs to be
placed in one of the following:
“System CF card\user\Sinumerik
\hmi\hlp\eng\sinumerik_alarm_plc_pmc”
Or
“System CF card\oem\sinumerik
\hmi\hlp\eng\sinumerik_alarm_plc_pmc”
Testing the help file:
To test the Help file the alarm specified in the Help file should
be activated.
Alarm 700001 is activated by DB1600.DBX0.1
Active the 700001 alarm locate the “Alarms/Messages”

screen.
The HELP function is activated by the “HELP” key located to Alarm Log
the bottom right of the screen.
A log of alarms that have occurred can be seen by selecting
the “Alarm log” soft key.
This shows the time when the alarm occurred and when it
was cleared.
Notes :

The “Display new” soft key is used to refresh the list and Number of entries:
display any alarms that have recently occurred. This sets the maximum number of alarms displayed on the
alarm log page.
Write mode file:
Off: No storing of the log file will take place to the internal
flash memory (Compact flash card)
At every event: Each time an alarm occurs this will be rec-
orded to the compact flash memory.
The “Settings” soft key is used to refresh the list and display
any alarms that have recently occurred.
When this option is selected, a warning is displayed. By

leaving this option permanently set, the life of the internal
flash card will be reduced.
There are a number of options which can be selected by

using the cursor and select keys and confirmed with the “OK”
soft key:
The controller needs to be restarted to make the changes

effective.
Time controlled: The log will be saved at the interval entered

in the Write interval area (max. 32000 seconds). Store log: This allows the log file to be manually saved in a
file which can be retrieved and used for diagnostic
purposes.
The file destination is displayed at the bottom of the screen

for several moments after pressing the “Store log” soft key.
This option carries similar risk to the “At every event” option
and the same warning is displayed.
Use the following soft key sequence to locate the log file:-
Use the “Cursor” and “Input” to locate the “alarm log”

directory.
The controller needs to be restarted to make the changes

effective.
Notes :

Extended Alarm Configuration
On a complex machine the need for more than 250 alarms

may be required, this can be achieved by using the
“Extended PLC Alarms”, thus giving an extra 1000 alarms.
To use the “Extended alarms” the relevant DB must be add-

ed to the PLC program. First check the PLC type in the PLC
programming tool:
PLC -> Type…
The file can be viewed by using the “Open” soft key.
The file can be copied and pasted to other destina-

tions such as an external storage device.
This could then, for example be forwarded to tech- PLC Type -> 828D Step 2 07.01
nical personnel for assistance. Activate compatibility mode should be unticked.
As shown above.
Note: If the tick is removed from “Activate compatibility mode”

and acknowledged, the above window will be shown, also
acknowledge too.
DB9913 ALARM_INI should now be loaded into the project.

Located in the PLC libraries, in “Special Data Blocks”.
Double click on Data Block and acknowledge.
Notes :

The table below shows the extended alarm numbers and Below: An example of how Alarm 701000 is activated via
their associated interface signals and configuration data. input I8.7.
Alarm Activation bit Configuration Variable for

No. Data alarm text
function
701000 DB1600.DBX4000.0 DB9913.DBW0 DB1600.DBD5000

Configuration data:
The configuration using the “Bit Editor” is used to determine
how the controller reacts to that particular alarm. Each alarm
701005 DB1600.DBX4000.5 DB9913.DBW10 DB1600.DBD5020 has a bit pattern assigned to it for this purpose, this Bit pat-
tern is configured via the PLC programming tool.
701007 DB1600.DBX4000.7 DB9913.DBW14 DB1600.DBD5028 Open the PLC program using the PLC programming tool.
Locate DB9913 in the “User Data Blocks” of the PLC pro-
701008 DB1600.DBX4001.0 DB9913.DBW16 DB1600.DBD5032 gram and double click.
Now double click the “Initial Value” for the required alarm
701009 DB1600.DBX4001.1 DB9913.DBW18 DB1600.DBD5036 number. The bit editor window will be shown.
... ... ... ...
Bit Editor functionality:
Bits 0 to 4 determine how the controller reacts to that partic-

ular alarm, Bit 5 determine if the PLC message is shown in
the alarm log. while Bits 6 & 7 determine how the alarm is
acknowledged.
The bit editor is also used to determine whether the mes-

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

quires no acknowledgement and will clear as soon as the
activation bit becomes zero.
The alarm/message will appear on the message page.
If bits 6 & 7 are used when the alarm/message appears on

the alarm page and an acknowledgement is required.
If bits 8 & 9 are used when the alarm/message appears on

the alarm page and an acknowledgement is required in
channel 1 or channel 2 or both.
Notes :

DB9913.DBWxx Alarm reaction/Acknowledgement - Cycle Alarm Configuration

channel
Bit 0 NC start inhibit Alarms can be set from within an NC program. Alarms are
displayed in alarm window in either RED or BLACK text.
Bit 1 Read in disable
An example is shown using the SETAL command.
Bit 2 Feed disable …
Bit 3 Emergency stop N10 SETAL(65000)
…
Bit 4 PLC stop
Bit 5 Alarm log The valid range for alarm numbers lies between 60000 and
Bit 6 Acknowledged by DB1600.DBX3000.0 69999, 0f which 60000 to 64999 are reserved for SIEMENS
cycles and 65000 to 69999 are available to OEM / User.
Bit 7 Acknowledged by Power off/on
Bit 8 PLC user alarm for channel 1 The alarm text must be entered into the language specific
Bit 9 PLC user alarm for channel 2 files in the control via AMM or HMI alarm text editor, which is
described in this module.
When entering the alarm text string there are 4 parameters

that can be used.
Parameter Meaning
%1 Channel number
%2 Block number
%3 Text index for cycle alarm

%4 Additional alarm parameters
Example text entered into the language file via AMM or HMI
alarm text editor:
Chan%1,%2,OEM_CYCLE_ALARM,%4
The effect is shown below:
View's of the entered text using AMM and the HMI text editor.
Notes :

Program Messages Configuration The alarm text can also be entered into the language specif-
ic files in the control via AMM or HMI alarm text editor, which
Messages can be set from within an NC program. Messages is described n this module.
are displayed in alarm window in GREEN text.
An example is shown using the MSG command. The text in the NC program is entered as a “text identifier”,
starting with the character “$”
…
N10 MSG(“MESSAGE”) Eg MSG(“$65000”) and text added into language specific file
… “PART PROGRAM MESSAGE”
The effect is shown below: The effect is shown below:
View's of the entered text using AMM and the HMI text edi-
tor.
Text and Colour Configuration files
The standard colours for the HMI alarms and messages are,
RED or BLACK for PLC and CYCLE alarms and GREEN for
MESSAGES. These colours can be chosen when using the
HMI alarm text editor and in AMM.
There is the ability to register an OEM file that is not restric-

ted by these basic colours.
The colour of :-
Alarm number
Alarm number background
Alarm text
Alarm text background
Can be changed. In the following example a “CYCLE
ALARM” background will be changed to “Yellow”
We must first declare a new OEM file in the configuration

files for the text and colour. The name of these file is going
to be “alarm_example”.
Notes :

Open the text configeration file slaesvcadapconf.xml in following directory: /oem/sinumerik/hmi/cfg, and add the line.
<AlarmTextEditor_oem_alarm_example type="QString" value="oem_alarm_example"/>
This is the edited content of the file.
<?xml version="1.0" encoding="UTF-8" standalone="yes"?>

<CONFIGURATION>
<AlarmTexts>
<BaseNames>
<AlarmTextEditor_oem_alarms_plc type="QString" value="oem_alarms_plc"/>
<AlarmTextEditor_oem_alarms_cycles type="QString" value="oem_alarms_cycles"/>
<AlarmTextEditor_oem_partprogram_messages type="QString" value="oem_partprogram_messages"/>
<AlarmTextEditor_oem_alarm_example type="QString" value="oem_alarm_example"/>
</BaseNames>
</AlarmTexts>
</CONFIGURATION>
Next create a file oem_alarm_example_eng.ts in the following directory: /oem/sinumerik/hmi/lng,
This is the content of the file.
<!DOCTYPE TS>
<TS>
<context>
<name>slaeconv</name>
<message><source>65200/NCK</source>
<translation>Chan%1,%2,alarm_example,%4</translation>
</message>
</context>
</TS>
Notes :

OEM Alarm text Configuration file location
siemens/sininumerik/hmi/cfg/ slaesvcadapconf.cfg Siemens default configeration file
oem/sinumerik/hmi
- hmi
- Ing
oem_alarms_cycles_eng.ts
The standard Alarm text files that are
oem_alarms_plc_eng.ts generated when text is entered via the HMI
editor or using AMM
oem_alarms_partprogram_messages_eng.ts
oem_alarms_alarm_example_eng.ts oem_alarms_alarm_example_eng.ts is dec-

lared in the slaesvcadapconf.xml
- cfg
OEM_Configuration file that is generated when

slaesvcadapconf.xml text is entered via the HMI editor or using AMM
Additional alarm text files must be declared in slaesvcadapconf. xml!

A sample-configuration file "oem_slaesvcadapconf. xml" is in following directory: /siemens/sinumerik/hmi/template/cfg.
But it must be renamed "slaesvcadapconf. xml" when transfered to its destination folder.
Notes :

Open the colour configeration file slaesvcconf.xml in following directory: /oem/sinumerik/hmi/cfg, and add the line.
<OEM_DataBase_05 type="QString" value="alarmtexteditor_db_oem_alarm_example"/>
This is edited content of the file.
<?xml version="1.0" encoding="UTF-8" standalone="yes"?>


<CONFIGURATION>
<DataBases>
<OEM_DataBase_01 type="QString" value="oem_slaedatabase"/>
<OEM_DataBase_02 type="QString" value="alarmtexteditor_db_oem_alarms_cycles"/>
<OEM_DataBase_03 type="QString" value="alarmtexteditor_db_oem_alarms_plc"/>
<OEM_DataBase_04 type="QString" value="alarmtexteditor_db_oem_partprogram_messages"/>
<OEM_DataBase_05 type="QString" value="alarmtexteditor_db_oem_alarm_example"/>
</DataBases>
</CONFIGURATION>
Next create a file alarmtexteditor_db_oem_alarm_example.xml in the following directory: /oem/sinumerik/hmi/cfg,
This is edited content of the file.

<?xml version="1.0" encoding="ISO-8859-1"?>
<!DOCTYPE SlAeAlarmAttributes>
<SlAeAlarmAttributes Version="01.00.00.00">
<Types></Types>
<Sources>
<Source CatLink="1" SourceID="0" SourceURL="/NCK">
<Alarms>
<Alarm AlarmID="65200"><DISPLOC>0</DISPLOC>
<MSGTEXT>slaeconv|65200/NCK</MSGTEXT>
<NUMBERBACKGROUNDCOLOR>#FF0000</NUMBERBACKGROUNDCOLOR>
<NUMBERCOLOR>#FFFFFF</NUMBERCOLOR>
<TEXTBACKGROUNDCOLOR>#FFFF00</TEXTBACKGROUNDCOLOR>
<TEXTCOLOR>#FF0000</TEXTCOLOR>
</Alarm></Alarms>
</Source></Sources>
</SlAeAlarmAttributes>
Notes :

OEM Color configuration file
siemens/sininumerik/hmi/cfg/ slaesvcconf.cfg Siemens default configeration file

slaesvcadapconf.cfg
oem/sinumerik/hmi
- hmi
- cfg
alarmtexteditor_db_oem_alarms_cycles.xml
Color files that are generated when colour
alarmtexteditor_db_oem_alarms_plc.xml is entered via the HMI editor or using AMM
alarmtexteditor_db_oem_alarms_partprogram_messages.xml
alarmtexteditor_db_oem_alarm_example.xml alarmtexteditor_db_oem_alarm_example.xml
is created by OEM so that non standard
colours can be used
slaesvcconf.xml OEM_Configuration file that is generated when

text is entered via the HMI editor or using AMM
Additional colour files must be declared in slaesvcconf. xml

A sample-configuration file "oem_slaesvcconf. xml" lies in following directory: /siemens/sinumerik/hmi/template/cfg.
But it must be renamed "slaesvcconf. xml" when transfered to its destination folder.
Notes :

There is a html colour code list which is Color Name HEX Crimson #DC143C
reprecented by a hexidecimal number.
AliceBlue #F0F8FF Cyan #00FFFF
HTML Codes format: AntiqueWhite #FAEBD7 DarkBlue #00008B
Each HTML code contains symbol "#"
and 6 letters or numbers. These numbers Aqua #00FFFF DarkCyan #008B8B
are in hexadecimal numeral system. For Aquamarine #7FFFD4 DarkGoldenRod #B8860B
example "FF" in hexadecimal represents
number 255 in Decimal. Azure #F0FFFF DarkGray #A9A9A9
Beige #F5F5DC DarkGreen #006400
Meaning of symbols:
The first two symbols in HTML color code Bisque #FFE4C4 DarkKhaki #BDB76B
represents the intensity of red color. 00 is
the least and FF is the most intense. The Black #000000 DarkMagenta #8B008B
third and fourth represents intensity of BlanchedAlmond #FFEBCD DarkOliveGreen #556B2F
green and fifth and sixth represents the
intensity of blue. So with combining the Blue #0000FF DarkOrange #FF8C00
intensity of red, green and blue an unlim- BlueViolet #8A2BE2 DarkOrchid #9932CC
ited colour pallet can be created;)
Brown #A52A2A DarkRed #8B0000
By defining the colour in the alarmtextedi- BurlyWood #DEB887 DarkSalmon #E9967A
tor_db_oem_test.xml we can adjust:
Alarm number CadetBlue #5F9EA0 DarkSeaGreen #8FBC8F
Alarm number background Chartreuse #7FFF00 DarkSlateBlue #483D8B
Alarm text
Alarm text background Chocolate #D2691E DarkSlateGray #2F4F4F
Coral #FF7F50 DarkTurquoise #00CED1
CornflowerBlue #6495ED DarkViolet #9400D3
Cornsilk #FFF8DC DeepPink #FF1493
DeepSkyBlue #00BFFF Lavender #E6E6FA Magenta #FF00FF

DimGray #696969 LavenderBlush #FFF0F5 Maroon #800000
DodgerBlue #1E90FF LawnGreen #7CFC00 MediumAquaMarine #66CDAA
FireBrick #B22222 LemonChiffon #FFFACD MediumBlue #0000CD
FloralWhite #FFFAF0 LightBlue #ADD8E6 MediumOrchid #BA55D3
ForestGreen #228B22 LightCoral #F08080 MediumPurple #9370DB
Fuchsia #FF00FF LightCyan #E0FFFF MediumSeaGreen #3CB371
Gainsboro #DCDCDC LightGoldenRodYellow #FAFAD2 MediumSlateBlue #7B68EE
GhostWhite #F8F8FF LightGray #D3D3D3 MediumSpringGreen #00FA9A
Gold #FFD700 LightGreen #90EE90 MediumTurquoise #48D1CC
GoldenRod #DAA520 LightPink #FFB6C1 MediumVioletRed #C71585
Gray #808080 LightSalmon #FFA07A MidnightBlue #191970
Green #008000 LightSeaGreen #20B2AA MintCream #F5FFFA
GreenYellow #ADFF2F LightSkyBlue #87CEFA MistyRose #FFE4E1
HoneyDew #F0FFF0 LightSlateGray #778899 Moccasin #FFE4B5
HotPink #FF69B4 LightSteelBlue #B0C4DE NavajoWhite #FFDEAD
IndianRed #CD5C5C LightYellow #FFFFE0 Navy #000080
Indigo #4B0082 Lime #00FF00 OldLace #FDF5E6
Ivory #FFFFF0 LimeGreen #32CD32 Olive #808000
Khaki #F0E68C Linen #FAF0E6 OliveDrab #6B8E23
Notes :

Orange #FFA500 SandyBrown #F4A460 Yellow #FFFF00

OrangeRed #FF4500 SeaGreen #2E8B57 YellowGreen #9ACD32
Orchid #DA70D6 SeaShell #FFF5EE
PaleGoldenRod #EEE8AA Sienna #A0522D
PaleGreen #98FB98 Silver #C0C0C0
PaleTurquoise #AFEEEE SkyBlue #87CEEB
PaleVioletRed #DB7093 SlateBlue #6A5ACD
PapayaWhip #FFEFD5 SlateGray #708090
PeachPuff #FFDAB9 Snow #FFFAFA
Peru #CD853F SpringGreen #00FF7F
Pink #FFC0CB SteelBlue #4682B4
Plum #DDA0DD Tan #D2B48C
PowderBlue #B0E0E6 Teal #008080
Purple #800080 Thistle #D8BFD8
RebeccaPurple #663399 Tomato #FF6347
Red #FF0000 Turquoise #40E0D0
RosyBrown #BC8F8F Violet #EE82EE
RoyalBlue #4169E1 Wheat #F5DEB3
SaddleBrown #8B4513 White #FFFFFF
Salmon #FA8072 WhiteSmoke #F5F5F5
oem_alarm_example_eng.ts, which states the text for the alarmtexteditor_db_oem_alarm_example.xml, which states
cycle alarm.This file is declared in slaesvcadapconf.xml con- the text for the cycle alarm.This file is declared in slaes-
figeration file. vcconf.xml configeration file.
Notes :

B031 END Alarms and Messages
Once all the files have been created and edited, reboot the This simple program when run will post this alarm.
HMI.
This method of creating alarm text and backgrounds with

different coulours will not be affected by colour changes
done by the HMI editor or AMM.
B031: END
Notes :

B058 PLC On-board Diagnostics
Sinumerik
Operate
Module Description:
The 828D controller has on-board PLC diagnostic capabilities to aid the user with the fault finding
process. It is possible to check the status of inputs, outputs etc.
There is also a ladder editor, which allows editing of the user PLC program, and a rewire function,
which allows inputs or outputs to rewired while keeping the original PLC logic intact.
Module Objective:
Upon completion of this module you will be able to use the 828D PLC viewer to diagnose PLC relat-
ed problems. You will also be able to rewire inputs and outputs using the ladder editor
Content:
Sinumerik
PLC Diagnostics
PLC Editor
Interrupt Routines
828D SINUMERIK Operate V4.8 Page 1 This document was produced for training purposes.
A058
B058
A058 Page 2 828D SINUMERIK Operate

PLC Onboard Diagnostics B058
PLC On-board
Diagnostics:
START
PLC
Diagnostics
PLC
Editor
Interrupt
Routines
PLC On-board
Diagnostics:
END
Notes
828D SINUMERIK Operate Page 3 B058

B058 PLC Onboard Diagnostics
PLC Diagnostics A Word can only be addressed as 0 or an even number (IW0,

IW2, IW4 etc) odd numbers are not allowed.
Address Formats:
As with the Byte format the numbering starts from the right.
Bit- This refers to a single element of logic e.g. I6.0, Q5.5, Example IW6:
M100.6, V38040002.1. IB7 IB6
The Bit portion is the number after the decimal point. The val- Bit no 7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0
ue of a bit is either 1 or 0. Value 1 0 1 0 0 1 0 1 0 1 1 1 0 0 1 1
Byte- A Byte is a collective of 8 bits of logic in the same In this example I6.0, I6.1, I6.4, I6.5, I6.6, I7.1, I7.2, I7.5, I7.7.
group, e.g. Input Byte 4 (IB6) contains the bits I6.0, I6.1, I6.2, are equal to 1.
I6.3, I6.4, I6.5, I6.6, I6.7. Output Words (QW) and Marker Words (MB) can also be used
When working with bytes it must be remembered that the in the same way.
numbering counts up from the left as shown below.
Example IB6 Double Word- A Double Word is a collective of 32 bits of logic
IB6 which encompasses two consecutive Words (Four consecu-
Bit no 7 6 5 4 3 2 1 0 tive Bytes).
Value 1 0 1 0 0 1 0 1
A Double Word can only be addressed as 0 or an even num-
In this example I6.0, I6.2, I6.5 & I6.7 are equal to 1. Another ber which is a multiple of four, (ID0, ID4, ID8, ID12 etc) odd
term for being equal to 1 is that these bits are High. numbers are not allowed.
The bits equal to 0 are termed as being Low.
Example ID6
IB9 IB8 IB7 IB6
Output Bytes (QB) and Marker Bytes (MB) can also be used in Bit no 7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0
the same way. Value 1 0 1 0 0 1 0 1 0 1 1 1 0 0 1 1 1 0 1 0 0 1 0 1 0 1 1 1 0 0 1 1
Word- A Word is a collective of 16 bits of logic which encom- Output Double Words (QD) and Marker Double Words (MD)
passes two consecutive Bytes. can also be used in the same way.
Data Blocks (DB):

System Data Blocks are used for interfacing between the dif- Operating
ferent areas of the controller and the user PLC. Status
Name: Taken from the PLC828D project
Module B034 describes this in more detail. name.
The user can also create Data Blocks. Last Changed: Last time the project was
modified.
Data Blocks can be written in different formats e.g.:
DB3804.DBX0.0 Data Block 3804 Bit 0.0

DB3801.DBX1000.7 Data Block 3801 Bit 1007.0
DB3801.DBB1000 Data Block 3801 Byte 1000
DB3804.DBW0 Data Block 3804 Word 0
DB3804.DBD0 Data Block 3804 Double Word 0
To locate the PLC status screens use the following soft key
sequence.
By default, the first page displayed is the “PLC-CPU” screen.

This contains information regarding the PLC project and cy-
cle time information. Processing Cycle Time: Version Information:
Time: The time The cycle time of Supplied by the
taken to process PLC-CPU system.
the PLC logic. processor.
Notes

The processing time information display can be reset NC/PLC Status

by the “Reset pro. time” soft key The status of the operands/variables used within the PLC
program can be checked via the “PLC Status” soft key.
Operating Status:
The operating status can be in Run or Stop mode. The status
is indicated at the top of the screen. It is possible to change
the operating state via soft-keys.
After certain procedures the PLC may be left in STOP mode The operands are typed into the left hand column. They can
and require manually starting. It my also be necessary to stop be viewed in different formats. The format is changed by us-
and start the PLC to clear PLC related faults. ing the cursor key to highlight the letter in the “Format” col-
umn and then toggling with the “Select” key.
B = Binary
PLC Stop: D = Decimal
H = Hexadecimal
F = Floating point number (only for
Double Words)
PLC Start:
By using the “Operand +” and ”Operand -” soft keys it is pos-

sible to quickly locate a different operand in a similar range.
The operand in question has to be highlighted and the new
value entered and confirmed with the “OK” soft key.
Or
The “Delete all” soft key will delete all entries on the list.
Changing M8.0 from 0 to 1.
Individual entries can be edited/deleted by using the Insert,

Delete and Cursor keys found on the keyboard.
The marker M8.0 should now have changed to a value of 1.

For test purposes it may be necessary to manually change
(Force) an operand. This is achieved with the “Change” soft
key.
Notes

Caution should be taken when attempting to manually change Inserting Variables:

variables as unwanted movements may occur.
It is not possible to force operands which are being addressed The “Insert Variable” soft-key opens a list system variables
by the PLC program. which can be directly selected for monitoring.
The default screen shows all available variables.
The values stored in counters and timers can also be viewed.
This is best done in decimal format.
Adding and Displaying Comments:
By selecting the “Display comments” soft-key it is possible to

add comments to identify the function of each operand.
Confirm the entries with the “Input” key.
Variable Filter/Search: Variable Search

Ensure the “Search” tab is highlighted and type all or part of
To find a particular variable the “Filter/Search” function is the variable name.
available. The search is automatic and as soon as the first letter is en-
tered the search will begin.
When the desired variable is found and highlighted, select the
“OK” soft-key.
The variable will then appear in the NC/PLC Status List.
Filter:
The Filter is available to narrow down the number of variables
on display. Cursor to the filter tab, the list is revealed by se-
lecting the “Insert” key.
Confirm the filter selection with the Input key.
Notes

1 is for the 1st NC axis

2 is for the 2nd NC axis etc.
Further information about the variable can be displayed by

selecting “Details” soft-key.
By selecting the “Operand +” & “Operand -” soft keys the vari-

able can be change to view different axes.
Or
Further functions are available when the following soft-key is Enter a suitable file name:
pressed:
Save mask: The list of operands that have been typed can be
saved to a file.
Confirmation of the file save is displayed above the horizontal
soft-keys for several seconds.
Load Mask: Previously saved files can be loaded using this

function.
Cursor to the preferred target area for the file:
Notes

Status List: The default list of operands is shown in the above screen.
The “Set address” soft key allows this list to be configured.
A further method of checking the status of operands is via the
“Status list” soft key.
The value entered in box will become the first entry at the top
of the list.
Each of the three columns can be changed this way .
Select the columns using the cursor keys.
The operands can be manually changed via the ”Change” soft

key.
Notes

PLC Program Status The Window 2 soft-keys can also be used to open up a sub-
routine (Program block). By default, the first subroutine is
The PLC program ladder logic can be seen by selecting the opened.
Window 1 OB1 soft key. In this example, SBR220, is opened.
By default, OB1 will be opened.
The Window 1 & Window 2 soft-keys can be used to open The status of the PLC is shown by selecting Program stat.
different blocks within the program. soft key.
The operands which are true are highlighted in blue.
It is recommended that the status be switched when not in use
to free more resources for the system.
Program status OFF:

A list of available blocks is displayed, by highlighting a block
and pressing the Open soft-key, the selected block will be
opened.
Program status ON:
The soft-key text changes to match the selected block:
Notes

Symbolic and Absolute Addressing: Example: with Symbolic addresses deselected, i.e. Absolute
addresses active:
The status can be viewed with or without symbolic addressing
information.
By selecting the “Symbolic” option, the operands will be dis-
played with information taken from the symbols table.
The symbols table is where the operands are given a short
text description which is designed to assist the user to identify
the function of the operands without referring to additional
documentation
Confirmation that Absolute
Example with “Symbolic addresses” selected: addressing is active.
Confirmation that Symbolic

Addressing is active.
Any operand, assigned to a symbolic address, will now dis-

play that symbolic address.
Symbol Info Any available additional information is indicated by the input

The symbol information for a whole network can be viewed by and select symbols on the right side of the subroutine title bar.
selecting the network followed by the Symbol info soft key
Pressing the Select key will reveal the full symbolic/absolute

information.
An operand with absolute address selected showing a trun-

cated number (Orange rectangle is in place):
Select the Back soft-key to exit the symbol data

table.
Additional information:
Due to the space restrictions of the screen it is not always

possible to see the whole symbolic/absolute description. Display after Select key is pressed:
The cursor keys can be used to position the orange rectangle

around an operand.
Notes

Display after “Input” key is pressed:
Example: The display at maximum magnification.
The display can be magnified via the “Zoom +” and “Zoom -”

soft keys.
Example: The display at minimum magnification.
Search Functions: After typing in the search target, e.g. I0.4, it is possible to
choose between Find all or Search downwards.
The search function allows operands etc. to be located easily
in the program.
It is also possible to search in the current program block or all

program blocks.
By pressing the select key it is possible to choose between
Search or Go to. Use the cursor keys to highlight the option
required.
The Select key is used to expand the menu and reveal the
choices which are confirmed by the “Enter” key.
Press he OK soft-key to initiate the search.
Notes

After a successful search the target will be highlighted by an Example: the result of searching for network 3.
orange rectangle.
Symbol Info and Symbol tables
The Symbol table soft key allows different symbol tables to

be selected:
To search for further occurrences of the target the
Continue search soft key is available.
When all occurrences have been found a message
will be displayed above the horizontal soft keys.
Select a symbol table:
The Go to option is used for searching for a network within the

open program block.
The symbol table shows the symbolic addresses and additional Cross Reference
comments for individual operands.
The Cross ref. function allows the user to see which operands
are in use and in which blocks they are used.
The search function is also available:
The Symbolic addresses soft-key allows different symbolic

or absolute addresses to be displayed.
Notes

Operands can be located with the Search function or the cur- Protected Blocks:
sor keys.
It is possible to be protect individual blocks (subroutines) via
the controller.
Note: it is also possible to protect blocks using the PLC Pro-
gramming Tool.
Select the block to be protected:
Once the operand has been found, the subroutine where it is

located can be opened via the Open in window 1 or Open in
Window 2 soft-keys.
Or A four digit/character password needs to be defined by the

user:
The block will now open:
A yellow padlock symbol will appear alongside the protected Once the password has been entered the block remains ac-
block: cessible until the controller is powered off/on.
This is indicated by the green padlock symbol.
The password is required to open the block.

It is also possible to choose whether to keep the protection
enabled each time the block is opened.
Notes

Any changes must be saved in the CPU:
PLC in stop mode: When SBR0 is opened and network 1 examined it can be
seen that the Divide operation is attempting to divide 200 by
0.
If the PLC goes into stop mode information is available on the
This is not permitted and so the PLC is put into stop mode.
diagnostics screen. To locate the diagnostics screen, use the
The program needs to be corrected and then loaded to the
following soft-key sequence:
controller.
The next section shows how the PLC can be corrected on the
controller.
Several alarms will occur, some are as a result of the PLC

going into stop.
The important alarm is the one that indicates the cause of the
PLC going into stop. In this case it is alarm: 400010 Arithme-
tic error in user program: Type 1 SBR0 network 1.
PLC Editor Editing a Subroutine:

It is possible to edit the user PLC program directly on the The editing is done the Setup menu:
828D controller.
Machine Data, 51232, needs to be set to 1 to enable the PLC

editing function:
Or
Highlight and open the required block (subroutine):
The PLC Editor function allows existing subroutines and OB1

to be edited.
It is also possible to:

• add new subroutines
• add INT100 & INT101 (see the next chapter)
• add INT0 (servo synchronous interrupt - see the PLC
Design document)
No Data Block functionality is available.
Notes

A range of instructions is available via the

horizontal and vertical soft-keys.
The program status function needs to be off before editing can

commence.
Press the OK soft-key to exit program status.
In the following example a modification will be made to an ex-
isting arithmetical function.
Use the cursor keys to navigate through the subroutine to the

place to be edited (orange rectangle):
Input a new value:
Use the Input key to locate the required parameter of the

arithmetic function e.g. IN2.
Notes

Saving the changes:
Any changes must be saved in the CPU:
The changes have now been saved in the CPU.
Notes

Interrupt Routines
Subroutines INT_100 and INT_101 (Rewire function)
Interrupt routines 100 & 101 can be used to influence the user PLC. This is known as the rewire function because it allows a
faulty input/output to be rewired to a spare location; the logic for the new input/output can then be added to the interrupts.
This means that the original user PLC program remains intact; this is important for compatibility reasons.
The interrupt routines belong to the individual data class type.
The S7-200 PLC works cyclically - At the beginning of the scan the status of the inputs is copied to the Process Image Table
(Inputs). This is then applied to the user PLC logic.
The Subroutines are processed in the order they appear in OB1.
This means that, for example, an output which was set early in the scan might then be reset later in the scan. It is the command
that appears later in the scan that takes priority.
When the scan is complete the results are transferred to the Process Image Table (Outputs). This the point at which the outputs
etc. are physically set.
The diagram below shows the position of the Interrupt Blocks INT_100 and INT_101.
Their position enables them to be used to influence the state of the inputs and outputs without making changes to the main user
programme.
Beginning of Scan
Process Image Table At the beginning of the scan, the status of the inputs is
(Inputs) transferred to the Process Image Table.
Interrupt INT_100 The INT_100 interrupt block can be used to influence

the Process Image Table (Inputs).
Main Routine OB1

Subroutine
Subroutine
Subroutine Subroutines are processed in the

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

influence the Process Image Table (Outputs).
Process Image Table At the end of the scan, the status of the outputs is
(Outputs) transferred to the Process Image Table.
End of Scan
Interrupt INT_0 The INT_0 interrupt block runs independently of OB1.

It runs synchronously with the servo cycle. This cycle time is very
fast and could be used for example with a fast turret where the sig-
nals need to be decoded sooner than they can be achieved with
OB1.
it is recommended not to use it (see PLC design document).
Notes
828D SINUMERIK Operate Page 17

Inserting the Subroutines The required interrupt can now be selected:

If the PLC program does not contain the Interrupt routines
they can be inserted using the PLC828D programming tool or
directly on the controller. Interrupt Routine INT_100
Details can be added to identify the author and indicate the
Inserting the interrupt routines on the controller: purpose of the block.
Use the “Accept” soft-key to complete the action.
Interrupt 100/101 not present:
The interrupt will now appear in the list.
Use the cursor keys and soft-keys to add the required logic:
The interrupt can now be opened and logic entered.
A range of instructions is available via the

horizontal and vertical soft-keys.
Notes

Example: rewiring I6.0 to I6.5. Example logic for INT100:
The table below shows that the PLC status for I6.0 is at 0.
This is despite there being a +24v signal present at the input
terminal. This indicates a problem with the PP72/48. All other
inputs are functioning correctly.
One solution would be to replace the PP72/48. Another possi-
bility would be to rewire the faulty input to an unused input.
Interrupt 100 could then be used to set I6.0, internally, via the
new input.
I6.5 is now controlling I6.0
Original wiring to faulty input:
Input 6.0 rewired to input 6.5:
PP72/48 PLC input/output module PP72/48 PLC input/output module
Function Signal Input PLC Status Function Signal Input PLC Status
Coolant on switch +24v I6.0 0 Faulty input 0v I6.0 1
Work light switch +24v I6.1 1 Work light switch +24v I6.1 1
Tool clamped switch 0v I6.2 0 Tool clamped switch 0v I6.2 0

Door closed switch 0v I6.3 0 Door closed switch 0v I6.3 0
Air pressure switch +24v I6.4 1 Air pressure switch +24v I6.4 1
Spare 0v I6.5 0 Coolant on switch +24v I6.5 1
Spare 0v I6.6 0 Spare 0v I6.6 0
Spare 0v I6.7 0 Spare 0v I6.7 0
Interrupt Routine INT_101

The Interrupt is added in the same way as INT_100. PP72/48 PLC input/output module
Output PLC
Status Signal Function
Q6.0 1 0v Machine light
Q6.1 1 +24v Unclamp tool
Q6.2 1 +24v Conveyor on
Q6.3 0 0v Lock door
Q6.4 1 +24v Hydraulics on
Q6.5 0 0v Spare
Q6.6 0 0v Spare
Q6.7 0 0v Spare
Example logic for INT101:
Example: rewiring Q6.0 to Q6.5.
The following table shows that the PLC status for Q6.0 is at 1,
but the +24v output is missing. This indicates a problem with
the PP72/48. All other outputs are functioning correctly. Q6.0 is now controlling Q6.5.
One solution would be to replace the PP72/48. Another possi-
bility would be to rewire the faulty output to an unused output. Any changes must be saved in the CPU:
Interrupt 101 can then be used to set Q6.5, internally, via the
existing output.
Notes

B058 END PLC Onboard Diagnostics
Output Q6.0 rewired to output Q6.5:
PP72/48 PLC input/output module

Output PLC
Status Signal Function
Q6.0 1 0v Faulty output
Q6.1 1 +24v Unclamp tool
Q6.2 1 +24v Conveyor on
Q6.3 0 0v Lock door
Q6.4 1 +24v Hydraulics on
Q6.5 1 +24v Machine light
Q6.6 0 0v Spare
Q6.7 0 0v Spare
B058: END
Notes

B009 Easy Extend
Sinumerik
Operate
Module Description:
Easy extend is a system which gives the seller of the machine a mechanism to enable the hardware
options which are offered by the machine tool builder, without the necessity for service intervention.
A machine option could typically be a:
• Spindle motor speed

• Tool change
• Spindle centre coolant
• Tailstock
• Parts catcher
• Barfeed
• Coolant filter
Module Objective:
Upon completion of this module you will be able write Easy extend scripts to enable and activate
machine builder options.
Content:
Sinumerik
General Information and Concept

Creating XML scripts
User PLC Program
Enabling and Testing Devices
Example of XML Scripts
Creating and Restoring Rollback Archives
Additional Axis
Addressing of variables.
General Tag Descriptions
Tag Descriptions - Dialogue Screens
Adding language files
B009
B009

Easy Extend B009
Easy Extend:
START
Tag
Descriptions
:
Dialogue
Screens
General
Information
and Concept
Adding
language
files
Creating
XML scripts
Easy Extend:
END
User PLC
Program
Enabling
and Testing
Devices
Creating and
Restoring a
“rollback“
archive
Additional
Axis
Addressing
of Variables
General Tag
Descriptions
Notes :

B009 Easy Extend
General Information
• Each OEM option is assigned to an Easy Extend device.

• A maximum of 64 devices can be configured.
• The dealer can enable activate an option when it is purchased.
XML Files
Easy Extend uses Extended Mark-up Language.
The agm.xml file is the main file and entry point for Easy Extend.
All Easy Extend devices originate from the agm.xml file, this can include calls to other xml files to simplify the programming
structure.
The XML language used in the 828D is none standard and has been extended to allow the following data processing and high-
level language elements:-
• Archiving of NC/PLC data

• Reading and writing of NC/PLC/Drive data
• Conditional jumps within an xml block
• Execution of program loops
• Execution of arithmetic operations
• Creation of local variables
• Loading/creating archives
• Displaying messages
User PLC
Data Block EE_IFC (DB9905) is located in the PLC828D library and has to be integrated into the OEM´s PLC project.
Interface signals for activating and deactivating devices are to be found in the Data Block.
A user Data Block is required for password protecting devices.
Device Enabling
Devices first need to be enabled, this can be done using one of two methods.
Enabling by PLC variable: A PLC variable is declared in the agm.xml file, the status of the variable is checked. This method is
used if the device is to be password protected.
Enabling by machine data: A user machine data is declared in the agm.xml file. If the corresponding bit of the machine data is
set the device will be enabled.
Device Activation
Once a device has been enabled it can be activated. Activation is done with a soft-key on the Easy Extend screen and with PLC
interface signals for acknowledgement.
Toolbox Examples
The 828D toolbox supplied with the controller contains various Easy Extend and PLC project examples which can be used to
supplement the information supplied in this module.
Notes :

Easy Extend B009
Easy extend Concept <OPTION_MD name = $MN_USER_DATA_INT[0]"index"0"/>

<OPTION_MD name = "plc/9061.dbw0"index="0"/>
Agm.xml
<AGM>
<SET_ACTIVE>
</SET_ACTIVE>
<DEVICE> 1
<DEVICE> 2
<DEVICE> 3
<SET_INACTIVE>
<DEVICE> 4 </SET_INACTIVE>
<START_UP>
</START_UP>
<list_id> x </list_id> <name> "Device name" </name> <FORM>

</FORM>
</AGM>
<AMG>
<OPTION_MD name = "plc/db9061.dbw0" index = "0">
<!.....................................................................................................>
<DEVICE>
<list_id>1</list_id>
<name> "Basic Machine Settings"</name>
<password refvar - "plc/db9062.dbd0" />
<START_UP>
</START_UP>
<FORM>
..
</FORM>
<SET_ACTIVE>
..
</SET_ACTIVE>
<SET_INACTIVE>
..
</SET_INACTIVE>
</DEVICE>
<!.....................................................................................................>
PLC <DEVICE>
DB9905 <name> "Spindle Motor (Speed)"</name>
</DEVICE>
<!.....................................................................................................>
<DEVICE>
Byte Bit Description <list_id>3</list_id>
0 0 = = 1 - device has been commissioned (HMI feedback signal) <name> "Tool Changer"</name>
1 = = 1 - device should be activated (HMI request) </DEVICE>
2 = = 1 - device should be de-activated (HMI request) <!.....................................................................................................>
<DEVICE>
3-7 Reserved <list_id>4</list_id>
1 0-7 Reserved <name> "Spindle Centre Coolant"</name>
2 0 = = 1 - device is activated (PLC feedback signal) </DEVICE>
1 = = 1 - device has faulted <!.....................................................................................................>
</AMG>
2-7 Reserved
3 0-7 Unique ID of the device
Notes :

B009 Easy Extend
An example of the Easy Extend screen from an actual machine showing some of the types of options which can be handled us-
ing the Easy Extend function.
Possible sequence to follow in order to use a builder option.
ENABLE Device - with or without Password
STARTUP Device - 1st Startup of Device. With or without input parameters
ACTIVATE Device - To enable device useage
DEACTIVATE Device - To remove device
Notes :

Easy Extend B009
Creating XML Scripts The agm tag is the root element of the agm.xml.
All other tags are written inside this tag.
A unique file named “agm.xml” is required for Easy Extend.
This file has to be created by the user. Creation of the xml files can be done directly on the controller
or indirectly using AMM Access MyMachine or suitable editing
It is possible to configure all devices within the “agm.xml’. It is program such as Notepad ®.
also possible to use separate xml files for each individual de- Advanced xml editing software programmes are also commer-
vice. These files are called from within the agm.xml file. cially available.
The xml files use tags, which are required for code execution. The required directory is found under the following path:
Each tag performs a specific function. System CF card\oem\sinumerik\hmi\dvm
Executing script is written between tags, the script is written

after the “open tag” and finishes at the “Close tag”.
Example:
<name of tag> “open tag”
Enter script in here
</name of tag> “close tag with / slash”
Short Version <name of tag...Enter script in here…/>
Use the following soft-key sequence to locate the system data

area of the controller
Type in the name-”agm.xml” (Lower case!) and confirm with
the “OK” soft-key.
Editing agm files using AMM Access MyMachine
It is often more convenient to create and edit files remotely.

Editing the XML files offline and transferring them to the con-
troller is possible using AMM Access MyMachine.
Start AMM Access MyMachine:
Notes :

B009 Easy Extend
The following example shows how to configure Easy Extend

Device 1 using the agm.xml file and a separate file for the de-
vice itself.
Rather than have one file containing the code for many
devices, it makes sense to have one file for each device.
Locate the “dvm” folder . These separate files can then be called from within the
agm.xml file.
The device is assigned the name of “Test Password” and will

be enabled via the PLC with a user defined password.
The following example is of an agm.xml file with the “include

src” command (Blue text is for information only; orange text is
to be typed into the “agm.xml”):
Below: The agm.xml file without descriptions:

<!Password Example for device 1->
<!Data block 9061 is required in the user PLC program-> <!Password Example for device 1->
<!Data block 9061 is required in the user PLC program->
<AGM> Open the AGM tag
<AGM>
<OPTION_MD name = "plc/db9061.dbw0" index="0" />
<!OPTION_MD name = "plc/db9061.dbw2" index="1" /> <OPTION_MD name = "plc/db9061.dbw0" index="0" />
<!OPTION_MD name = "plc/db9061.dbw4" index="2" /> <!OPTION_MD name = "plc/db9061.dbw2" index="1" />
<!OPTION_MD name = "plc/db9061.dbw6" index="3" /> <!OPTION_MD name = "plc/db9061.dbw4" index="2" />
<!OPTION_MD name = "plc/db9061.dbw6" index="3" />
OPTION_MD tag: <?include src= "Password_test.xml" ?>

Declaring the PLC variable for enabling the devic-
es in user DB9061. </AGM>
Index 0 - Devices 1 to 16 Bits 0 - 15
Index 1 - Devices 17 to 32 “ 0 - 15
<?include src= "Password_test.xml" ?>
“Include src” tag:

Call to the individual device xml files eg
“Password_test.xml”
</AGM> Close the AGM tag
Notes :

Easy Extend B009
The individual xml files for each device should be placed in the
same directory as the agm.xml file.
Example: Password_test.xml (Blue text for information only;

orange text to be typed into the “password_test.xml”) :
<DEVICE> Open the DEVICE tag

<list_id> 1 </list_id> Device number e.g. 1
<name> "Test Password" </name> Device name
<password refvar = "plc/db9062.dbd0" />
password_refvar tag:
The password entered on the Easy Extend screen
will be stored here i.e. DB9062.DBD0
</DEVICE> Close the DEVICE tag
Power the controller off/on to activate the xml files
Below-The Password_test.xml file without descriptions:
<DEVICE>
<list_id> 1 </list_id>
<name> "Test Password" </name>
</DEVICE>
User PLC Program
Adding system data block DB9905 to the user PLC
For “Easy Extend” to work a system Data Block (DB9905) is

required. The Data Block is found in the Library of the Pro-
gramming Tool and is used for the communication between
PLC and the HMI.
Data Block in the library of the PLC828 programming tool:
Notes :

B009 Easy Extend
Double clicking the DB will open up the properties and allow The Data Block will now appear in the Data Block folder of the
the Data Class to be selected, also the author can enter project. Other Data Blocks may also be present.
details if required.
Select the “OK” button:
By double clicking the DB, the contents can be viewed. Up to

64 devices can be handled by the DB. A set of signals are
assigned to each device which are to be used in the user PLC
for activating, deactivating and device status.
Enter a suitable name and select the required Data Block

number. Select “OK” to confirm.
User PLC requirements
The example will require a user Data Block to be created so

that the defined and entered passwords can be compared. The
DB to be used is defined in the xml file with the “password
refvar” tag. It is also possible to use the same DB to signal the
HMI that the device is enabled. This is determined by the
“OPTION_MD” tag.
Right click on the Data Block folder and select “Insert Data
Block”.
Notes :

Easy Extend B009
The user DB will require certain information to be entered depending on the number of devices in use.
DB9061
DB9062
The following PLC example can be used for enabling and activating devices using the PLC interface signals and the previously
created user Data Block.
Defining the required password as 123456
Comparing the password entered by the

user with the defined password.
If true the enable signal is then set.
Fault reset on first power on.
Password reset on deactivation of the device.
Notes :

B009 Easy Extend
Enabling and Testing Devices
Device Enabling
Inputting the password:
To input the password, first locate the “Easy Extend” screen
via the following soft-key selection.
To enable the device select the “Enable function” soft-key.

The device created in the AGM file will be listed.
The device will now be enabled, this is indicated by a green

The password (123456) needs to be entered.
tick in the “Function” column.
Notes :

Easy Extend B009
The device is enabled but it is not operational until it is activated. This is achieved by pressing the “Activate” button.
A green tick symbol will appear in the “Activated” column to confirm this.
When the activation is successful the “Activate” interface signal will be high for one PLC cycle. This should be used in the PLC
logic to set the “Activated” interface signal.
Defining the required

password:123456
Device enabled:
Entered password matches required
password, enable signal is then set.
Device activated:
Activation interface signal is set.
When the “Deactivate” soft-key is pressed the “Deactivate” interface signal is high for one PLC cycle. This should be used in the
PLC logic to reset the “Activate” signal
Device disabled:
Password no longer matches, enable signal = 0
Activation interface
signal is reset
Password is reset to zero by deactivate

interface signal
Notes :

B009 Easy Extend
Message Box Test:
The agm.xml file has to be modified to include the new file:
<AGM>

<?include src= "MessageBox_test.xml" ?>


</AGM>
The “Set_Active” tag:
The script within the Set_Active tag is run when the “Activate” soft-key is pressed. Likewise, the “Deactivate” soft-key runs the
script included in the Set_Inactive tag.
“MessageBox_test.xml”
<DEVICE>
<name> "Messagebox" </name>
<SET_ACTIVE>
<LET name = "var_return"> 0</LET>
<MSGBOX text="Activate Option 1. %n Press OK" caption="Activation of Option" retvalue="var_return" type="BTN_OK" />
</SET_ACTIVE>
<SET_INACTIVE>
<LET name = "var_return"> 0 </LET>

<MSGBOX text="Deactivate Option 1. %n Press OK" caption="Deactivation of Option" retvalue="var_return" type="BTN_OK" />
</SET_INACTIVE>
</DEVICE>
Notes :

Easy Extend B009
Message Box Attributes:
text - The text to be displayed in the message box. Using the characters “%n” results in a new line.
caption - The header of the text box.
retvalue - Defines the variable where the return value is copied. (Return values– OK = 1, CANCEL = 0.)
type - Acknowledgement possibilities:
“BTN_OK” - OK button.
“BTN_CANCEL - CANCEL button.
“BTN_OKCANCEL” - OK & CANCEL buttons
When the “Activate” soft-key is pressed a message

box will appear containing the specified text.
To activate the device select the “OK” soft-key. The
device will then be activated in the usual way.
Notes :

B009
Switching on an output using the “Write_PLC_output.xml”
Modify the agm.xml to include the new file:- <?include src= "Write_PLC_output.xml" ?>
Create the device file containing the function for switching a PLC output. This example has also been configured with a cancel
soft-key. The functions IF, THEN & ELSE are used to evaluate whether the OK or Cancel key was pressed. If the cancel key is
pressed the system variable “$actionresult” is set to 0. This interrupts the processing of the function.
<DEVICE>
<name> "Write PLC output" </name>
<SET_ACTIVE>
<MSGBOX text="Activate Option 1 %n Press OK%n%nAbort press Cancel" caption="Activation of Option" retvalue="var_return" type="BTN_OKCANCEL" />
<IF>
<condition> var_return==1 </condition>
<THEN>
<DATA name = "PLC/Q4.7"> 1</DATA>
</THEN>
<ELSE>
<OP> "$actionresult" = 0</OP>
</ELSE>
</IF>
</SET_ACTIVE>
<SET_INACTIVE>
<MSGBOX text="Deactivate Option 1 %n Press OK%n%nAbort press Cancel" caption="Deactivation of Option" retvalue="var_return"
type="BTN_OKCANCEL"/>
<IF>
<THEN>
<DATA name = "PLC/Q4.7"> 0</DATA>
</THEN>
<ELSE>
<OP> "$actionresult" = 0 </OP>
</ELSE>
</IF>
</SET_INACTIVE>
</DEVICE>
When the device is activated the option to cancel is now available:

B009
The Test Tag
ThisSinumerik
tag is used to check that the requested actions have been successfully achieved. n the example below the test tag has been used
to check that the output Q4.7 is set to one.
Operate
<DEVICE>
Module Description:
<name> "Test PLC output" </name>
<SET_ACTIVE>
<MSGBOX text="Activate Option 1 %n Press OK%n%nAbort press Cancel" caption="Activation of Option" retvalue="var_return" type="BTN_OKCANCEL" />
<IF>
<THEN>
<DATA name = "PLC/Q4.7"> 1 </DATA>
</THEN>
<ELSE>
<OP> "$actionresult" = 0</OP>
</ELSE>
</IF>
</SET_ACTIVE>
<SET_INACTIVE>
<MSGBOX text="Deactivate Option 1 %n Press OK%n%nAbort press Cancel" caption="Deactivation of Option" retvalue="var_return" type="BTN_OKCANCEL"/>
<IF>
<THEN>
<DATA name = "PLC/Q4.7"> 0 </DATA>
</THEN>
<ELSE>
<OP> "$actionresult" = 0 </OP>
</ELSE>
</IF>
</SET_INACTIVE>
Module Objective:
<TEST>
<IF>
<condition>
"PLC/Q4.7"==1
</condition> The condition of Q4.7 is
<THEN>
checked for a value of 1
<op> "$actionresult" = 1 </op>
</THEN>
<ELSE> If the above condition is true, a value of 1 is
<op> "$actionresult" = 0 </op> written to the system variable $actionresult
</ELSE>
</IF> If the condition is false, a value of 0 is written
</TEST>
to system variable $actionresult
</DEVICE>
Content:
To run the Test function first enter the “Start up” area of the Easy Extend area. The “Function test device” soft-key should be
pressed to initiate the test. A dialogue box will display the result of the test.
Sinumerik
Q4.7 = 1 Q4.7 = 0
B009
B009 Easy Extend
The Form Tag

One custom screen can be defined for each device, this is done using the form tag. The custom screen can include texts and
bitmaps. Input fields can be linked to machine variables allowing the operator to set machine parameters.
The “Addition. parameter” soft-key is reserved for the instructions contained in the Form tag.
Within the Form tag the following tags can be utilised:-
LET
INIT
PAINT
TIMER
CLOSE
CAPTION
SOFTKEY_OK
SOFTKEY_CANCEL
Creating the Picture_test.xml: The following example shows how a bitmap is selected and positioned on the screen.
The bitmap file has to be placed in the same folder as the agm.xml file.
<DEVICE>
<password refvar="plc/db9062.dbd0"></password>
<name> "Picture Test" </name>
<FORM>
<init>
<caption>Easy Extend Picture Test</caption>
</init>
<paint>
<img xpos = "155" ypos = "90" name = "tiger.bmp" height="250" width="250"/>
</paint>
</FORM>
</DEVICE>
The script will result in a device named “Picture Test”

When the device is enabled and the “Addition. parameter” soft-key is selected, the “tiger.bmp” picture will appear on the screen in
the position specified by the IMG tag. The caption “Easy Extend Picture Test” will be displayed in the title bar.
Notes :

B009
Sinumerik
Operate
Module Description:
System variables
The following examples shows how R parameters can be used:
<DEVICE>
<name> "R Parameters" </name>
Module Objective:
<FORM>
<init>
<caption>Easy Extend Picture Test</caption>
<control name = "r_param_0" xpos = "100" ypos = "30" refVar = "nck/channel/parameter/r[0]" />
</init> Content:
<paint>
Sinumerik
<text xpos = "40" ypos = "30">R0</text>

<img xpos = "200" ypos = "150" name = "tiger.bmp" height="180" width="180"/>
</paint>
</FORM>
</DEVICE>
B009
B009 Easy Extend
The following screen shows the R parameters and the resized

image.
The values are written to the variables when the “OK” soft-key
is pressed or can be set to be immediately written.
For information on this see the “Hotlink” element under the
“Control” tag description.
The “Undo” and “Repetition” soft-keys are available to switch

each single entry between its new and original value.
The “Last configuration” soft-key is available to restore all the

entries to their original values.
Values can be typed directly on the Easy Extend screen and

confirmed with the “OK” soft-key.
Creating and Restoring a “Rollback” Archive

These values can be checked in the “User variable” area.
It is possible to create a complete NC/PLC/Drives/HMI archive
from within Easy Extend\Setup area. This is achieved by se-
lecting the “Start setup” soft-key.
The fixed name for the archive is “rollback.arc”.
If an error occurs while initialising a device, the “rollback”
archive can be used to return the controller to its original sta-
tus.
The “Start-up” soft-key is only available if the “START_UP” tag
is used within each individual device.
The “START_UP” tag does not need to contain any instruc-
tions.
Example:
<DEVICE>
<name> "Rollback Archives" </name>
<START_UP>
</START_UP>
</DEVICE>
It is possible to write to other system variables, addressing

these variables is described in Section 9.
Notes :

Easy Extend B009
To create the archive:
The archive is created with the following soft-keys
Acknowledge the confirmation box with the “OK” soft-key.
When the archive has been created the „Back“ soft-key is se-
lected.
An archive file with the name of “Rollback.arc” will now be

created and stored in the “dvm_rb” folder.
Restoring a “Rollback” archive Additional Axis
In the event that the previously created archive needs to be Activating and deactivating axes
restored, the “Restore” soft-key can be selected and the dia-
logue box acknowledged. A common requirement is for an extra axis to be added.
A machine can be initially commissioned to include all axis
possibilities. The optional axis can then be deactivated until
required.
Note: When changing certain types of drive parameter it is

necessary to disable the drives.
An example of how axis number five is activated/deactivated is

shown on the next page :
The dialogue box will clear when the read-in is complete.
Notes :

B009 Easy Extend
<DEVICE> After activation/deactivation, the system waits for drive

<list_id>1</list_id> parameter “p971 Save drive objects parameters” to become
<name> "switch drive active" </name> zero (condition), an NC and drive reset is then carried out to
<password refvar="plc/db9062.dbd0"/> activate the changed machine data.
<SET_ACTIVE> As can be seen in the example xml file, the drive parameter-
<data name = "drive/dc/p105[DO5]">1</data> “P105 Activate/deactivate drive object” is responsible for
<data name = "$MC_AXCONF_MACHAX_USED[4]">5</data> activating/de-activating the drive part of the system.
<data name = "drive/dc/p971[DO5]">1</data>
<while>
<condition> "drive/dc/p971[DO5]" !=0 </condition>
</while>
<control_reset resetnc ="true" resetdrive = "true"/>
</SET_ACTIVE>
<SET_INACTIVE>
<data name = "$MC_AXCONF_MACHAX_USED[4]">0</data>
<while>
<condition> "drive/dc/p971[DO5]" !=0 </condition>
</while>
<control_reset resetnc ="true" resetdrive = "true"/>
</SET_INACTIVE>
</DEVICE>
To activate/de-activate the axis in the NC part of the system,

channel machine data
“20070 MC_AXCONF_MACHAX_USED” is used.
The additional axis is the 5th axis therefore a value of 5 or 0 is
entered into 20070[4] to activate/deactivate.
The activated axis appears on The deactivated axis does not

the machine page: appear on the machine page:
Drive parameter “P971Save drive object parameters” is set to

1 to save the drive Parameters. When the data has been
saved the parameter automatically reverts to a value of 0.
Notes :

B009
Addressing of Variables
Sinumerik
Machine and Setting Data
Operate
The $ character must be used before the name of the data.
Machine
ModuledataDescription:
addresses:
$MX_<Name[index, AXyy]>
MN - General machine data

MC - Channel machine data
MA - Axis machine data
Setting data addresses:
$SX_<Name[index, AXyy]>
SN - General setting data

SC - Channel setting data
SA - Axis setting data
Index - Specifies the index number of the variable.

AXyy - Specifies the axis number in the case of axis specific data.
The axis index number can also be read from a local variable:
Example:-
Axis index with the index number obtained from the variable called “axis”. This would be written as AX$axis.
Examples:-
Module
<data
Objective:
name=“$MN_AXCONF_MACHAX_NAME_TAB[0]”>X1</data> Writing a value of X1 to general machine data
$MN_AXCONF_MACHAX_NAME_TAB[0]
<data name=“$MA_CTRLOUT_MODULE_NR[0, AX1]”>1</data> Writing a value of 1 to axis1 machine data

$MA_CTRLOUT_MODULE_NR, index 0.
Indirect addressing:-
<let name=“axisindex”>1</let> Declaring a temporary variable called “axisindex” and setting the value to 1.
<data name=“$MA_CTRLOUT_MODULE_NR[0, AX$axisindex]”>1</data> Using the temporary variable to determine the axis
index number and writing a value of 1 into axis1 machine data $MA_CTRLOUT_MODULE_NR, index 0.
Addressing user data
The GUD path is first specified followed by the specific area. If a field is to be used, this follows next and is contained in square
brackets.
Content:
The following GUDS can be addressed:-
Sinumerik
SGUD Siemens GUDS.

MGUD Manufacturer (OEM) GUDS.
UGUD User GUDS.
Examples:-
<data name=“gud/channel/mgud/syg_rm[0]”>1</data> Defining the channel manufacturer gud - syg_rm, index 0 and writing
a value of 1 to it.
<op>“gud/channel/mgud/syg_rm[0]” = 5*2</op> The result of the multiplication of two numbers (5 x 2) is written to the
syg_rm[0] gud.
B009
B009
PLC Addressing
x = variable numeric identifier, b = Bit number.
Inputs Outputs Markers Data Blocks

Mx.b MBx Mx.b DBx.DBx.b
IBx QBx MBx DBx.DBBx
IWx QWx MWx DBx.DBWx
IDx QDx MDx DBx.DBDx
Examples:
<data name = “plc/mb200”> 1 </data> Writing a value of 1 to MB200
<data name = “plc/db9905.dbx2.4”> 1 </data> Writing a value of 1 to db9905.dbx2.4
<data name = “plc/q0.5”> 0 </data> Writing a value of 0 to q0.5
NC Variables
<LET>name = “TempStatus”><LET Declaring a temporary variable with the LET tag.
<OP>TempStatus = “nck/channel/state/chanstatus” </OP> Writing the channel status in to the variable “TempStatus”.
Drive Addressing
The drive path starts with the component identifier (cu for the Control Unit, dc for a drive component)
The object number should be placed in square brackets.

The drive object number differs from the actual drive number because the CU, ALM, DriveCliq Hubs etc are all assigned an ob-
ject number.
Representation Example: Parameter 970 for drive object 2 = p0970[do2]
The drive index number can also be read from a local variable:
Example: Parameter p0970 with the drive object number obtained from the variable called “drive”. This would be written as
p0970[do$drive]
Examples:
<data name=“drive/cu/p0092”>1</data> Writing a value of 1 to the cu, p0092
<data name=“drive/dc/p0092[do1]”>1</data> Writing a value of 1 to do1 p0092[do1]
Indirect Addressing:
<let name=“driveIndex”>0</let> Declaring a temporary variable called “driveindex” and setting the value to 0.
<op>driveIndex = $ma_ctrlout_module_nr[0, AX1]</op> Reading the value of the NC variable (ctrlout_module_nr Axis 1) into
the temporary variable (driveindex)
<data name =“drive/dc[do$driveIndex]/p0092”>1<data> Using the temporary variable to determine the drive object number
and writing a value of 1 into p0092.

Easy Extend B009
Special XML characters Operators
Some XML editors can incorrectly display certain characters. The following operations are available for use:
These have to be re-written.
The following characters are affected: Operator Significance

= Assignment
Character XML Notation
== Equal to
< < (Less than)
<, &lt Less than
> > (Greater than)
>, &gt Greater than
& & (Ampersand)
<=, <= Less than or equal to
“ " (Quotation) >=, >= Greater than or equal to
, ' (Apostrophe) I Logical OR operation (Bitwise)
II Logical OR operation
Operator Significance
&, & Logical AND operation (Bitwise)
&&, Logical AND opertaion
&&amp
+ Addition
— Subtraction
* Multiplication
/ Division
! Not
!= Not equal to
Operations are executed from left to right. Brackets can be

used to define the priority of expressions.
Notes :

B009 Easy Extend
General TAG Descriptions
Tag Function
AGM Main Tag, defines the device. All other tags are contained within this tag.
BREAK Conditional Interrupt.
For reboot of the NC (resetnc) or Drive (resetdrive)

CONTROL_RESET Eg <control_reset resetnc=“true” />
<control_reset resetdrive=“true”/>
For writing directly to the NC, PLC, GUD and Drive areas.
Attributes: name variable address
All alphanumeric values can be used as tag values. When writing directly from a local variable the $
symbol should be used immediately in front of the variable name.
DATA Examples:
<data name=“plc/mb160”>1</data> (Writing a value of 1 into mb160.
<let name= “tempvar”>7</let> (Declaring a variable named “tempvar” and loading a value of 7 into
it.)
<data name= “plc/mb170”>$tempvar</data> (Writing the contents of the variable into marker byte
170.
For saving/restoring the listed drive and machine data. Up to 20

addresses can be listed line by line.
Attributes:
Action=“read” - saves the value of the variable into temporary memory.
Action=“append” - Attaches the value of the listed variable to an existing list.
Action=“write” - writes the saved values into the machine data
Id=“name” - Label given to the temporary memory
DATA_LIST Examples: Reading the values of R200, R201 & R202 into the temporary memory called “name”:-
<data_list action=“read” id=“<name>”>
nck/channel/parameter/r[200]
</data_list>
Writing the values back into the listed machine variables:-
<data_list action=“write” id=“<name>”>
DEVICE Used to describe the device.
The version number of the drive is copied into the $driveversion variable that is valid within the
DRIVE_VERSION
Device tag
ELSE A condition used if the instruction was not fulfilled.(Used in conjunction with IF, THEN)
The Form tag contains the user dialogue description. One dialogue is permitted per device. The
“Addition. Parameter” soft-key displays the user dialogue that is entered under this tag.
Attributes:
color - Background colour of the dialogue screen.
label - Optional name for the form.
FORM xpos - X Position of the upper left-hand corner of the dialogue box
ypos - Y Position of the upper left-hand corner of the dialogue box.
width - Extension in the X direction (Pixels).
height - Extension in the Y direction (Pixels).
Example:- <FORM name=“dialog name” color=“#ff000”/>
Function call-Executes the functions within the “name” attribute.

Attribute:
FUNCTION
Name - “Name of the function body”.
Example: <FUNCTION name=“function name”/>
Notes :

Easy Extend B009
Tag Function
For the creation and restoring of archive files.

Attributes:
Create=“true” - Command to create an archive
Name=“filename.arc” or “filename.ard”- Filename
specified by user (.arc = complete archive, .ard = dataclass archive)
Class - Specifies that the archive will be a “Data class” archive (Choice of User, Manufacturer or Individu-
al).
If a class is not specified a standard archive containing NC, PLC, HMI & Drive data will be created.
Group - Specifies the data groups to be included in the archive.(Choice of NC, PLC, HMI & Drive data)
FILE Examples:-
Read in a standard archive called “complete.arc”-
<file name=”complete.arc/>
Read in a data class archive called “dataclass.ard”-
<file name=”dataclass.ard/>
Create a standard archive called “user.arc”-
<file name=”user.arc create=“true” />
Create a data class archive called “user.ard”-
<file name=”user.ard” create=“true” class=“manufacturer individual user” group=“nc plc hmi
drv”>
The archives are stored in the following path:- System CF card\oem\sinumerik\hmi\dvm\archives.
Contains the function body of a sub-function. This should be programmed within the AGM or DEVICE
tags. Globally used functions should be set up in the AGM tag.
Attribute:
name = “Name of the function body”
FUNCTION_ BODY Example:
<FUNCTION_BODY name=“function name”>
…
…
</FUNCTION_BODY>
ID Dialogue screen index of the device.
Conditional instruction (IF, THEN, ELSE)
Used with the THEN and ELSE tags.

Following the IF tag, a condition is declared. If this condition is true, the THEN tag is executed. Should the
condition be false the ELSE tag will be executed.
Example:
The following example checks IF MB120 has a value not equal to 5. If this id true, the THEN tag contains
the instruction to load a value of five to MB120.
IF MB120 was already had a value of 5, the THEN tag would be ignored and the code in the ELSE tag
would be auctioned.
IF
<IF>
<CONDITION> “plcmb120” !=5 </CONDITION>
<THEN>
<OP> “plc/mb120” =5 </OP>
</THEN>
<ELSE>
…
…
</ELSE>
</IF>
This tag is used to call other XML files from within the AGM.XML.
INCLUDE Example: <?include src=“name of xml file to be included”?>
For displaying a message specified in the tag. This can be used in the case of alarm numbers, the dia-
MSG logue box would display the text associated with the alarm number.
NAME The NAME instruction defines the name of a device to be displayed in the dialogue screen.
Notes :

B009 Easy Extend
Tag Function
Setting up of a local variable with a user specified name.

Attribute:
name - variable name
type - The format of the variable can be integer (INT),
double (DOUBLE) or string (STRING). The default of INT is
assumed if no format is specified.
Examples:
LET <LET name=“variable_name” type=“STRING”/>
It is possible to assign a value to the variable eg 99:
<LET name=“variable_name” type=“STRING”>99</LET>
NC and PLC variables can be saved in a local variable using the “=“ operation. The format of the local varia-
ble automatically takes the format of the NC/PLC variable.
Variables that are required to be globally available should be set up directly after the AGM tag.
When used with a dialogue box, processing of the message opens up the corresponding DEVICE tag, this
tag is closed after the message is executed and as such deletes all variables within the DEVICE tag.
A message box is opened with this tag, the return value can be used to make a branch.
Attributes:
text - The text to be displayed in the message box. Using the characters “%n” results in a new line.
caption - The header of the text box.
MSGBOX retvalue - Defines the variable when/where the return value is copied. 0 - CANCEL, 1- OK,
type - Acknowledgement possibilities.
“BTN_OK” - OK button.
“BTN_CANCEL - CANCEL button.
“BTN_OKCANCEL” - OK or CANCEL buttons.
Execute instruction. For carrying out mathematical Operations with system and temporary variables.
Examples:
Setting a temporary variable equal to PLC system variable MB100
<op> tmpVar=“plc/mb100” </op>
OP Multiplying a variable by 2.
<op> tmpVar= tmpvar * 2 </op>
Setting PLC system variable MB100 equal to a temporary variable.
<op> “plc/mb100”=tmpVar </op>
Text can be output in the dialogue line or copied into a variable.

Attributes:
name - Name of the variable where the text is to be saved (optional)
text - The text to be output.
PRINT Values:- Number of variables whose values should be inserted in the text.
Format:- d Integer
f Floating point value
s String
Example: <print name=“variable name” text=“text” %formatting”> variable..</print>
SET_ACTIVE Data within this tag is used to activate the device.
SET_INACTIVE Data within this tag is used to de-activate the device.

START_UP Data within this tag is used to commission the device.
STOP Stops a sequence at this position
The switch tag allows the value of a variable to be compared with a number of constants. If a match is
SWITCH found the value will be written into the variable specified in the DATA tag.
Used for testing that a device is functional.. The test result should be entered into the $actionresult varia-
TEST ble. If the variable contains a value of one, then the device is functional. A value of zero indicates a faulty
device.
Notes :

Easy Extend B009
Tag Function
THEN Used with the IF, & ELSE commands. See the description for IF
VERSION Version Information
For Loop – This tag checks for a condition, if the condition is false, the loop will end.
Example:- Declaring a local variable as “count” with an initial value of 0. Set the condition to check that the
variable is less than or equal to 7. Increment the count by increments of one. When the value of the varia-
ble is more than 7 (False) add 1 to the count value and place the result in output byte 10.
<let name=“count=0”</op>
<for>
<init>
FOR <op> count=0 </op>
</init>
<condition> count <= 7 </condition>
<increment>
<op count = count +1</op>
</increment>
<op “plc/qb10” = 1+count</op>
</for>
This tag is used for the enabling of the device.

Enabling via PLC machine data:
14510 $MN_USER_DATA_INT[0] to $MN_USER_DATA_INT[3]
The devices are assigned to the machine data in logical order, each machine data handles 16 devices-
$MN_USER_DATA_INT[0] Devices 1 to 16 (Bits 0 to 15)
“ “ “ “ [1] “ 17 to 32 (Bits 0 to 15)
“ “ “ “ [2] “ 33 to 48 (Bits 0 to 15)
“ “ “ “ [3] “ 49 to 64 (Bits 0 to 15)
Bit assignment examples:
$MN_USER_DATA_INT[0] bit 15 = device 16
OPTION_MD Attributes:
name - machine data address - $MN_USER_DATA_INT
Index - index of machine data - [x]
Example:- <option_md name=“$MN_USER_DATA_INT0[0]/>
Enabling via PLC variable:
Example DB9061.DBWx.
When only devices 1 to 16 are in use, no index is required:
<option_md name=“PLC/DB9061.DBW0”/>
When more than 16 devices are in use, the index must be specified:
<option_md name=“PLC/DB9061.DBW0” index=“0”/>
When this tag is used for a device and the option is not set, a soft-key is available which allows the entry
of a password. The entered password is placed in the specified variable and should be verified by the user
PLC. Acknowledgement of this to the HMI is required using the relevant interface bit (DB9061).
PASSWORD Attribute:
refvar - name of the reference variable.
Example: Declaring DB9062.DBD0 as the target for the entered password-
<password refvar=“plc/db9062.dbd0”/>
Notes :

B009 Easy Extend
Tag Function
The interface signals are handled as standard by DB9905. This tag allows the interface to be re-defined.
Attribute:
PLC_INTERFACE Name - Address of the new interface.
Example: <plc_interface name=“address of the new interface”/>
With this tag a message will appear instructing the operator to power down the system. The message
POWER_OFF text is fixed by the System.
While Loop - This tag executes a sequence of instructions for a multiple number of times providing that a
certain condition is true. The sequence is halted when the condition becomes false.
Example:- Set the condition that IB9 should be equal to 0. Providing that this is the case, write a value of
15 into QB11 using the data tag.
WHILE <while>
<condition> “plc/ib9” ==0</condition>
<data name “plc/qb11> 15 </data>
</while>
Do-While Loop - This tag executes a sequence for instructions and then checks for a condition, if the
condition is true, the instructions will be processed again. The processing stops when the condition is
false.
Example:- Write a value of 15 into QB11 using the data tag. Then check the condition that IB9 should be
equal to 0.
DO_WHILE Providing that this is the case, again write a value of 15 into QB11. When the condition is false, stop the
loop.
<while>
<data name “plc/qb11> 15 </data>
<condition> “plc/ib9” ==0</condition>
</while>
?UP Update Agent Syntax -
Notes :

Easy Extend B009
TAG Descriptions - Dialogue Screens
Tag Function
The Form tag contains the user dialogue description. One dialogue is permitted per device. The “Addition.
Parameter” soft-key displays the user dialogue that is entered under this tag.
The following tags are processed by the Form tag:-
LET
INIT
PAINT
TIMER
CLOSE
CAPTION
SOFTKEY_OK
SOFTKEY_CANCEL
FORM Attributes:
color - Background colour of the dialogue screen.
name - Optional name for the form.
xpos - X Position of the upper left-hand corner of the dialogue box
ypos - Y Position of the upper left-hand corner of the dialogue box.
width - Extension in the X direction (Pixels).
height - Extension in the Y direction (Pixels).
Example:- <FORM name=“dialog name” color=“#ff000”/>
The INIT tag is executed immediately after the generation of the dialogue box. All the screen input ele-
INIT ments and hotlinks should be written in here.
The PAINT tag is executed when the dialogue box is displayed.

PAINT All texts and graphics for the dialogue box should be written in here.
The CAPTION tag contains the title of the dialogue box and should be used within the INIT tag.
CAPTION Example: <caption> Title of Dialogue box </caption>
The tag controls the behavior of the dialog screens when saving user entries.
The behavior should be defined within the INIT tag.
If the tag is not used then the entries are always buffered.
Exception: The hotlink attribute is set to true.

DATA_ACCESS Attribute:
type = "TRUE" – values that have been entered are not buffered. The dialog screen directly copies the
values that have been entered into the reference variables.
type = "FALSE" – the values are only copied into the reference variable when tag UPDATA_DATA type =
"FALSE".
Notes :

B009 Easy Extend
Tag Function
The CONTROL tag generates the control elements.
Attributes:
name:- label of the field. The label also represents a local variable.
xpos:- X position of the upper left hand corner.
zpos:- Y position of the upper left hand corner.
fieldtype:- Field type (Optional).
“edit” - Data can be changed
“readonly” - Data cannot be changed.
“combobox” - A drop down list with text that can accept a value or be used for selection purposes.
If no type is specified, the default is set to “edit”.
refvar – label of the reference variable that can be linked to the field. (optional)
hotlink – “TRUE“ the field is automatically updated when data is changed (optional)
format – formatting data, refer to the print tag (optional)
time – specifies the refresh rate of the data (optional). The following refresh rates are possible:
“super fast“ - refresh time < 100ms
“fast“ - refresh time, approx. 100ms
“normal“ - refresh time, approx. 200ms
“slow“ - refresh time, approx. 500ms
If the combo box field type is selected then the expressions to be displayed also have to be defined. The tag
<item> should be used for this purpose. The combo box saves the index of the currently selected text in the
variables belonging to the control (variable name). Indexing starts with the value 1.
CONTROL Syntax:
<item>Expression</item>
Example:
<control name = "button1" xpos = "10" ypos = "10" fieldtype=” combobox “>
<item>text1</item>
<item>text2</item>
<item>text3</item>
<item>text4</item>
</control>
If any integer value should be assigned to an expression then the value=“value“ attribute must be added to the
tag. Instead of the consecutive numbering - the control variable now contains the assigned value of the item.
Example:
<control name = "button1" xpos = "10" ypos = "10" fieldtype=” combobox “>
<item value = “10” >text1</item>
</control>
Note: The hotlink attribute results in the appropriate control being cyclically updated. This means that if a value
is entered, then the next update cycle overwrites the value that has been entered. In order to avoid this, use the
DATA_ACCESS tag to activate the function where entered data is immediately saved.
An additional possibility is to include the SOFTKEY_OK tag in the form. This tag is then run before the dialog
box is closed. In this block - using the UPATE_CONTROLS instruction - data can be aligned between the con-
trol and reference variables.
Notes :

Easy Extend B009
Tag Function
The tag is used to display a text at the specified position on the screen. If the text is to be read from a text file,
then the “$$” character string should be placed in front of the label.
If the contents of a string variable are to be displayed, then the “$$$” character string should be located in front of
the variable.
Syntax: <text xpos = "X position" ypos = "Y position"> Text </text>
Attributes:
xpos - X position of the upper left-hand corner
ypos – Y position of the upper left-hand corner
color – text color
Value: Text to be displayed
Example: Direct text output: <text xpos=“10“ ypos=“20“> Hello World </text>
Example: Indirect text output with text from a file:

The text to be output should be set-up in the oem_aggregate_eng.ts file, “eng” specifies that the file is the Eng-
lish version. The German version would be “deu”. This should be changed to suit the language of the controller.
The file has to exist in the following directory: System CF card\oem\sinumerik\hmi\lng

Example of the file:
TEXT
<TS>
<context>
<name>EASY_EXTEND</name>
<message>
<source>MY_TEXT_SYMBOL</source>
<translation>R2</translation>
<chars>20</chars>
</message>
<message>
<source>R3</source>
<translation>RPAR3</translation>
<chars>20</chars>
</message>
</context>
</TS>
Example tag to be placed in the relevant xml file: <text xpos=“10” ypos=“20”>$$MY_TEXT_SYMBOL </text>
Example: Indirect text output with text form a variable:

<LET name=“TextVar” type=“string”> Hello World </text><text xpos=“10” ypos=“20“>$$$TextVar </text>
The tag is used to display an image/graphic at the specified position.
The bit maps in the BMP or PNG format should be saved in the directory CF-Card/oem/sinumerik/hmi/dvm.
Linux: Lower case letters should be used for all file names.
Syntax: <img xpos = "X position" ypos = "Y position" name=“name“ />
Attributes:
IMG xpos - X position of the upper left-hand corner
ypos – Y position of the upper left-hand corner
name – bit map name
Optional: If the display of an image/graphic deviates from the original size then the dimensions can be defined
using the width and height attributes.
width – width in pixels
height - height in pixels
Notes :

B009 Easy Extend
Tag Function
The tag draws a solid square at the specified position in the specified color.
Syntax:
<box xpos="X position" ypos = "Y position" width=“X extension“ height=“Y extension“ color=“color code“ />
BOX Attributes:
xpos – X position of the upper left hand corner
ypos – Y position of the upper left hand corner
width – extension in the X direction (in pixels)
height – extension in the Y direction (in pixels)
color – color coding
TIMER Dialog box message. Tag is cyclically executed.

CLOSE Dialog box message. Tag is executed before the dialog box is closed.
Using the tag, a variable is included in the cyclic read utility (hotlink).
This tag is only valid within the INIT instruction of a form.
Attribute:
REQUEST name - address label
Syntax: <REQUEST name = “NC Variable“ />
The tag synchronises data between the operator elements and the reference variables.
Attribute:
type – the attribute defines the direction of the data alignment.
TRUE – data is read out of the reference variables and copied into the operator elements.
FALSE – data is copied from the operator elements into the reference variables.
UDATE_CONTROLS Syntax:
<update_controls type="<direction>"/>
Example:
<softkey_ok>
<update_controls type="false"/>
</softkey_ok>
This tag overwrites the standard behavior when a dialog box is closed using the "Cancel" softkey.
The tag should be programmed in the first sub-level of a form tag.
The following functions can be executed in this tag:
• Data manipulation
• Conditional processing
• Loop processing
SOFTKEY_ CANCEL
Example:
<form>
<softkey_cancel>
<data name=”plc/mb170”>2</data>
</softkey_cancel>
</form>
Notes :

Easy Extend B009
Tag Function
This tag overwrites the standard behavior when closing a dialog box using the "OK" softkey.
The tag should be programmed in the first sub-level of a form tag.
The following functions can be executed in this tag:

• Data manipulation
• Conditional processing
• Loop processing
Syntax:
<SOFTKEY_OK>
…
…
</SOFTKEY_OK>
Example:
SOFTKEY_OK <form>
….
….
<softkey_ok>
<update_controls type="false"/>
<let name="msgbox_result">0</let>
<MsgBox text="Execute NCK Reset!! " caption= "NCK Reset" retvalue= "msgbox_result" type=
"BTN_OKCANCEL" />
<if>
<condition> " msgbox_result " == 1 </condition>
<then>
<CONTROL_RESET resetnc="TRUE"/>
</then>
</if>
</softkey_ok>
</form>
Notes :

B009 Easy Extend
Adding language files
Open the "Project" within AMM software, go "Online" to the

controller.
In the project window highlight the "EasyExtend" menu. Se-

lect the file "oem_aggregate_eng.ts.

text

text
Notes :

Easy Extend B009
Access MyMachine can be used to the create additional lan-

guage specific files for the Easy Extend function.
To add the files, select the "EasyExtend" tab followed by the
"New target language" button:
When all the required alarm text have been edited
Notes :

B009 Easy Extend
Select the file "oem_aggregate_deu.ts. and open with the

"Edit" key
Enter the required text for the second language.
Select, with a tick, all the required boxes, as shown.

Download the two files using the "transfer" button.
The respective files will be
transferred to the controller
Editing the "agm.xml" and "oem_device_1.xml" files:
In the controller window, select the following path: System-CF

-card/oem/sinumrek/hmi/dvm
Notes :

Easy Extend B009
<AGM>
<DEVICE>
<name>$$Option_01</name>
</DEVICE>
<DEVICE>
</DEVICE>
<DEVICE>
</DEVICE>
<DEVICE>
Open the agm.xml file and modify the text: <password refvar = "plc/db9062.dbd24" />
</DEVICE>
</AGM>
On the controller the HMI needs to be rebooted
When the language is changed on the controller, the respec-

tive text will be shown.
Notes :

B009 Easy Extend
English: German:
Explanation
In the file "oem_aggregate_eng.ts/oem_aggregate_deu.ts",

the language text is being assigned to a "source" name
(identifier).
In this example the "source" name is "Option_01"
In the file "agm.xml/oem_devive_1.xml" files, the control will

look for the source identier, by using the prefix $$ and the
stated source identifier used from the ts file eg. "$$Option_1",
The text associated with the source identifier will be

displayed.
Notes :

Easy Extend B009
<AGM>
<DEVICE>
</DEVICE>
<DEVICE>
</DEVICE>
<DEVICE>
</DEVICE>
<DEVICE>
</DEVICE>
</AGM>
The active language of the controller determines which lan-

guage file is used.
Therefore:
A controller with English language selected uses the
"oem_aggregate_eng.ts" file.
A controller with German language selected uses the
"oem_aggregate_deu.ts" file.
The file name is: oem_aggregate_eng.ts. The “eng” part of

the name is the language identifier.
Language identifiers:
eng = English
deu = German
fra = French
ita = Italian
esp = Spanish
chs = Chinese (Simplified)
cht = Chinese (Traditional)
kor = Korean
ptb = Portuguese (Brazil)
B009: END
Notes :

B009 END Easy Extend

B035 Program Handling Using External Storage
Sinumerik
Operate
Module Description:
It is often a requirement to store machining programs externally to the controller.
The EES (Execute from External Storage) feature can then be used to execute the programs, from
the external source, as if they were stored in the NC memory.
The external storage can be on the User CF card, USB memory, or a networked PC.
Examples reason for storing programs externally:

• The size of the program.
• The number of programs on the controller is at the limit.
• Centrally stored programs can be accessed by many networked machines.
• Ensures that the programs can be recovered in the event of data loss.
Module Objective:
Upon completion of this module you will know how to:
• Setup a networked logical drive

• Activate the Execute from an External Source command
• Activate the NC Extend memory.
• Use main programs and subprograms with the above features.
Content:
Sinumerik
Program handling - General information
Setting up a Networked Logical Drive
NC Extend Function
Execute from an External Source Function
Program Use With EES & NC EXTEND
B035
B035

Program Handling B035
Program
Handling:
START
Program
Handling -
General
information
Setting up a
Networked
Logical
Drive
NC Extend
Function
Execute
from an
External
Source
Function
Program
Use With
EES & NC
EXTEND
Program
Handling:
END
Notes :

B035 Program Handling
Program Handling - General information. NC Extend: Releases 100MB of System CF card memory.
(Option number: 6FC5800-0AP77-0YB0)
Logical Drives
Execute from External Source (EES): Suitable for connect-
The logical drive features allows storage of machining pro- ing via Ethernet to an external PC for unlimited storage ca-
grams in addition to the standard NC memory. pacity. (Option number: 6FC5800-0AP75-0YB0)
.
The additional storage can be: Global Part Program Memory:
• On the controller (System CF card). The Global Part Program Memory feature behaves like
standard NC memory and has no restrictions on program
• A USB device.. jumps, block search etc.
• A networked computer. The feature can be activated for one of the following memory
types:
By default, the USB feature are already active. • System CF card (NC Extend).
Programs can be easily copied and pasted between the con- • USB.
troller and a logical drive. • Networked computer (EES).
It is also possible to execute a program from a logical drive Standard NC memory allocation and availability of EES/NC
however, there are limitations with program jumps and block Extend functions:
search, for example.
NC Extend, EES, and Global Part Program Memory.

828D NC Memory NC Extend EES
Software
Options are available which allow full program functionality
for programs stored externally of the controller. 24x 3MB  
26x 5MB ✓ ✓
28x 8MB ✓ ✓
28xA 10MB ✓ ✓
29x.3 10MB ✓ ✓
Setting up a Networked Logical Drive. The following example shows how to connect to a Win-
dows7® computer via the X130 (Factory network) interface
Option: The following software option is required.:
of the controller (Direct connection without DHCP)
X130 will be configured with an IP address of
• Network drive management - 6FC5800-0AP01-0YB0 192.168.100.1.
The computer will be configured with an IP address of
192.168.100.2
Both will have the subnet mask of 255.255.255.0
Note:
There are certain IP addresses that must be avoided as they
are reserved for use by the system.
IP addresses in the 192.168.214.xxx range must be avoid-
ed.
IP addresses in the 192.168.215.1 to 31 range must also be
avoided.
Configuring Interface X130:

Activate the option with an NCK Reset.
Connect a suitable Ethernet cable between the computer
and the X130 interface of the controller.
X130
Notes :

Locate the network settings screen: Setting the X130 IP Address:
Deselect the DHCP client option and enter the required IP

address and subnet mask (192.168.100.1/255.255.255.0):
Note: The control needs to be switched off/on to activate

the new settings
Setting up the Logical Drive: Select a free soft-key. Further soft-keys, 24 in total, are ac-
cessed via the >>Level soft-key.
Locate the logical drives set-up area:
Example - Soft-key 8:
Default Logical drives screen:
Choose the NW Windows option:
Notes :

For this example the following data is required (the external The relevant data has to be entered:
computer settings will be changed later):
Computer name: 192.168.100.2

(IP address of the PC)
Enabling name: Programs

(Name of the shared folder on the PC).
User name: AUDUSER

(Login name of the PC)
Password: SUNRISE
(Login password of the PC, for example)
Soft-key text: Programs

(the text that will appear on the soft-key in the Program
manager area).
The remaining parameters are to be left unchanged for this

example.
Computer Network Set-up.
The computer must now be given an IP address that is in the

same subnet mask.
The IP address for this example is: 192.168.100.2 with a
subnet mask of 255.255.255.0.
Locate and open the Network and Sharing Center of the

computer to be connected to the controller.
Right click the

network icon.
Select ”open Network and Sharing Centre”
Notes :

The IP address and the subnet mask can now be entered:
Double click the Internet Protocol Version 4(TCP/IPv4)

option.
Computer- Shared Folder Select View:
A shared folder allows it to be accessed via the network.

The folder is required for the storage of programs which will
be accessible from the controller.
For reasons of security it is possible to restrict access to the

shared folder by setting permissions.
The following example will show how to create a folder on

the D drive and how to set up sharing and permissions.
The option - Use sharing Wizard - can be deselected, via

the Tools menu in Windows® Explorer, to ease setup:
From Windows® Explorer, select the Tools menu, followed

by Folder options:
Notes :

Deselect the Use Sharing Wizard option:
Creating a New Folder
Example:
In Windows® Explorer:
• Select the D drive.
• With the mouse pointer In the right hand window, right
click and create a new folder.
• Give a suitable name to the folder.
Example Programs.
Sharing the New Folder • Select the Sharing tab.

• Select the Advanced sharing tab.
• Right click with the mouse pointer on the Programs
folder.
• Select the Properties option from the list
Notes :

• Select Share this folder. • Select Permissions.
The default setting is for everyone to have read only access It is possible to restrict access to the shared folder by other
to the folder. users of the PC.
If restrictions are required, the Everyone user can be re-
moved or the permissions deselected.
Users can than be added via the Add button.
The required users of the computer can be searched for in

the Check Names field.
Notes :

In the following example, the user AUDUSER is going to be If the user exists, it will be displayed.
given permission to access the shared folder.
Enter AUDUSER in the Check Names field, then select the

Check Names button.
Example: AUDUSER has been granted full access to the It should now be possible to access the shared folder from
shared Programs folder. the Program manager area of the controller.
The Share permission for Everyone has been removed.
Notes :

The shared folder being accessed from the controller. Accessing individual sub-folders.
If a folder is created within the shared folder it will inherit the

share properties of the host folder.
It is possible to directly access a subfolder by entering a path

on the Logical drive set-up screen.
Example:
The Programs folder has been shared.
Two folders, Share 1 & Share 2, have been added within the
shared folder.
There is no need to share these new folders.
Note: If the Soft-key for accessing the shared folder is

grey, this indicates a problem with the network set up or
possibly the security of the computer hosting the Access the Program manager screens:
shared folder.
Firewall settings should be checked and temporarily
disabled to see if this is causing problems.
The new folders can be seen inside the original shared

folder:
Accessing individual folders.
By entering a path in the logical drives set-up screen it is

possible to access individual folders contained within the
main shared folder.
Example:
The following example shows two additional soft-keys which
have been set-up to give access to one each of the new
folders.
Notes :

The path to Share 1 has been included. The path to Share 2 has been included.
Access soft-keys 9 & 10 in the Program manager area: NC Extend Function.
The NC Extend function releases 100MB of System CF card

memory which, when used with the Global part program
memory feature, behaves exactly like standard NC memory.
i.e. there are no restrictions on block search, long program
jumps etc. that are found with other methods of executing
programs from external storage.
The option - 6FC5800-0AP77-0YB0 - needs to be set.
The two sub-folders can now be accessed: Activate the option with an NCK reset:
After the reset it will be possible to the NC Extend soft-key
in the Program Manager area
Notes :

The settings for the NC Extend can be viewed in the Logical Setting the Global part program memory:
drives area.
Only one Global Part Program Memory can be active, there-

fore, If it was already active on another logical drive it will be
automatically deactivated for that drive.
The default settings, e.g. soft-key text can be changed if The result of the Global part program memory being set is
required. the creation of the folder structure on the NC Extend drive:
The result of activating the Global part program memory is

the creation of three folders which match the default NC
memory folders.
The NC Extend area has 100MB of additional memory for Navigate to the Program manager screen:
storage of part programs/sub-programs/workpieces.
The folder structure that was created by the Global part pro-
gram memory.
This is the same as the folder structure in the NC memory

area.
The available space, in this case on the System CF card,

can be seen at the bottom right of the screen.
Notes :

Execute from an External Source Function Once the option is set and activated it can be decided which
logical drive is to be used.
The EES (Execute from External Source) function allows a This can be:
networked logical drive to be used with the Global part pro-
gram memory setting. The size of available memory is limited
• USB memory device
only by the space available on the networked PC. • Networked computer.
It is also possible to use the EES function on a USB memory
device.
Setting the Global part program memory
When the option is used in conjunction with the Global part
program memory setting, it behaves exactly like standard NC Locate the Logical drives area:
memory. i.e. there are no restrictions on block search, long
program jumps etc., that are found with other methods of exe-
cuting programs from an external source. It is also possible to
edit the program in NC stop.
Activating the EES Function:
The option, 6FC5800-0AP75-0YB0, needs to be set. The global part program memory setting can be applied to
either:
• A USB device
• The NC Extend memory
• A networked computer.
Activate the option with an NCK Reset.
Example - Setting the Global part program memory for a From within the Logical drives area, select the EES logical
networked computer. drive, followed by the Change and then Details soft-keys.
For the example a new networked logical drive (EES

SHARE) has been assigned to soft-key 6:
The Global part program memory can now be set.
The EES SHARE folder has been created and shared on the
networked computer:
Notes :

The EES SHARE Logical drive will now be activated for
Global part program memory.
Confirmation the Global part program memory is active is

seen on the Logical drive page for that particular logical
drive:
The available space, in this case the networked computer’s

hard disk, can be seen at the bottom right of the screen.

memory folders, also this drive whether a local drive, USB or
a networked drive will become the “MASTER NC MEMORY”.
Navigate to the Program manager screen:
The folder structure that was created by the Global part pro-
gram memory.
This is the same as the folder structure in the NC memory

area.
Notes :

Program Use With EES & NC EXTEND
Part programs, subprograms etc. can now be stored on the

external source or on the NC Extended memory and used in
the same way as the NC memory.

memory folders, also a drive whether a local drive, USB or a
networked drive will become the “MASTER NC MEMORY”.
The result of activating NC Extend is the ability to “Block

Search” from the CF card/ and external PC/server.
Siemens would recommend that the “NC Memory” softkey

should be removed, as shown in the examples.
Note: remove soft-key in the AREA: Setup -> HMI ->
Log.drives
Bloch search being performed from an external drive, in this

case a directory called EES on a PC.
Three folders which match the default NC memory folders.
PPU configuration
“NC” softkey removed so that there is only ONE “MASTER

NC MEMORY”.
Notes :

External PC/server configuration
“NC” and “NC Extend” softkey removed so that there is only

ONE “MASTER NC MEMORY”.
B035 : END
Notes :

Notes :

B011 Run MyScreens
Sinumerik
Operate
Module Description:
Run MyScreens is a function of the Sinumerik 828D which allows the manufacturer to write custom
screens.
The OEM screens are intended as an interface to the specific functions offered by the OEM.
Module Objective:
Upon completion of this module the course participant will be able to create Run MyScreens display
screens.
Content:
General Information
Sinumerik
Basic Configuration Information
Creating Run MyScreens OEM Files
Creating CUSTOM screen OEM Files
Creating Language Dependent Texts
Creating CYCLE screens OEM Files
Parameters and Variable Description
SINUMERIK 828D v4.8 Page 1 This document was produced for training purposes. B011
B011 Run MyScreens

Run MyScreens B011
Run MyScreens Creating CYCLE

START screens OEM
files
General Parameters
Information and
Variable
Descriptions
Basic
Configuration Run MyScreens
Information END
Creating
Run MyScreens
OEM Files
Creating
CUSTOM
screen OEM
files
Creating
Language
Dependant Texts
Notes:

B011 Run MyScreens
General Information
The Easy XML function is configured using *.XML files. These files contain the descriptions of the user interface.
In order to use images in the screens, a graphic programme is required, e.g. Paint Shop Pro® and Paint® are programmes which
are compatible with the 828D controller.
Easy XML can be used for the following functions:
1. Display of dialogs and provision of:

• Soft-keys
• Variable tables (this function will be available with a later level of implementation)
• Text and help text
• Graphic displays and help displays
2. Calling up dialogs by means of:

• The (entry) soft-keys
• PLC selection
3. Dynamic re-structuring of dialogs:

• Changing or deleting soft-keys
• Defining and designing variable fields
• Showing, replacing and deleting (language-dependent/independent) display texts
4. Initiating actions when:

• Showing dialogs
• Entering values (variables)
• Pressing soft-keys
• Closing dialogues
5.. Exchange of data between dialogs.
6. Variables
• Reading (NC, PLC, user variables)
• Writing (NC, PLC, user variables)
• Linking with mathematical, comparative or logic
operators
7. Executing functions:
• Subroutines
• File functions
• PI Services
8. Taking into account levels of protection defined for use groups.
Notes:

Run MyScreens B011
Basic Configuration Information
Configuration files are used to create the screens.

These configuration files are automatically interpreted by the
controller.
The files are not available as standard and have to be created
by the user using an ASCII editor (e.g. Notepad® or directly
on the controller).
The “easyscreen.ini“ file is a master file which is required to

specify which other files are to be used to create a user
screen.
These files contain the information which determine what is
displayed on a particular screen.
The screen is split into different areas:
1 Main dialog area

2 Title bar containing screen name (Left) and
“Long text” description of the selected
variable (Right)
3 Variable input/output field
4 Variable name “Short text”
5 Graphics related text
6 Unit text
Operating areas overview
To enable custom screens in other area of the controller, the

“easyscreen.ini” file has to be modified.
There are eight areas in total:-
Machine Area-Sub divided into:-

Jog
MDA
Auto
Parameter Area
Program Edit Area
Program Manager Area
Diagnosis Area
Start-up Area
Each area should have a “com” file specified.
Notes:

B011 Run MyScreens
Operating area Permissible position for start soft-keys File Name

Machine JOG HSK6 ma_jog.com
Machine MDA HSK6 ma_mda.com
Machine AUTO HSK6 ma_auto.com
Parameter HSK7 param.com
Program HSK6 aeditor.com
Program-Manager HSK2-8, 12-16, if not used for networked drives progman.com
Diagnostics HSK7 diag.com
Commissioning HSK7 startup.com
[STARTFILES]
StartFile01 = area := AreaMachine, dialog := SlMachine, menu := SlMaJogMillMenuHU, startfile := ma_jog.com

StartFile02 = area := AreaMachine, dialog := SlMachine, menu := SlMaAutoMenuHU, startfile := ma_auto.com
StartFile03 = area := AreaMachine, dialog := SlMachine, menu := SlMaMdaMenuHU, startfile := ma_mda.com
StartFile04 = area := AreaParameter, dialog := SlParameter, startfile := param.com
StartFile05 = area := AreaProgramEdit, dialog := SlProgramEdit, startfile := aeditor.com
StartFile06 = area := AreaProgramManager, dialog := SlPmDialog, startfile := progman.com
StartFile07 = area := AreaDiagnosis, dialog :=SlDgDialog, startfile := diag.com
StartFile08 = area := AreaStartup, dialog :=SlSuDialog, startfile := startup.com
Creating Run MyScreens OEM Files Creating the “easyscreen.ini” file on the controller
The files required for the Run MyScreens function need to be This file sets up the links to the files which are to be used to
created. This can be done directly on the controller by navi- create the user screens, it also determine which operating
gating to the relevant folders. Use the following key sequence areas these files are available in. The file has to be located in
to locate the “System data” area. one of the following paths/directories:-
“System CF card\oem\sinumerik\hmi\cfg”
“System CF card\user\sinumerik\hmi\cfg”
Use the cursor keys to locate and open this directory.
Notes:

Run MyScreens B011
To create the file select the “New” soft-key and ensure that The “com” file, the content of which will determine what ap-
the “Any” soft-key is selected. pears on the Run MyScreens screens, is also declared here.
The “Any” soft-key allows the file type to be determined by the (startfile := param.com)
user. In the dialogue box type in the name of the file and con-
firm with the “OK” soft-key. The first step is to enter the header ([STARTFILES])
The file name must be in lowercase due to the LINUX operat- The code for specifying the controller area and “com” file is
ing system. then entered on a new line as shown below.
[STARTFILES]
StartFile04 = area := AreaParameter, dia-
log := SlParameter, startfile := param.com
Creating the User Files on an external PC
As mentioned previously it is possible to create the Run My-

Screens files directly on the controller or offline using an
ASCII editor (e.g. Notepad®).
These files have to be transferred to the controller and placed
in the correct folders using the USB Interfaces or with Ac-
cess MyMachine software.
The newly created file will be automatically opened in prepa-
ration for editing. Below: The easyscreen.ini file located in the cfg directory
Example: easyscreen.ini file
The following example will show how the “easyscreen.ini” file
is used to specify the “Parameter” area of the controller as the
area from where the “Run MyScreens” are to be accessed.
(area := Area Parameter)
To activate the files, perform: Creating the “param.com” file
The param.com file has been declared in the “easyscreen.ini”

file and now needs to be created.
Code contained within the param.com file is used to create

soft keys and display texts and graphics etc.
The file needs to be created and placed in one of the following

folders:
“System CF card\oem\sinumerik\hmi\proj”
“System CF card\user\sinumerik\hmi\proj”
Notes:

B011 Run MyScreens
Example: param.com file Below: The param.com file located in the proj directory.
It is necessary to specify a soft-key to be used as the entry

point to the Run MyScreens.
Further soft-keys can be assigned within the Run MyScreens if
required.
//S(START)
HS7=("Run%nMyScreens")
PRESS(HS7)
LM("mask1")
END_PRESS
//END
//M(mask1/"Picture
Test"/"picture2.png"///110,25)
//END
To activate the files, perform:
The example defines the 7th horizontal soft-key as the entry Storage path for the image files:
point, the soft-key will have the text “Run MyScreens” (on 2 “System CF card\oem\sinumerik\hmi\ico\ico640”
lines). “System CF card\user\sinumerik\hmi\ico\ico640”
//S(START)
HS7=("Run%nMyScreens") To see the results of the example we have to locate the
“parameter” area of the control.
When the soft-key is pressed a Mask (mask1) will be loaded:
PRESS(HS7)
LM("mask1")
END_PRESS
//END
The Mask contains the code which determines the content of

the Run MyScreens. The 7th horizontal soft-key contains the text specified in the
The first line of the mask (Mask header) contains the mask “param.com” file: HS7=("Run%nMyScreens").
name, text and graphic information.
The following example shows mask1 with the title of Picture

Test. An image named tiger.bmp, will be displayed when HS7
is pressed. The image will be positioned 110 pixels from the left
and 25 pixels from the top of the screen.
//M(mask1/ "Picture Test" /

"picture2.png" / / / 110, 25)
//END
Notes:

Run MyScreens B011
Screen title/caption Picture2.png image
Mask header information: Parameter Description
The various parameters are separated by the “Forward slash” Graphic The position of the graphic in pixels. Distances
character (/). Position Position are from the left and top of the dialogue
screen and are separated by a comma.
//M(Identifier/header/Graphic/Dimension/Variable/Graphic
position/Attributes) Attributes CM (Column Mode) Column alignment.
Parameter descriptions: CM0: Default, the column distribution is carried

out separately for each line.
CM1: The column distribution is of the ling with

the most columns applies to all lines.
Parameter Description CB: (Change Block) Response when the dia-

logue is opened. The CB attribute can also be
Identifier Label of dialogue/mask. used on individual variables, in this case the
individual
Header Name of the screen. setting has priority over the CB setting in the
Mask Header.
Graphics Name of image to be displayed.
Dimension Position and size of the dialogue. (Distance from CB0: All change blocks associated with the dia-
the left hand side, right hand side, width, height) logue are processed when it is opened.
Values in pixels and separated by commas
CB1: Change blocks are only processed if the
Variable The cursor can be assigned to a variable. The relevant value changes.
first variable has an index of 1, the remaining
variables are indexed in the order that they were
configured.
Notes:

B011 Run MyScreens
Adding Dialogue Elements: HS1=("Variable%nTest")

VS8=(softkey_nav_back
Dialogue Elements refer to long and short texts, graphics texts,
unit texts and I/O fields. Additional soft-keys can also be added. PRESS(HS1)
LM("mask3")
The dialogue elements are added below the mask header. END_PRESS
In the following example (Shown in red text) a soft-key with the PRESS(VS8)
label “Variable Test” is added. When the soft-key is pressed the EXIT
screen will display a list of four variables. The four variables are END_PRESS
defined under a new mask (mask2-Workpiece Dimensions). //END
The parameters of the variables defined in mask2 are separat- //M(mask3/"Workpiece Dimensions"/)
ed by the forward slash character (/). Def Var1=(R2///"Length of component","R0 X
Length",,,"Length of component"///"$R[0]")
A detailed description of the Dialogue Element parameters can Def Var2=(R2///"Width of component","R1 Y
be found in chapter ”Parameters and Variable Descriptions”. Width",,,"Width of component"///"$R[1]")
Def Var3=(R3///"Height of component","R2 Z
Height",,,"Height of component"///"$R[2]")
//S(START) Def Var4=(I///"Main spindle speed","R3 Spindle
speed",,,"Main spindle speed"///"$R[3]")
HS7=("Run%nMyScreens")
PRESS(HS7) VS8=(softkey_nav_back)
LM("mask2") PRESS(VS8)
END_PRESS LM("mask2")
//END END_PRESS
//END
//M(mask2/"Picture Test"/"picture1.png"///110,25)
The additional soft-key can now be seen. Screen title/name Long text of the selected variable.
Short text Input field
Values entered in the input field will be transferred to relevant

variable.
When the soft-key is pressed the defined variable will be dis-
played.
Notes:

Run MyScreens B011
Detailed Analysis: Def Var1=(R2///"Length of component","R0 X

Length"///"$R[0]")
//M(Mask1/"Workpiece Dimensions")
R parameter 0 as a real number to 2 decimal places, sets the
Name of Mask1: component length:
HS1=("Variable %nTest")
Determines the text for horizontal soft-key 1 as “Variable Test”:
Def Var2=(R2///"Width of component","R1 Y

Width"///"$R[1]")

When the soft-key is pressed mask2 will be loaded. component width:
PRESS(HS1)
LM("mask2")
END_PRESS
Def Var3=(R3///"Height of component","R2 Z VS8=(sofkey_nav_back)

Height"///"$R[2]")
Determines a predetermined softkey of the sysem.
component height:
Checking the entered values
Values can be entered directly on the custom screen. These

values are transferred directly to the variables.
They can be checked by viewing the variables on the stand-
ard screen by pressing the “User variable” soft-key.
Def Var4=(I///"Main spindle speed","R3 Spindle
speed"///"$R[3]")
R parameter 3 as an integer, sets the spindle speed:
Notes:

B011 Run MyScreens
CUSTOM Screen OEM files
The “CUSTOM softkey is an extra “AREA” softkey so that the OEM can create there own dialogs or additional softkey bars and can
be loaded and used for executing additional actions. The start point for the “CUSTOM” screens is the “menu select “ (main) area as
shown below.
Press first
Free “Area” softkeys
Free “Area” softkeys
The "xmldial.xml" file is pre-named by the system and is automatically called when the softkey is activated, this is used to initiate
the OEM operating sequences.
The initial menu is defined by the form name "main" in the "xmldial.xml" file. You can use the "main" menu to link additional dialogs
or additional softkey bars so that they can be loaded and used for executing additional actions.
Notes:

Run MyScreens B011
A configuration file required for the Run MyScreen function, Creating the “slamconfig.ini” file on the controller
needs to be created. This can be done directly on the control-
ler by navigating to the relevant folders. Use the following key This file activates the softkey in the “Area” and activates the
sequence to locate in the “System data” area. custom.ini file which is to be used to create the user screens,
it also determine which operating areas these files are availa-
ble in. The file has to be located in one of the following paths/
directories:-
The labelling and position of the softkey for the "Custom" op-
erating area are configured in the
slamconfig.ini file.
To create the file select the “New” soft-key and ensure that the Example: slamconfig.ini file.
“Any” soft-key is selected.
point to the “MENU” area.
The following example will show content of the

“slamconfig.ini ” file for the “OEM Control Panel” in the side-
screen area of the controller.
[Custom]
TextId=Run%nMyScreens
Picture=Custom.png
SoftkeyPosition = 12
Visible=true
The example defines the 12th horizontal soft-key as the entry

The newly created file will be automatically opened in prepa- point, the soft-key will have the text “CUSTOM”.
ration for editing, enter the text below.
Creating the User Files on an external PC
As mentioned previously it is possible to create the Easy XML

files directly on the controller or offline using an ASCII editor
(e.g. Notepad®). You need the easyscreen.ini and custom.ini files to configure
These files have to be transferred to the controller and placed the operating area.
in the correct folders using the USB/CF Interfaces or with The file easyscreen.ini already contains a definition line for the
Access MyMachine software. "Custom" operating area:
Notes:

B011 Run MyScreens
To create the file select the “New” soft-key and ensure that The “com” file, the content of which will determine what ap-
the “Any” soft-key is selected. pears on the Run MyScreens screens, is also declared here.
(startfile := mycustommasks.com)
The first step is to enter the header ([STARTFILES])

The code for specifying the controller area and “com” file is
then entered on a new line as shown below.
[STARTFILES]
StartFile04 = area := AreaParameter, dialog := SlParame-

ter, startfile := param.com
StartFile05 = area := Custom, dialog := SlEsCustomDia-

log, startfile := mycustommasks.com
Below: The easyscreen.ini file located in the cfg directory

ration for editing.

(area := Area Parameter)
To activate the files, perform: Creating the “custom.ini” file
The custom.ini file has been declared in the “easyscreen.ini”

file and now needs to be created.
Code contained within the custom.ini file is used to create

The file needs to be created and placed in one of the following

folders:
Notes:

Run MyScreens B011
To create the file select the “New” soft-key and ensure that the ; Text on the caption bar of the form in the
“Any” soft-key is selected. start screen
[Header]
;Text=Custom Test Page
; Picture shown on the form in the start

screen
[Picture]
;Picture=logo.png
; Mask shown with startup of area "custom"

[Startup]
Startup = Mask:=mask1,
File:=mycustommasks.com
The example defines the name of the “Mask” to be loaded and

the name of the file with the screen content for the
The newly created file will be automatically opened in prepa- “CUSTOM” area.
Startup = Mask:=mask1, (mask1 to be loaded)
Example: custom.ini file.
File:=mycustommasks.com (name of the file which will
The following example will show content of the “custom.ini ” contain mask1 to be loaded)
file for the “OEM custom Areal” of the controller.
The contents of the “mask” can be created using the file
“mycustommasks.com”.
Creating the “mycustommasks.com” file on the controller To create the file select the “New” soft-key and ensure that
the “Any” soft-key is selected.
This file activates the content of the custom screens as stated
in the custom.ini file. The file has to be located in one of the
following paths/directories:-

Example: mycustommasks.com file.
The following example will show content of the

“mycostommasks.com ” file for the “OEM custom Areal” of
the controller.
Notes:

B011 Run MyScreens
//M(mask1/"Custom Test Run MyScreens"/"picture1.png"///50,25)

Def Var5=(I///"Feedate of X Axis","Actual Feed of X Axis",,,"Feed of X Axis"///"/Nck/MachineAxis/
actFeedRate1]"/250,,200/475,,70,)
Def Var6=(I///"Feedate of Y Axis","Actual Feed of Y Axis",,,"Feed of Y Axis"///"/Nck/MachineAxis/
actFeedRate[2]"/250,,200/475,,70,)
Def Var7=(I///"Feedate of Z Axis","Actual Feed of Z Axis",,,"Feed of Z Axis"///"/Nck/MachineAxis/
actFeedRate[3]"/250,,200/475,,70,)
Def Var8=(I///"Main spindle speed","Actual Spindle Speed",,,"Spindle Speed"///"/Channel/Spindle/
actSpeed[u1, 4]"/250,,200/475,,70,)
END_PRESS
//END
To activate the files, perform:
To see the result of the example the “CUSTOM” Area softkey has to be located on the control.
The 12th horizontal soft-key contains the text specified in the “xmldail.xml” file: HS12="CUSTOM".
The new “CUSTOM” softkey MAIN area
The new “CUSTOM” softkey placed on the sidescreen.
Notes:

Run MyScreens B011
When the “CUSTOM” softkey is pressed the Run “MyScreen”

code in the file custom.ini is used.
Code contained within the mycustommasks.com file is used

to create soft keys and display texts and graphics etc.
If required, the OEM can add more screens with entry points
along the “Horizontal” or “Vertical” soft keys as shown below.
Notes:

B011 Run MyScreens
Creating Language Dependant Texts Example Text File:
It is possible to configure the Run MyScreens configuration 85100 0 0 "English%nMyScreens"

files so that the Run MyScreens language matches that of 85101 0 0 "English Mask Header"
the system. 85102 0 0 "English Long Text"
In order to do this it is necessary to create one text file for 85103 0 0 "English Short Text"
each required language.
The text that is to be displayed is contained within the text
files.
The Run MyScreens configuration files use identifiers to en-
sure that the correct text is displayed.
The files containing the text can be placed in one of the

following locations:
Identifier Not used Required text
“System CF card\oem\sinumerik\hmi\lng”
“System CF card\user\sinumerik\hmi\lng” Allowable range of identifiers 85000 to 89899
Part of the file name can be assigned by the user but must
also contain the correct 3 letter language coding. This is so
that the system can display the contents of the correct file.
Filename Examples: The files for English and German can be seen located in the
OEM area.
easyscr_eng.txt English filename example
easyscr_deu.txt German filename example
User part File

of extension
filename
Language
coding
Example of a second text file for the German language
85100 0 0 "Deutsch%nMyScreens"
85101 0 0 "Deutsch Mask Header" The identifier is used in place of the text in the param.com file.
85102 0 0 "Deutsch Long Text" The identifier has to be prefixed by the $ symbol.
85103 0 0 "Deutsch Short Text" The text associated with the identifier will be displayed.
Notes:

Run MyScreens B011
Example param.com file for language dependent text. The language file needs to be declared in the
“easyscreen.ini” file. No language coding is required.
//S(START) Declarations of other text files may also be present.
HS7=($85100)
[STARTFILES]
PRESS(HS7)
LM("mask1") StartFile04 = area := AreaParameter, dia-
END_PRESS log := SlParameter, startfile := param.com
//END
[LANGUAGEFILES]
//M(mask1/$85101/"picture1.png"///110,25) LngFile01 = almc.txt
HS1=("Variable%nTest") LngFile02 = alsc.txt
PRESS(HS1) LngFile03 = aluc.txt
LM("mask2") LngFile04 = easyscr.txt
END_PRESS
//END
//M(mask2/"Workpiece Dimensions"/)
Def Var1=(R2///$85102, $85103///"$R[0]")
VS8=("EXIT")
PRESS(VS8)
EXIT
END_PRESS
//END
Setting the controller language: When using the examples shown earlier it can be seen that
the text displays change with the selected language.
The controller language is selected via the “Start-up” menu.
Or
English long and short texts:
German long and short texts:
Notes:

B011 Run MyScreens
Creating CYCLE screens OEM files
NOTE:
This example is based on files that to be located in the follow-
ing paths/directories:-
“HMI data\Templates\Examples\Easyscreen\Standard”
The files required for the Run MyScreens function need to be

created. This can be done directly on the controller by navi-
gating to the relevant folders. Use the following key sequence
to locate the “System data” area.
Creating the “easyscreen.ini” file on the controller
This file sets up the links to the files which are to be used to
create the user screens, it also determine which operating
areas these files are available in. The file has to be located in
one of the following paths/directories:-

ration for editing.

(area := Area AreaProgramEdit)
To create the file select the “New” soft-key and ensure that the
“Any” soft-key is selected.
The “com” file, the content of which will determine what ap-
The “Any” soft-key allows the file type to be determined by the
pears on the Run MyScreens screens, is also declared here.
(startfile := e_dr_o1.com)
firm with the “OK” soft-key.
The file name must be in lowercase due to the LINUX operat-
The first step is to enter the header ([STARTFILES])
ing system. The code for specifying the controller area and “com” file is
then entered on a new line as shown next:
Notes:

Run MyScreens B011
[STARTFILES]
StartFile04 = area := AreaParameter, dialog := SlParameter, startfile := param.com
StartFile05 = area := Custom, dialog := SlEsCustomDialog, startfile := mycustommasks.com
StartFile06 = area := AreaProgramEdit, dialog := SlProgramEdit, screen:= SlStepShopMillDrill-

Screen, startfile := e_dr_o1.com
Below: The easyscreen.ini file located in the cfg directory
Creating the “e_dr_o1.com” file Below: The e_dr_o1.com file located in the proj directory.
The e_dr_o1.com file has been declared in the

“easyscreen.ini” file and now needs to be created.
Code contained within the param.com file is used to create

The file needs to be created and placed in one of the follow-

ing folders:
To create the file select the “New” soft-key and ensure that
the “Any” soft-key is selected.
The “Any” soft-key allows the file type to be determined by the
firm with the “OK” soft-key.
Notes:

B011 Run MyScreens
Example: e_dr_o1.com file

point to the Run MyScreens.
Further soft-keys can be assigned within the Run MyScreens if
required.
The example defines the 6th vertical in the “Program Editor for
ShopMill, Drilling section” soft-key as the entry point, the soft-
key will have the text “OEM Drilling” (on 2 lines).
//S(START)
VS6=(["OEM%nDrilling"],TP0,SE1,PA1)
When the soft-key is pressed a Mask (MASK_E_DR_O1_MAIN)

will be loaded:
PRESS(VS6)
LM("MASK_E_DR_O1_MAIN")
END_PRESS
//END
The Mask contains the code which determines the content of

the Run MyScreens.
The first line of the mask (Mask header) contains the mask
name, text and graphic information.
The following example shows MASK_E_DR_O1_MAIN with the

title of OEM Drilling. Images are used to help with PARAME- The 6th vertical soft-key contains the text specified in the
TER inputs that are required for the OEM DRILLING cycle, are “e_dr_o1.com” file:
displayed when VS6 softkey is pressed. VS6=(["OEM%nDrilling"],TP0,SE1,PA1)
//S(START)
VS6=(["OEM%nDrilling"],TP0,SE1,PA1)
PRESS(VS6)
LM("MASK_E_DR_O1_MAIN")
END_PRESS
//END
//M(MASK_E_DR_O1_MAIN/"OEM Drilling"/"empty.png"///50,60/XG1,FA2,TA7//)
DEF VarTF=(S20////wr0///0,0,24/44,0,24)
DEF VarPOS=(IDD////wr0///0,0,24/44,0,24)
; name for the program step
DEF VarOemName=(S17//"OEM Drilling"//wr0///0,0,8/0,0,208/10,5)
; -- Technology block tool, feed, spindle --
DEF VarTool=(S20///,"T",,,"Tool name"//"e_dr_z1.png"//2,2,24/41,2,129),
VarD=(I/* 1,2//,"D",,,"Cut edge number"//"e_dr_z1.png"//171,2,10/181,2,25)
; feed + unit toggle
DEF VarF=(R//0.0/,"F",,,"Feed"//"e_dr_z1.png"//2,,24/41,,85///"F_Unit"),
F_Unit=(I/*3="mm/rev", 1="mm/min"/1///"e_dr_z1.png"//,,0/131,,75)
; speed + unit toggle
DEF VarS=(R//0.0/,"S",,,"Spindle speed"//"e_dr_z1.png"//2,,24/41,,85///"S_Unit"),
S_Unit=(I/*1="rpm", 2="m/min"/1///"e_dr_z1.png"//,,0/131,,75)
; -- Actual step data
; individual element/group element
DEF VarModeDispl=(I/* 4="Single element", 1="Group element"//,,,,"Machining posi-
tion"//"e_dr_x0.png"//,,0/41,,136)
DEF VarX0=(R3//0.000/,"X0",,,"Reference point X0"//"e_dr_x0.png"//2,,24/41,,85)
DEF VarY0=(R3//0.000/,"Y0",,,"Reference point Y0"//"e_dr_x0.png"//2,,24/41,,85)
DEF VarZ0=(R3//0.000/,"Z0",,,"Reference point Z0"//"e_dr_z0.png"//2,,24/41,,85)
Notes:

Run MyScreens B011
; shaft/tip (inc/abs)
DEF VarDrillModeDispl=(I/* 0="Shank",1="Tip"//,,,,"Drilling depth%nrelated to
tip"//"e_dr_sp.png"//,,0/41,,136)
; depth + unit toggle
DEF VarZ1=(R3//0.000/,"Z1",,,"Drilling depth"//"e_dr_z1.png"//2,,24/41,,85///"Z_Unit"),
Z_Unit=(I/*0="abs", 1="inc"/0///"e_dr_z1.png"//,,0/131,,42)
DEF VarDT=(R3//0.000/,"DT",,"s","Dwell time"//"e_dr_z1.png"//2,,24/41,,85,,5,60)
; -- Auxiliary variable
DEF ZZ1A=(I//0//wr0///2,,0/24,,44) ; shaft/tip Z1 abs/inc
; -- The following variables are only required for recompilation
; -- They are only assigned when executing the program.
; -- As a consequence there are no input fields.
DEF VarBO
DEF VarIDD
; -- Vertical softkey bar
VS1=("")
VS2=("")
VS3=("")
VS4=("")
VS5=("")
VS6=("")
VS7=(["Cancel","\\sk_cancel.png"]) ; "Cancel"
VS8=(["OK","\\sk_ok.png"]) ; "accept"
; -- LOAD - Block
LOAD
; cutting speed
IF S_Unit==2
VarS.tt="Constant%ncutting speed"
VarS.st="V"
ENDIF
; initializing the fields

CALL("StateChange")
; -- Z1 abs/ink --
IF ZZ1A == 1 OR ZZ1A == 91 ;shaft/tip depth ink?
Z_Unit = 1 ;ink
VarZ1.tt="Drilling depth%nrelated to Z0"
ELSE
Z_Unit = 0 ;abs
VarZ1.tt="Drilling depth"
ENDIF
IF ZZ1A == 0 OR ZZ1A == 1 ;shaft

VarDrillModeDispl.tt="Drilling depth%nrelated to shaft" ;depth referred to shaft
VarDrillModeDispl=0
ELSE
IF ZZ1A == 90 OR ZZ1A == 91 ;tip
VarDrillModeDispl.tt = "Drilling depth%nrelated to tip" ;depth referred to tip
VarDrillModeDispl = 1
ENDIF
ENDIF
END_LOAD
Notes:

B011 Run MyScreens
; ------ Switchover speed/cuting speed --------

CHANGE(S_Unit)
IF S_Unit==2
VarS.tt = "Constant%ncutting speed"
VarS.st="V"
ELSE
IF S_Unit==1
VarS.tt="Spindle speed"
VarS.st="S"
ENDIF
ENDIF
END_CHANGE
; ------ Switchover individual/group element --------
CHANGE(VarModeDispl)
;group element/individual element
CALL("StateChange")
END_CHANGE
; ------ Switchover shaft/tip -----
CHANGE(VarDrillModeDispl)
IF VarDrillModeDispl == 0 ; shaft
VarDrillModeDispl.tt = "Drilling depth%nrelated to shaft"
IF Z_Unit == 1 ; Z1 inc
ZZ1A=1
ELSE
IF Z_Unit == 0 ; Z1 abs
ZZ1A=0
ENDIF
ENDIF
ELSE
IF VarDrillModeDispl == 1 ; tip
VarDrillModeDispl.tt = "Drilling depth%nrelated to tip"
IF Z_Unit == 1 ; Z1 inc
ZZ1A=91
ELSE
IF Z_Unit == 0 ; Z1 abs
ZZ1A=90
ENDIF
ENDIF
ENDIF
ENDIF
END_CHANGE
; ------ Switchover Z1 abs/inc -----
CHANGE(Z_Unit)
IF Z_Unit == 0 ; abs
VarZ1.tt = "Drilling depth" ; drilling depth
ZZ1A=0
ELSE
ZZ1A=90
ENDIF
ENDIF
ELSE
IF Z_Unit == 1 ; inc
VarZ1.tt = "Drilling depth%nrelated to Z0" ; depth refered to Z0
ZZ1A=1
ELSE IF
Notes:

Run MyScreens B011
ZZ1A=91
ENDIF
ENDIF
ENDIF
ENDIF
END_CHANGE
; -- Initialization or state change
SUB(StateChange)
; -- Group element/individual element --
IF VarModeDispl == 1
VarX0.wr = 4
VarY0.wr = 4
VarZ0.wr = 4
ELSE
; individual element-> X0,Y0,Z0 - initialize fields
VarX0.wr = 2
VarY0.wr = 2
VarZ0.wr = 2
VarX0.st = "X0" ;X0
VarY0.st = "Y0" ;Y0
VarZ0.st = "Z0" ;Z0
ENDIF
END_SUB
; -- Checking the dwell time
CHANGE(VarDT)
IF 0 > VarDT
VS8.se=2
DLGL("Dwell time too small")
VarDT.bc = "#ffbea5" ; background color red

VarDT.vld = FALSE
ELSE
VS8.se=1
VarDT.bc = 10 ; background color white
ENDIF
END_CHANGE
; -- Exit the screen form with cursor left and generate code
PRESS(SL)
; For these fields "Cursor left" not execute any accept.

IF (FOC <> "VarD") AND (FOC <> "F_Unit") AND (FOC <> "S_Unit") AND (FOC <> "Z_Unit")
; Check for validity
IF VarDT.vld == TRUE
IF VarF.vld == TRUE
IF VarS.vld == TRUE
IF VarD.vld == TRUE
; -- generate code and exit --
GC("OUT_E_DR_O1")
EXIT
ELSE
DLGL("Tool nose value incorrect.")
ENDIF
ELSE
DLGL("Spindle value incorrect.")
ENDIF
ELSE
DLGL("Feed incorrect.")
ENDIF
Notes:

B011 Run MyScreens
ELSE
ENDIF
ENDIF
END_PRESS ; <-- cursor left

; -- PRESS(VS7) : exit screen form without generating code
PRESS(VS7)
EXIT
END_PRESS ; <-- VS7
; -- PRESS(VS8) : generate code and exit screen form
PRESS(VS8)
; -- interrogate several parameters --
IF VarDT.vld == TRUE
IF VarF.vld == TRUE
IF VarS.vld == TRUE
IF VarD.vld == TRUE
; -- generate code and exit --
GC("OUT_E_DR_O1")
EXIT
ELSE
DLGL("Tool nose value incorrect.")
ENDIF
ELSE
DLGL("Spindle value incorrect.")
ENDIF
ELSE
DLGL("Feed incorrect.")
ENDIF
ELSE
ENDIF
END_PRESS ; <-- VS8

; -- OUTPUT - Block
OUTPUT(OUT_E_DR_O1)
"E_DR_O1(" VarModeDispl "," VarBO "," VarIDD ",""" VarTool """,""" VarTF """," VarD ","
VarF "," F_Unit "," VarS "," S_Unit "," VarPOS "," VarZ1 "," ZZ1A "," VarDT "," VarX0 "," VarY0
"," VarZ0 ")"
END_OUTPUT
//END ; <-- M (MASK_E_DR_O1_MAIN)
Notes:

Run MyScreens B011
Storing of icons
Icon files are stored under one of the following paths:

/oem/sinumerik/hmi/ico or
/user/sinumerik/hmi/ico
Depending on the screen resolution, under the following sub-
directories:
/ico1024 for HD Ready
/ico1280
/ico1600 e_dr_sp.png e_dr_x0.png
/ico640
/ico800
In the example, four icons are used:

e_dr_sp.png
e_dr_x0.png
e_dr_z0.png
e_dr_z1.png
e_dr_z0.png e_dr_z1.png
The four icons placed in the ico640 directory
To activate the files, perform a power off / on.
Notes:

B011 Run MyScreens
The completed cycle mask
Parameters and Variables Descriptions Detailed description:
When a variable is assigned certain properties can be set. 1. Variable type

These properties are contained rounded brackets, each prop- R[x] Real number, “x” indicates the number of decimal
erty is separated by a forward slash (/) places displayed
If a property is not used, the slash still needs to be present. I Integer.
S[x] String,”x” indicates the string length.
Basic description: C Character (Individual character)
B Boolean number
DEF Var1=(1/2/3/4/5/6/7/8/9/10) V Variant type
1. Variable type 2a. Limit values-

2. Limit values, toggle field or table identifier A minimum and a maximum value can be specified. The val-
3. Default ues are separated by a comma, the minimum value is speci-
4. Texts fied first.
5. Attributes Values can be in I, C and R decimal formats or as characters
6. Help display in the format “A” , “F”
7. System or user variable The limit value also works in conjunction with the limit attrib-
8. Position of short text ute, see the attribute property for more information.
9. Position of I/O field (Left, top, width, height)
10. Colours 2b. Toggle field-
Creates a list of predefined entries in the I/O field. The list is
initiated by the “*” character.
The entries can be assigned a value.
The Limit value is interpreted as a list for the Toggle field.
If only a “*” is used, a variable Toggle field is generated.
Notes:

Run MyScreens B011
2c. Table Identifiers- 5. Attributes-

Identifiers can be assigned to tables containing NCK/PLC The following properties can be influenced by the attributes
values of the same type. The “%” character is used to differ- • Input mode
entiate an identifier from a toggle field or limit value.
A comma is required after the identifier, the file name contain- • Access level
ing the table information is then typed. • Alignment of short text
• Font size
3. Default setting- • Handling limit values
The value in the assigned variable can take on various states.
This depends on whether a default value, system or user vari- • Response when screen is opened (Change block)
able (Or both) has been assigned to the variable field (I/O or
toggle field) The attributes are separated by commas, and are not valid for
Toggling is not possible until a valid value is assigned to the toggle fields.
variable.
Input mode:-
4. Texts- Attribute Effect
Text possibilities are- wr0 I/O field invisible, short text visible.
wr1 Read only, no inputting of data, short text visible.
• Long text = text displayed when each element is high- (Default setting)
lighted. wr2 Read & write possible, long and short text visible.
• Short text = name of the element wr3 As with wr1 but with I/O field visible, long and short
• Graphics text = text relating to the graphics, if used. text visible.
• Unit text = unit of the variable e.g. mm, rpm etc wr4 All elements invisible.
wr5 As wr2 except entries are immediately active.
The texts types are separated by commas and need enclos- with wr2 the entry becomes active exiting the field
ing in speech marks:- /”Long”, “Short”, “Graphics”, “Unit”/ or pressing enter/input/return.
Access level:- Limits:

Attribute Level Password/Key position Checking whether the value of the variable is within the limits
ac0 0 Not released specified by the limit values.
ac1 1 SUNRISE Attribute Effect
ac2 2 EVENING li0 No check.
ac3 3 CUSTOMER li1 Check with respect to minimum
ac4 4 Key switch pos 3 li2 Check with respect to maximum.
ac5 5 Key switch pos 2 li3 Check with respect to minimum and maximum.
ac6 6 Key switch pos 1
ac7 7 Key switch pos 0 Behaviour when opening (Change block):
Alignment of short text:- Attribute Effect

Attribute Effect cb0 The change block defined for this variable is
al0 Left justified (Default) processed when the screen opens (Default).
al1 Right justified cb1 The change block defined for this variable is
al2 Centred processed if there is a change in the value of the
variables.
Font size:
Attribute Effect The “cb” attributes, specified in the variables definition, take
fs1 8pt. font size (Default) precedence over the globally specified attributes in the “screen
fs2 16pt font size form” definition.
The clearance between lines is defined. The default font size

allows 16 lines. The graphics and unit text can only be 6. Help Display-
configured in the default font size.
The name of the HTML file containing the help text needs to be
typed in speech marks. The display appears automatically if the
cursor is positioned on the variable.
Notes:

B011 Run MyScreens
7. System or user variables- PLC Data Syntax

The variable to be viewed is entered here, these have to be Byte y of bit z of data block x DBx.DBXy.z
contained within speech marks. The variable must be
addressed in the correct way. Byte y of data block x DBx.DBBy
Addressing Variables: Word y of data block x DBx.DBWy

Double word y v. of data block x DBx.DBDy
Machine Data Syntax String y with length z from data block x DBx.DBSy.z
Global machine data $MN_... Real y of data block x DBx.DBRy
Axis specific machine data $MA_... Flag byte x bit y Mx.y
Channel specific machine data $MC_... Flag byte x MBx
Flag word x MWx

Setting Data Syntax
Flag double word x MDx
Global setting data $SN_...
Axis specific setting data $SA_...
Channel specific setting data $SC_...
PLC Data Syntax 8. Position of short text
Input byte x bit y Ix.y The Short Text defined in attribute No.4 is positioned using
parameter No.8.
Input byte x IBx The measurements are in pixels and relate to the top left
corner of the main dialogue body.
Input word x IWx
Three values can be entered to define the position from the left,
Input double word x IDx
the position from the top and the width of the short text.
Output byte x bit y Qx.y Each entry has to be separated by a comma.
Output byte x QBx The following example would position the text “Short text” 200
pixels from the left and 100 pixels from the top with a width of
Output word x QWx 250 pixels:
Output double word QDx Def Var1=(R2///" ","Short text"///"$R[0]"/200, 100, 250//)
Soft-key Status Syntax
Visible (Default) Se1
Disabled (Grey text) Se2
Displayed(Last soft-key used) Se3
Notes:

Run MyScreens B011
9. Position of I/O field 1. Colours
The I/O field can be positioned and sized using parameter The foreground and background colours of the I/O field can be
No.9. chosen by using parameter No.10.
The measurements are in pixels and relate to the top left The default colours are foreground: Black, background: White.
corner of the main dialogue body. These are determined by the “Write mode” (See parameter 5)
The following table shows index numbers to be used to achieve

Four values can be entered to define the position from the left, the required colour.
the position from the top and the width and height of the I/O The foreground colour is defined first, followed by a comma
field. then the background colour:
Each entry has to be separated by a comma.
The following example would position the I/O field for the
defined variable, 600 pixels from the left and 100 pixels from Index Colour
the top with a width of 100 pixels and a height of 150 pixels:
1 Black
Def Var1=(R2///" "," "///"$R[0]"//600, 400, 100, 150/) 2 Red/brown
3 Dark green
4 Light grey
5 Dark grey
6 Blue
7 Red
8 Brown
9 Yellow
10 White
A list of predefined softkeys :-
Name Softkey
SOFTKEY_OK
SOFTKEY_CANCE
SOFTKEY_APPLY
SOFTKEY_MORE
SOFTKEY_BACK
SOFTKEY_ASSISTANT_NEXT
SOFTKEY_ASSISTANT_PREVIOUS
SOFTKEY_NAV_BACK
Notes:

B011 END Run MyScreens
Notes:

B020 Service Planner
Sinumerik
Operate
Module Description:
The 828D controller has a Service Planner function which allows the user to set up maintenance
tasks. The tasks require an acknowledgement to confirm that the task has been completed, the tasks
are based on timed intervals. Each task has to be parameterised to suit the individual requirements of
that task.
Module Objective:
Upon completion of this module you will be able to set up maintenance tasks using the Service
Planner function.
Content:
Sinumerik
Enabling the Service Planner
PLC Programme Example
Setting up the Maintenance Tasks
ts Language Files
PLC Interface Signals
Confirming/Resetting/Saving Tasks
Adding additional language files
B020
B020

Service Planner B020
Service
Planner:
START
Enabling the
Service
Planner
PLC
Programme
Example
Setting up
the
Maintenance
Tasks
ts Language
Files
PLC
Interface
Signals
Confirming/
Resetting/
Saving
Tasks
Adding
additional
language
files
Service
Planner:
END
Notes :

Enabling the Service Planner

The Data Block templates can
In order for the Service planner to function the PLC user be found in the Libraries folder.
project must contain DB9903 and DB9904. These are Transferring them to the Data
created with the PLC828 programming tool and then Block folder is achieved by
downloaded to the controller. double clicking the required
template.
To create the Data Blocks first open up the correct project
and open the Data Block folder.
Double Click each Data
Block to add the PLC Project
In this example the It is possible to change the Data Class of the Data Block and
required Data Blocks add the name of the author if needed.
(DB9903 & DB9904) are The box is closed by clicking the “OK” key.
not present.
Below: Data Blocks DB9903 & DB9904 are present in the

Data Block folder of the PLC Project.
Save the user project.
Download the project to the controller.
Notes :

PLC Programme Example
Below is an example of how to activate and reset messages using the Service Planner.
Setting the
alarm
Setting the
message
Resetting the
alarm
Resetting the
message
Deactivating the
service interval
Notes :

Setting up the Maintenance Tasks
To set up a Maintenance task the password level needs to be

set to Manufacturer.
To locate the Service Planner screen use the following key

sequence.
To create a new task use the “New task” soft-key
Example:-
In the following example, the interval is 168 hours. The 1st
warning will appear after 144 hours and then every 3 hours
until the alarm is triggered after 168 hours.
The interval for between the warning is obtained by the fol-
lowing:
“Interval” minus the “1st warning” divided by the

“Quantity”.
(168 - 144) ÷ 8 = 3
To confirm the data, use the “Input” key, to navigate the dia-
logue boxes use the cursor keys. When the data required
fields have been entered press the “Enter” key.
Task information now needs to be entered.
Input Field Explanation:- (All time values are in hours)
Maintenance Task: A brief description of the task

Interval:
1st warning: Interval at which a pre-warning is issued
Quantity: Determines the number and interval of pre-
warning.
Remaining time:- Indicates the time remaining to the alarm
being triggered.
Notes :

Location of the Service Planner files:
The red clock symbol
Will be replaced with a green tick
ts Language Files
When a task is created the task names are stored in a

language dependent ts file. These files can be viewed and
edited on the controller or offline.
PLC Interface Signals

The information entered earlier via the screen can be seen in
the text of the file. It is possible to use an AMM software for The data entered on the screen is stored in the data blocks
creating or editing the offline file. created earlier. This can be seen in the PLC diagnosis area:-
Below is the “oem_maintenance_eng.ts” file containing the
text of the example used above.
For a task to have an effect on the controller the interface

signals have to be evaluated in the user PLC program.
When a first warning or interval is reached a message must
be generated to warn/advise the operator of any action
required.
Data Blocks and variables are available to assist with this.
When values are entered via the HMI they are transferred
into DB9903 (Initial Data Table) The system uses these
values to determine when the interface bits need
setting.
DB9903 uses four data words per maintenance task.
Notes :

DB9903 Initial Data Table for Service Planner [r]
Word Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
0 Task 1: Interval (Hours)

2 Task 1: 1st warning
4 Task 1: Quantity
6 Reserved
12 Task 2: Quantity
14 Reserved
20 Task 3: Quantity
22 Reserved
The sequence is continued up to Task 32.

252 Task 32: Quantity
254 Reserved
Data Block 9904 is used to report the status of the maintenance tasks.
DB9904 Actual Data Table for Service Planner [r]
Word Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
0 Task 1 Residual time (Hours)

2 Task 1: Number of warnings issued
4 Reserved
6 Reserved
8 Task 2: Residual time (Hours)
12 Reserved
14 Reserved
The sequence is continued up to Task 32.
248 Task 32: Residual time (Hours)

252 Reserved
254 Reserved
Notes :

User interface warning signals.
When the maintenance task is acknowledged the relevant interface bit will be set for one PLC cycle.
DB1800 Acknowledgement signals PLC -> HMI [r/w]

4000 Ackn 8 Ackn 7 Ackn 6 Ackn 5 Ackn 4 Ackn 3 Ackn 2 Ackn 1
The following interface signals are used for signalling that an alarm or message has been activated. Example: by checking that
the remaining time is not zero then the user PLC can be written to produce a message can be issued. If the remaining time is
zero then an alarm can be issued in the same way. The signal is active for one PLC cycle.
DB1800 Warning/Alarm signals HMI -> PLC [r]

3000 Alarm 8 Alarm 7 Alarm 6 Alarm 5 Alarm 4 Alarm 3 Alarm 2 Alarm 1
It may be necessary to deactivate a task, switching the signal high will result in the task being frozen.
DB1800 Deactivation signals PLC -> HMI [r/w]

2000 Deact 8 Deact 7 Deact 6 Deact 5 Deact 4 Deact 3 Deact 2 Deact 1
Notes :

Confirming/Resetting/Saving Tasks
When a task has reached the time limit, it requires, depend-

ing on the task type, some kind of action is to be completed.
Once this is complete then the task can be acknowledged
and the time limits reset.
Only qualified personnel should reset the task after the

maintenance action has been completed. Simply resetting
the task without completing the task could result in damage
to the machinery.
The user PLC program should trigger a PLC user alarm

when a task has reached a time limit. If it is a pre-warning the
message response can usually acknowledged by the “Alarm
Cancel” key with no interference to the machine operation.
When the Interval time has expired completely the PLC user
message should be configured to match the importance of
the maintenance task.
When the status of the task is checked in the Service Planner
screen, a red clock symbol should have appeared in the Once the maintenance task is complete then it can be
“Status” column and the remaining time column will be zero. acknowledged by pressing the “Maintenance executed”
soft-key.
The red clock symbol
will be replaced with a green tick
This will reset the remaining time back to the original and the Saving Service Tasks:
interface bit will remain high for one PLC cycle. This can be All the Service Tasks can be saved/read-in to/from an
used by the user PLC to acknowledge user alarms etc. external USB memory device.
It is possible to reset a maintenance task at any time prior to
the interval time expiring. Exporting tasks:
The “Exporting tasks” soft-key is used to save the tasks.
Tasks can be changed or deleted at any time with the
“Change task” & “Delete task” soft-keys.
The ‘Reset all” soft-key will reset the remaining

times for all the tasks.
Notes :

A warning appears that existing files on the USB/CF device

Select the destination of the file e.g. USB and will be overwritten, select “OK” to continue.
then select the “OK” soft-key.
Enter a suitable name for the file and then select the “OK”
soft-key.
Reading in Service Tasks: The procedure will overwrite any existing tasks on the con-
The “Importing tasks” soft-key is used to read in a task file. troller, select the “OK” soft-key to continue.
The save procedure creates two files, one file is of the “xml”
type, while the second file is of the “ts” type. The “xml” has to
be selected for the import procedure, followed by the “OK”
soft-key.
Adding additional language files
Open the "Project" within AMM software, go "Online" to the

controller.
Notes :

Creating additional language files using AMM-Project. Language files can be uploaded from the controller into the
project.
Access MyMachine can be used to the create language To upload the language files, tick all boxes in the bottom
specific files. Start the Access MyMachine program and window.
make an online connection to the controller.

Example- Adding additional language specific files for the

“Maintenance Planner” texts:
To add additional language files for the alarm texts, highlight
the "Mainten. planner" menu, followed by "New target lan-
guage"
Notes :

Adding additional language specific files to "Maintenance

Planner".
Highlight the "Mainten. Planner" menu
Select the file "oem_maintenance_deu.ts.

Open with the "Edit" key.
Notes :


text

text
When the editing of the alarm text is complete, select the

"Save" button, followed by the "Exit" button.
0 Wartungsaufgabe Test
1 SchaltschrankfilterWechseln
Download the alarm text file by selecting it and using the

"transfer" button.
The respective files will be transferred to the controller
Notes :

In the project window, highlight the Alarm texts menu.

Select the "oem_alarms_plc_eng.ts" file, and open it with
the"Edit" key.
In the Edit window, change the alarm number and enter the
required text.
In the Edit window, change the alarm number and enter the
required text.
The second language can be edited in the same way by

using the "oem_alarms_plc_deu.ts file.
700099 Wartungsarbeiten durchführen Aufgabe1

700100 Warrung Wartungsaufgabe 1
When the editing of the alarm text is complete, select the

"Save" button, followed by the "Exit" button.
Notes :

Download the two alarm text files by selecting them and us-
ing the "transfer" button.
German:
The respective files will be transferred to the controller
On the controller the HMI needs to be rebooted
When the language is changed on the controller, the respec-

tive text will be shown.
Notes :

English:
B020: END
Notes :

Notes :

B029 Analogue Spindle
Sinumerik
Operate
Module Description:
The 828D system offers the possibility for the connection of an analogue spindle
Analogue output functionality is available for controlling a single analogue servo drive. The interface
for this is located on X252 of the 828D controller.
The analogue controlled axis must be declared as a spindle.
Module Objective:
Upon completion of this module you will be able to locate and configure the analogue interfaces.
Content:
Sinumerik
Analogue Servo Control via X252
B029
B029

Analogue Spindle B029
Analogue Spindle:
START
Analogue
Servo
Control via
X252
Analogue Spindle:
END
Notes :

B029 Analogue Spindle
Analogue Servo Control via X252 X252 Terminal Description:
Interfaces: Rear view of PPU showing X252 interface.
Pin 1 AOUT Output for analogue axis +/- 10V

X122 Pin 9 OUT9 NCK DO 9 Digital Output $A_OUT[9]
X132
Digital Output $A_OUT[11] /
Pin 12 OUT11 NCK DO 11 Controller enable/positive direc-
X242 tion for analogue spindle option
Digital Output $A_OUT[12] /
Pin 13 OUT12 NCK DO 12 Controller enable/negative direc-
X252 tion for analogue spindle option
X143
Machine Data for Analogue axis. MD30134 $MA_IS_UNIPOLAR_OUTPUT:
X252 pins 1 & 2 are reserved for the analogue output MD30134 Signal Function
Signal which is used for controlling an analogue servo drive.
(Nominal +/- 10V, can be changed via machine data.) =0 AOUT (X252.1) Analogue output +/- 10V
The functionality of the analogue signal can be influenced by Bipolar
spindle with AGND (X252.2) Analogue output 0V
Axis MD 30134 $MA_IS_UNIPOLAR_OUTPUT.
The resolution of the analogue output signal is 14bit. enable Controller enable (+24V
signal. DO11 (X252.12)
DC)
Sinamics digital outputs DO14 & DO15 (X132 pins 12 & 13) =1 AOUT (X252.1) Analogue output +10V
are used for enabling and direction signals. Unipolar spin-
dle, separate AGND (X252.2) Analogue output 0V
Machine Data Descriptions. enable/ Controller enable
direction sig- DO11 (X252.12) (+24V DC)
MD30100 $MA_CTRLOUT_SEGMENT_NR: nals.
Activates the axis as an analogue axis when set to 0 Negative direction
DO12 (X252.13)
(828D digital drive operation = 5) (+24V DC)
Note: MD30100 and X252 pins 12 & 13 =2 AOUT (X252.1) Analogue output +10V
Unipolar spin-
AGND (X252.2) Analogue output 0V
dle, direction
dependant Controller enable and
enable. DO11 (X252.12) positive direction
X252 Axis MD 30100 = 0 Axis MD 30100 = 5 (+24V DC)
Pin 12 Controller enable/positive Digital Output Controller enable and
direction for analogue spindle $A_OUT[11] DO12 (X252.13) negative direction
option (+24V DC)
Pin 13 Controller enable/negative Digital Output
direction for analogue spindle $A_OUT[12]
option
Notes :

Analogue Spindle B029
MD32250 $MA_RATED_OUTVAL : MD30240 $MA_ENC_TYP :
Sets the analogue output value (X252 pins 1 & 2) Sets the actual value encoder type.
up to a maximum of +/- 10 volts for maximum speed. Permitted values: 1 = Incremental, 4 = Absolute.
The value entered is a percentage of 10 volts.
Example: MD32250 = 80  80% of 10 volts  8 volts. MD36700 $MA_DRIFT_ENABLE[0] :
When the maximum speed is requested, 8 volts will be pre- Activation of automatic drift compensation
sent on X252 pins 1 & 2. Permitted values: 0 = Inactive , 1 = active.
MD32260 $MA_RATED_VELO : MD36710 $MA_DRIFT_LIMIT[0] :

Sets the maximum speed of the axis in rpm. At this speed the Limit for automatic drift compensation, if active.
voltage determined by MD32250 will be present on X252 pins
1 & 2. MD36720 $MA_DRIFT_VALUE[0] :
A basic drift value can be entered as an additional speed set-
MD30200 $MA_NUM_ENCS : point. Works with or without the presence of an actual value
Sets the number of actual value encoders used with the axis, encoder.
if no encoder used, must be set to 0.
MD30220 $MA_ENC_MODULE_NR[0] :
The encoder should be connected as the 2nd encoder of an
existing Sinamics axis via an SMC module.
MD30220[0] of the analogue axis should be set the same as
MD30220[0] of the axis that the encoder is connected to.
MD30230 $MA_ENC_INPUT_NR[0] :
As previously explained, the encoder is connected as the 2nd
encoder of an existing Sinamics axis, therefore a value of 2
must be entered in MD30230[0].
Example: Notes:
Machine data configuration for a system with 3 digital axes The analogue axis is restricted in the following areas:
and an analogue spindle. The spindle encoder is connected
via SMC to the Y axis Sinamics drive module. • Dynamic Stiffness Control - unavailable.
• Torque Feed Forward control - unavailable.

Machine
X Y Z SP
Data
• The Drive Ready signal is simulated and set by the
30100 5 5 5 0 drive software.
30110 1 2 3 1 • The drive parameters cannot be accessed. Utilisation

and other drive related functionality will not be seen on
30120 1 1 1 1 the Service Display screens.
30130 1 1 1 1
• Automatic speed and position controller optimisation is
30134 0 0 0 0, 1 or 2 not possible.
30200 1 1 1 1
30220[0] 1 2 3 2
30230[0] 1 1 1 2
30240 1 or 4 1 or 4 1 or 4 1 or 4
B029: END
Notes :

B029 END Analogue Spindle

Appendix A Hardware Differences
Sinumerik
Operate
Hardware
Differences:
START
PPU
Differences
Digital I/O
Hardware
Differences:
END
Sinumerik
Appendix A
PPU2xx.2 / PPU2xx.3: X122, X132, X242 & X252 Interface Description

The Binary Connectors (BiCo’s) of X122 and X132 are used to

Fault assign Sinamics inputs/outputs to a specific function e.g. Ena-
X100 Sync PN bling of drives, BERO’s, automatic line contactor control etc
Fault PN X242 and X252 is used for NC digital inputs and outputs.
X101 Sync
X102
Rx/Tx
Link
X130 Certain terminals are automatically assigned to a function by
default, remaining terminals can be assigned to a function via
X140 X135 machine data.
X122 The status of the terminals is transferred to CU parameter
X132 r0722 which is referred to when assigning a function.
X242
X252
X143
X1
M T1 T2 T3
PPU
X122 Drive NC X242

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

1 DI 4 +/- 10V AO Spindle 1
2 DI 5 AM Spindle 2
3 DI 6 IN9 3
4 DI 7 IN10 4
5 DI 20 IN11 5
6 DI 21 IN12 6
7 MEXT2 MEXT4 7
8 P24EXT1 P24EXT3 8
9 DI/DO 12 1* OUT9 9
10 DI/DO 13 1* OUT10 10
11 MEXT1 MEXT3 11
14 MEXT1 MEXT3 14
1* Fast inputs/outputs (Must be shielded).
Notes :
Appendix A Page 2 SINUMERIK 828D

Hardware Differences Appendix A
X122-Sinamics I/O

Source Destination
ON/OFF1 for DriveCLiQ line

CU-r0722.0 Infeed p0840
modules (ALM, SLM >=16Kw)
Pin 1 Sinamics DI0
Infeed ready for non DriveCLiQ
SLM X21.1 Drive p0864
SLM (SLM <16Kw)
Each drive 2nd OFF3,

Pin 2 Sinamics DI1 OFF3 drive enable-Fast Stop CU-r0722.1
p0849
Pin 3 Sinamics DI2 SINAMICS Safety Integrated CU-r0722.2
group)
(SH enable = p9601)
Pin 4 Sinamics DI3 SINAMICS Safety Integrated CU-r0722.3
group)
(SH enable = p9601)
SH/SBC 1 – Group 1 (Input) p9774 bit 1
Pin 9 Sinamics DI/DO8 SINAMICS Safety Integrated CU-p0738 BICO from CU after the
1st drive in the group
p9774 bit 1
SH/SBC 1 – Group 2 (Input) CU-p0739
Pin 10 Sinamics DI/DO9 BICO from CU after the
SINAMICS Safety Integrated
Pin 12 Sinamics DI/DO10 Bero 1 - external zero mark (Input) CU-r0722.10 Drive p0495=2
Each drive p0488,

Probe 1: Remote Measuring (Input)
Pin 13 Sinamics DI/DO11 CU-p680[0]=0 Index
(MD13210=1)
encoder 1, 2, 3=3
Notes :
SINUMERIK 828D Page 3 Appendix A

X132-Sinamics I/O

Source Destination
Pin 1 Sinamics DI4 DI 4 Free to assign CU-r0722.4
Pin 4 Sinamics DI7 Line contactor feedback signal CU-r0722.7 LM-p0860

Infeed operation (Output) LM-r0863.0 CU-p0742

Pin 9 Sinamics DI/DO12 (Line Module with DRIVE CliQ)
Infeed ready to start (Output) LM-r0899.0 CU-p0743
Pin 10 Sinamics DI/DO13 (If Line Module with DRIVE CliQ)
Line contactor control (Output) LM-r0863.1 CU-p0744
Pin 12 Sinamics DI/DO14 Bero 2 - external zero mark(Input) CU-r0722.14 Drive p0495=5
2nd OFF 2 (Input) CU-r0722.14 Drive p0845
Probe 2: Remote Measuring (Input) CU-p680[1]=0 Each drive p0488,
Pin 13 Sinamics DI/DO15 (MD13210=1) CU-p728 Bit 15=0 Index
encoder 1, 2, 3=6
Notes :


Pin 1 n/c n/c
Pin 2 n/c n/c
Pin 3 NCK DI1 (IN1) Digital Input $A_IN[1]
Pin 9 NCK DO1 (OUT1) Digital Output $A_OUT[1]

Pin 1 AOUT Output for analogue spindle +/- 10V
Pin 12 NCK DO11 (OUT11) Digital Output $A_OUT[11] / Analogue spindle enable/direction
Pin 13 NCK DO12 (OUT12) Digital Output $A_OUT[12] / Analogue spindle enable/direction
Notes :

PPU2xx.1: X122, X132 & X142 Interface Description

The Binary Connectors (BiCos) of X122 and X132 are used to

assign Sinamics inputs/outputs to a specific function e.g. Ena-
bling of drives, BERO’s, automatic line contactor control etc.
X142 is used for NC digital inputs and outputs.
Certain terminals are automatically assigned to a function by

default, remaining terminals can be assigned to a function via
machine data.
The status of the terminals is transferred to CU parameter

r0722 which is referred to when assigning a function.
PPU
X122 Drive NC X142

1 DI 0 DI0 1
2 DI 1 DI1 2 DC +24V
DC +24V 3 DI 2 DI2 3
4 DI 3 DI3 4
5 MEXT MEXT 5
7 DI/DO 8 1* DO4 7
8 DI/DO 9 1* DO5 8
9 MEXT1 MEXT3 9
10 DI/DO 10 1* DO6 10
11 DI/DO 11 1* DO7 11
12 MEXT1 MEXT3 12
X132 Drive
1 DI 4
2 DI 5
3 DI 6
4 DI 7
5 MEXT
6 P24EXT2
7 DI/DO 12 1*
8 DI/DO 13 1*
9 MEXT2
10 DI/DO 14 1*
11 DI/DO 15 1*
12 MEXT2
1* Fast inputs/outputs (Must be shielded).
Notes :

X122-Sinamics I/O
X122 Signal Function/Default Setting BiCo connection

Source Destination
ON/OFF1 for DriveCLiQ line modules CU-r0722.0 Infeed p0840
(ALM, SLM >=16Kw)
Pin 1 Sinamics DI0
Infeed ready for non DriveCLiQ SLM SLM X21.1 Drive p0864
(SLM <16Kw)
Pin 2 Sinamics DI1 OFF3 drive enable-Fast Stop CU-r0722.1 Each drive 2nd OFF3,
p0849
Pin 3 Sinamics DI2 SH/SBC 1 – Group 1 CU-r0722.2 p9620 (all drives in the
SINAMICS Safety Integrated group)
(SH enable = p9601)
Pin 4 Sinamics DI3 SH/SBC 1 – Group 2 CU-r0722.3 p9620 (all drives in the
SINAMICS Safety Integrated group)
(SH enable = p9601)
Pin 5 0V Ground (M) Ground for pins 1 to 4
Pin 6 +24V DC +24V DC common
Pin 7 Sinamics DI/DO8 SH/SBC 1 – Group 1 CU-p0738 p9774 bit 1

SINAMICS Safety Integrated BICO from CU after the
Pin 8 Sinamics DI/DO9 SH/SBC 1 – Group 2 CU-p0739 p9774 bit 1

SINAMICS Safety Integrated BICO from CU after the
Pin 9 0V Ground (M) Ground for pins 7, 8, 10, 11
Pin 10 Sinamics DI/DO10 Bero 1 - external zero mark CU-r0722.10 Drive p0495=2
Pin 11 Sinamics DI/DO11 Probe 1: Remote Measuring CU-p680[0]=0 Each drive p0488,
(MD13210=1) Index
encoder 1, 2, 3=3
Notes :

X132-Sinamics I/O
X132 Signal Function/Default Setting BiCo connection
Source Destination
Pin 1 Sinamics DI4 Digital Input $A_IN[1] CU-r0722.4 CU-p2082[0]
Digital Input $A_IN[4] CU-r0722.7 CU-p2082[3]
Pin 4 Sinamics DI7

Line contactor feedback signal CU-r0722.7 LM-p0860
Pin 6 +24V DC +24V DC common
Digital Output $A_OUT[4] CU-p2091.3 CU-p0742
Pin 7 Sinamics DI/DO12

Infeed operation LM-r0863.0 CU-p0742
(Line Module with DriveCLiQ connec-
tion)

Infeed ready to start LM-r0899.0 CU-p0743
(if Line Module with DriveCLiQ con-
nection)
Line contactor control LM-r0863.1 CU-p0744

Bero 2 - external zero mark CU-r0722.14 Drive p0495=5
2nd OFF 2 CU-r0722.14 Drive p0845

Probe 2: Remote Measuring CU-p680[1]=0 Each drive p0489,
(MD13210=1) CU-p728 Bit 15=0 Index
encoder 1, 2, 3=6
Notes :


Pin 1 NCK DI 0 Digital Input $A_IN[9]
Pin 6 +24V DC (P) +24V DC common
Pin 7 NCK DI/O 4 Digital Output $A_OUT[9]
Appendix A: END
Notes :


Appendix B
Sinumerik
Operate
Technology
Settings:
START
General
Machine
Data
51000-51999
Channel
Machine
Data
52000-52999
Axis
Machine
Data
53000-53999
General Set-
ting
Data
54000-54999
Sinumerik
Channel
Setting Data
55000-55999
Technology
Settings:
END
828D/840D sl SINUMERIK Operate V4.8 Page 1 This document was produced for training purposes.
Appendix B
General Machine Data
828D/840D sl SINUMERIK Operate
Technology Settings
MD Identifier Description Comment
51000 $MNS_DISP_RES_MM Display resolution in mm
51001 $MNS_DISP_RES_MM_FEED_PER_REV Display resolution in mm feedrate/rev
51002 $MNS_DISP_RES_MM_FEED_PER_TIME Display resolution in mm feedrate/min
51003 $MNS_DISP_RES_MM_FEED_PER_TOOTH Display resolution in mm feedrate/tooth
51004 $MNS_DISP_RES_MM_CONST_CUT_RATE Display resolution constant cutting speed m/min
51010 $MNS_DISP_RES_INCH Display resolution in inch
51011 $MNS_DISP_RES_INCH_FEED_P_REV Display resolution in inch feedrate/rev
51012 $MNS_DISP_RES_INCH_FEED_P_TIME Display resolution in inch feedrate/min
51013 $MNS_DISP_RES_INCH_FEED_P_TOOTH Display resolution in inch feedrate/tooth
51014 $MNS_DISP_RES_INCH_CUT_RATE Display resolution constant cutting speed ft/min
51018 $MNS_DISP_RES_SCALE Display resolution scaling
51019 $MNS_DISP_RES_ROT_WO Display resolution of rotation in work offsets
Page 2
51020 $MNS_DISP_RES_ANGLE Display resolution of angle

51021 $MNS_DISP_RES_SPINDLE Decimal places in speed entry field
51022 $MNS_DISP_RES_ROT_AX_FEED Display resolution of rotary axis feedrate
51023 $MNS_ACT_VALUE_SPIND_MODE Only display spindles in actual values window
This affects the display of the spindles in the axis actual values window.
0 = Spindles are always displayed
1 = Spindles are displayed only if in axis mode
51024 $MNS_BLOCK_SEARCH_MODE_MASK_JS Bit mask for available search modes (ShopMill/ShopTurn single-channel)
Bit 0: Block search with calculation without approach
Bit 1: Block search with calculation with approach
Bit 2: Reserved
Bit 3: Skip EXTCALL programs
Bit 4: Reserved
Bit 5: Block search with test run
Appendix B
51025 $MNS_FRAMES_ACT_IMMEDIATELY Active data (frames) are activated immediately after change
Appendix B
51026 $MNS_AXES_SHOW_GEO_FIRST When the machine data value is 1, the geometry axes of the channel are displayed first.
51027 $MNS_ONLY_MKS_DIST_TO_GO Distance-to-go display in work window
Appendix B
Appendix B
51028 $MNS_BLOCK_SEARCH_MODE_MASK Bit mask for available block search modes
Bit 0: Block search with calculation without approach
Bit 1: Block search with calculation with approach
Bit 3: Skip EXTCALL programs
Bit 4: Block search without calculation
Bit 5: Block search with test run
51029 $MNS_MAX_SKP_LEVEL The machine data defines how many skip levels are made available for operation.
Technology Settings
51030 $MNS_SPIND_MAX_POWER Maximum value of the permissible spindle power rating in percent; the display bar in the
machine image is shown in green within the range between 0 and the value stored in
SPIND_MAX_POWER.
51031 $MNS_SPIND_POWER_RANGE Scale end value for spindle power rating in percent; value must be equal to or greater than
SPIND_MAX_POWER.
The display bar in the machine image is shown in red in the range between the values of
SPIND_MAX_POWER and SPIND_POWER_RANGE.
51034 $MNS_TEACH_MODE Teach mode to be activated

Bit 0: Default teach-in
Page 3
Taught-in block is transferred to the program using the Accept softkey.

Bit 1: Acceptance of teach block can be blocked by the PLC.
- For 840D sl : PLC bit DB19.DBX13.0 Disable teach transfer
- For 828D : PLC bit DB1700.DBX1000.0 Disable teach transfer
Bit 2: Block selection only explicitly
51035 $MNS_WRITE_FRAMES_FINE_LIMIT Input limit for all work offsets fine

51036 $MNS_ENABLE_COORDINATE_REL Display REL coordinate system
0 = no relative coordinate system selectable
1 = REL coordinate system can be selected as an alternative of the WCS/SZS coordinate
system
51037 $MNS_ENABLE_COORDINATE_ACS Activate settable coordinate system

0 = WCS coordinate system is displayed.
1 = SZS coordinate system is displayed.

(SZS is WCS reduced by the offset components defined in MD24030)
Technology Settings
51038 $MNS_SET_ACT_VALUE Set actual value selection
0 = Set actual value is not offered.
1 = If a user frame (settable work offset e.g. G54) is active, it will be used. In G500 Set ac-
tual values is not offered (system frame is no longer used).
51039 $MNS_PROGRAM_CONTROL_MODE_MASK Options for machine - program influence:

Bit 0: Program test function available
51040 $MNS_SWITCH_TO_MACHINE_MASK Automatic operating area switchover to machine
Bit 0: When selecting a program in the program manager, the operating area does not
automatically switch over to Machine.
Bit 1: When switching the type of operation via the MCP, the operating area is not auto-
matically switched over to Machine.
Bit 2: Do not switch automatically in Programs during program selection.
Bit 3: No auto. Start of block search on selection / execution under Programs.
51041 $MNS_ENABLE_PROGLIST_USER Activates the PLC program list of the USER area. The programs entered there can be se-
lected by the PLC for processing.
51042 $MNS_ENABLE_PROGLIST_INDIVIDUAL Activates the PLC program list of the INDIVIDUAL area. The programs entered here can be
Page 4
selected by the PLC for processing.

51043 $MNS_ENABLE_PROGLIST_MANUFACT Activates the PLC program list of the MANUFACTURER area. The programs entered here
can be selected by the PLC for processing.
51044 $MNS_ACCESS_SHOW_SBL2 Display protection level SBL2
51045 $MNS_ACCESS_TEACH_IN Protection level TEACH IN
51046 $MNS_ACCESS_CLEAR_RPA Protection level delete R variables
51047 $MNS_ACCESS_READ_GUD_LUD Read user variable protection level
51048 $MNS_ACCESS_WRITE_GUD_LUD Write protection level of user variables
51049 $MNS_ACCESS_WRITE_PRG_COND Write program control protection level
51050 $MNS_ACCESS_WRITE_PROGRAM Write part program protection level
51051 $MNS_ACCESS_WRITE_RPA Protection level write R variables
Appendix B
51052 $MNS_ACCESS_WRITE_SEA Protection level write setting data
Appendix B
51053 $MNS_ACCESS_WRITE_BASEFRAME Write basic work offset (basic frame) protection level
51054 $MNS_ACCESS_WRITE_CYCFRAME Write cycle frame protection level

51055 $MNS_ACCESS_WRITE_EXTFRAME Write external work offset protection level
Appendix B
Appendix B
51056 $MNS_ACCESS_WRITE_PARTFRAME Write table reference protection level
51057 $MNS_ACCESS_WRITE_SETFRAME Write basic reference protection level
51058 $MNS_ACCESS_WRITE_TOOLFRAME Write basic tool reference protection level
51059 $MNS_ACCESS_WRITE_TRAFRAME Write transformation frame protec. level
Technology Settings
51060 $MNS_ACCESS_WRITE_USERFRAME Write settable work offset (G54 ... G599) protection level
51061 $MNS_ACCESS_WRITE_WPFRAME Write workpiece reference protection level
51062 $MNS_ACCESS_WRITE_FINE Write protection level for fine offset of all work offsets
51063 $MNS_ACCESS_SET_ACT_VALUE Set actual value protection level
51064 $MNS_ACCESS_WRITE_PROGLIST Write protection level of program list in USER area
51065 $MNS_NUM_DISPLAYED_CHANNELS Number of channels displayed simultaneously
51066 $MNS_ORDER_DISPLAYED_CHANNELS Channel numbers of the channels displayed

Page 5
Contains the numbers of the channels to be displayed under machine in the multi-
channel view, in the desired order and separated by commas, semicolons or spaces.
51067 $MNS_ENABLE_HANDWHEEL_WINDOW Show handwheel window.

If the machine data is set to 0, the window for handwheel assignment is hidden.
51068 $MNS_SPIND_DRIVELOAD_FROM_PLC1 Machine axis index of spindle 1 utilization display from PLC
51069 $MNS_SPIND_DRIVELOAD_FROM_PLC2 Machine axis index of spindle 2 utilization display from PLC
51070 $MNS_ACCESS_CAL_TOOL_PROBE Protection level for calibration of the tool probe (ShopTurn)
51071 $MNS_ACCESS_ACTIVATE_CTRL_E Protection level of CTRL-Energy
51072 $MNS_ACCESS_EDIT_CTRL_E Protection level of CTRL-Energy for changing profiles
51073 $MNS_ACCESS_SET_SOFTKEY_ACCESS Protection level of ”Adapt softkeys”

51074 $MNS_ACCESS_WRITE_WPC_COUNTER Write protection level of workpiece counter
51160 $MNS_ACCESS_WRITE_CA_MACH_JOG Write protection level collision monitoring machine jog
51161 $MNS_ACCESS_WRITE_CA_MACH_AUTO Write protection level collision monitoring machine automatic
51162 $MNS_ACCESS_WRITE_CA_TOOL Write protection level collision monitoring tool
51198 $MNS_ACCESS_READ_TM_ALL_PARAM Protection level TM details - read all parameters
51199 $MNS_ACCESS_WRITE_TM_GRIND Protection level of tool management for writing grinding data
Technology Settings
51200 $MNS_ACCESS_WRITE_TM_GEO Write tool offset geometry data protection level
51201 $MNS_ACCESS_WRITE_TM_WEAR Write tool offset wear data protection level
51202 $MNS_ACCESS_WRITE_TM_WEAR_DELTA Protection level for restricted writing of tool wear values,
s. SD 54213: TM_WRITE_DELTA_LIMIT
51203 $MNS_ACCESS_WRITE_TM_SC Write tool offset sum offset protection level
51204 $MNS_ACCESS_WRITE_TM_EC Write tool offset use offsets protection level
51205 $MNS_ACCESS_WRITE_TM_SUPVIS Write tool offset monitoring data protection level

One authorization applies to all limit values: quantity, service life, wear and the monitor-
ing type.
51206 $MNS_ACCESS_WRITE_TM_ASSDNO Write tool offset unique D number protection level
51207 $MNS_ACCESS_WRITE_TM_WGROUP Write tool offset wear groups (magazine location / magazine) protection level
51208 $MNS_ACCESS_WRITE_TM_ADAPT Write tool offset tool adapter geometry data protection level
Page 6
51209 $MNS_ACCESS_WRITE_TM_NAME Write tool offset tool name and duplo data protection level
51210 $MNS_ACCESS_WRITE_TM_TYPE Write tool offset tool type protection level
51211 $MNS_ACCESS_READ_TM Read tool offset data protection level
51212 $MNS_TM_WRITE_WEAR_ABS_LIMIT With TM_WRITE_WEAR_ABS_LIMIT, the max. possible value of a tool wear is limited
absolutely, independently of the current protection level (keyswitch position), i.e. also
independently of ACCESS_WRITE_TM_WEAR. Absolute and incremental wear limita-
tion can be combined, i.e. the wear can be changed incrementally up to the absolute
limit, see MD 51213.
51213 $MNS_TM_WRITE_WEAR_DELTA_LIMIT When entering tool offsets, the value of the change from the previous value to the new
value cannot exceed the value set here.
With TM_WRITE_WEAR_DELTA_LIMIT, the change to a tool wear can be limited incre-
mentally, if the current protection level is the same as or higher than the one set in AC-
CESS_WRITE_TM_WEAR_DELTA. With the current protection level being the same or
higher than ACCESS_WRITE_TM_WEAR, an incremental limitation is no longer per-
Appendix B
formed. incremental wear limitation can be combined, i.e. the wear can be changed up
to the absolute limit, see MD 51212.
Appendix B
51214 $MNS_TM_WRITE_LIMIT_MASK Validity of the restricted tool wear input

Bit 0: Use for cutting edge data, wear
Bit 1: Use for SC data, sum offsets
Bit 2: Use for EC data, use offsets
Appendix B
Appendix B
51215 $MNS_ACCESS_WRITE_TM_ALL_PARAM Protection level TM details - write all parameters
51216 $MNS_ACCESS_TM_TOOL_CREATE Protection level TM create tool
51217 $MNS_ACCESS_TM_TOOL_DELETE Protection level TM delete tool
51218 $MNS_ACCESS_TM_TOOL_LOAD Protection level TM load tool
Technology Settings
51219 $MNS_ACCESS_TM_TOOL_UNLOAD Protection level TM unload tool
51220 $MNS_ACCESS_TM_TOOL_MOVE Protection level TM relocate tool
51221 $MNS_ACCESS_TM_TOOL_REACTIVATE Protection level TM reactivate tool
51222 $MNS_ACCESS_TM_TOOL_MEASURE Protection level TM measure tool
51223 $MNS_ACCESS_TM_TOOLEDGE_CREATE Protection level TM create tool cutting edge
51224 $MNS_ACCESS_TM_TOOLEDGE_DELETE Protection level TM delete tool cutting edge

Page 7
51225 $MNS_ACCESS_TM_MAGAZINE_POS Protection level TM position magazine
51226 $MNS_FUNCTION_MASK_SIM Function mask Simulation

Bit 0: No automatic start on simulation selection
Bit 1: Deactivate simulation
Bit 4: Ignore frame components in X and Y (compatibility)
Bit 5: Turning tool can rotate in the tool spindle
Bit 6: Enable handwheel as simulation override
Bit 7: Interpretation of handwheel values as absolute values
Bit 10: Hide zero point symbol
51228 $MNS_FUNCTION_MASK_TECH Function mask Cross-technology

Bit 0: G code programming without multi-channel data
Bit 1: Enable print function of editor
Bit 2: With external program selection, test program
51230 $MNS_ENABLE_LADDER_DB_ADDRESSES Activation of DB addresses in PLC Ladder Viewer
51231 $MNS_ENABLE_LADDER_EDITOR Activation of PLC ladder add-on tool for INT100/101
51232 $MNS_ENABLE_LADDER_EDITOR_ADV Activation of PLC ladder editor for the complete PLC project
51233 $MNS_ENABLE_GSM_MODEM Activation of GSM Modem for Easy Message
51235 $MNS_ACCESS_RESET_SERV_PLANNER Protection level for acknowledgement of maintenance tasks
51300 $MNS_MAXNUM_WAITM_USER Number of wait marks available to the end user

Technology Settings
51600 $MNS_MEA_CAL_WP_NUM Number of calibration data fields for workpiece probes
51601 $MNS_MEA_CAL_EDGE_NUM Number of geometry data fields of gauging block for workpiece probes
51602 $MNS_MEA_CAL_TP_NUM Number of calibration data fields for tool probes
51603 $MNS_MEA_CAL_TPW_NUM Number of calibration data fields for tool probes
51618 $MNS_MEA_CM_ROT_AX_POS_TOL Entries in parameter $MN_MEA_CM_ROT_AX_POS_TOL are effective only if MD51740

$MNS_MEA_FUNCTION_MASK Bit 2 or Bit 16 is set.
The real angle position of the rotary axes can deviate from the programmed one (exact stop fine
window).
This deviation depends on the position control features of the axis. The maximum deviation ex-
pected on the concrete axis must be entered in this parameter. When the tolerance is exceeded,
alarm 61442 "Toolholder not in parallel with the geometry axes" is displayed.
51740 $MNS_MEA_FUNCTION_MASK Function mask for measuring cycles, workpiece and tool measuring
Bit 0: Workpiece, monitoring of the calibration status
Bit 1: Workpiece, length ref. of probe in infeed axis at the ball circumference
Page 8
Bit 2: Workpiece, correction in the tool, taking into account toolholders

Bit 4: Workpiece, probe fixed in the machine (not in a spindle)
Bit 5: Workpiece, correction in WO course, if no WO fine is set up
Bit 6: Measuring blocks in measuring cycles with feedrate override 100%
Bit 15: Workpiece, traverse measuring block with path behaviour G60 exact stop
Bit 16: Tool, turning technology, taking into account toolholders
51742 $MNS_MEA_FUNCTION_MASK Meas. cycles: Limitation of protection levels when writing system variables
51750 $MNS_J_MEA_M_DIST This parameter defines the measuring path in front of and behind the measuring setpoint.
51751 $MNS_J_MEA_M_DIST_MANUELL Measuring path, manual measurement ((for "Measure in JOG")) [mm] (in front of and behind the
measuring setpoint)
51752 $MNS_J_MEA_M_DIST_TOOL_LENGTH Measuring path for tool length measuring.
51753 $MNS_J_MEA_M_DIST_TOOL_RADIUS Measuring path for tool radius measuring.
Appendix B
51757 $MNS_J_MEA_COLL_MONIT_FEED Feedrate in the working plane with active collision detection.
Appendix B
51758 $MNS_J_MEA_COLL_MONIT_POS_FEED Feedrate of the infeed axis with active collision detection, for "Measure in JOG".
Appendix B
Appendix B
51770 $MNS_J_MEA_CAL_RING_DIAM Calibration ring diameter for Measure in JOG
51772 $MNS_J_MEA_CAL_HEIGHT_FEEDAX Calibration height in the infeed axis for probe length calibration
51780 $MNS_J_MEA_T_PROBE_DIAM_RAD Diameter of the tool probe for radius measurement for Measure in JOG
51781 $MNS_MEA_T_PROBE_THICKNESS Tool probe thickness
Technology Settings
51784 $MNS_J_MEA_T_PROBE_APPR_AX_DIR Approach direction in the plane on the tool probe for Measure in JOG
51786 $MNS_J_MEA_T_PROBE_MEASURE_DIST Measuring path for tool measurement with stationary spindle for Measure in JOG
51840 $MNS_GRIND_FUNCTION_MASK Function mask for grinding cycles

Bit 0: Reference point for recording dresser/grinding wheel is a work offset
Channel Machine Data

Page 9

52000 $MCS_DISP_COORDINATE_SYSTEM Coordinate system position
With this MD you adapt the operator panel of the coordinate system to the machine's coordinate
system. Depending on the selected position, all help screens, the sequence graphic, the simula-
tion and the input fields with the circular direction specified will change automatically.
Also note MD 52210 $MCS_FUNCTION_MASK_DISP, Bit 1.
52001 $MCS_DISP_COORDINATE_SYSTEM_2 Coordinate system for turning on milling machines
52004 $MCS_PROG_COORDINATE_SYS_CHAN Coordinate system during programming as described in the specific channel
52005 $MCS_DISP_PLANE_MILL Plane selection Milling

0: plane selection on the operator panel
17: always G17
18: always G18

19: always G19
52006 $MCS_DISP_PLANE_TURN Plane selection Turning

0: plane selection on the operator panel
17: always G17
18: always G18
19: always G19
52010 $MCS_DISP_NUM_AXIS_BIG_FONT Number of actual values with large font

Technology Settings
52011 $MCS_ADJUST_NUM_AXIS_BIG_FONT Adapt the number of actual values with large font if the number of geometry axes changes, e.g.
due to transformations like TRANSMIT or TRACYL.
0 = Only MD 52010 DISP_NUM_AXIS_BIG_FONT is valid. The number is assigned as a fixed
value.
1 = Only the geometry axes are displayed in large font. MD 52010 DISP_NUM_AXIS_BIG_FONT
is ignored.
2 = The number of geometry axes plus the content of MD 52010 DISP_NUM_AXIS_BIG_FONT
are displayed in large font.
52020 $MCS_ORIAXES_EULER_ANGLE_NAME Axis identifier of the orientation axes: Euler angle or geometry axis name
52032 $MCS_STAT_DISPLAY_BASE Number basis for display of articulated joint STAT
52033 $MCS_TU_DISPLAY_BASE Number basis for display of rotary axis position TU
52200 $MCS_TECHNOLOGY Technology

0: no specific configuration
1: turning
2: milling
Page 10
Also note MD 52201 $MCS_TECHNOLOGY_EXTENSION.
52201 $MCS_TECHNOLOGY_EXTENSION Extended technology

0: no specific configuration
1: turning
2: milling
Also note MD 52200 $MCS_TECHNOLOGY.
Example:
Turning machine with milling technology
MD 52200 $MCS_TECHNOLOGY = 1
MD 52201 $MCS_TECHNOLOGY_EXTENSION = 2
52206 $MCS_AXIS_USAGE Meaning of the axes in the channel
0 = no special meaning
1 = tool spindle (driven tool)
2 = auxiliary spindle (driven tool)
3 = main spindle (turning)
4 = C axis of the main spindle (turning)
5 = counter spindle (turning)
Appendix B
6 = C axis of the counter spindle (turning)
7 = linear axis of the counter spindle (turning)
8 = tailstock (turning)
Appendix B
9 = steady rest (turning)

10 = B axis (turning)
11 = reserved
12 = B axis of the counter spindle (turning)
13 = Traverse travel X of the counter spindle (turning)
Appendix B
Appendix B
52207 $MCS_AXIS_USAGE_ATTRIB Axis attributes

Bit 0: Rotates around the 1st geometry axis (applies to rotary axes)
Bit 1: Rotates around the 2nd geometry axis (applies to rotary axes)
Bit 2: Rotates around the 3rd geometry axis (applies to rotary axes)
Bit 3: Positive direction of rotation is counter-clockwise (applies to rotary axes)
Bit 4: Displayed direction of rotation for M3 is counter-clockwise (applies to spindles)
Bit 5: Direction of rotation M3 corresponds to rotary axis minus (applies to spindles)
This bit must be set in the same way as a PLC bit.
Technology Settings
- For 840D sl : PLC bit DBnn.DBX17.6, nn = 31 + machine axis index
- For 828D : PLC bit DB38xx.DBX2001.6, xx is machine axis index
Bit 6: Show rotary axis as offset target for measuring
Bit 7: Offer rotation axis in position pattern
Bit 8: Offer rotation axis to accept blank (at milling machines)
Bit 9: Spindle is not SPOS-capable
Bit 10: Rotary axis rotates around 1st geometry axis (for position pattern only)
Bit 11: Rotary axis rotates around 2nd geometry axis (for position pattern only)
Bit 12: Rotary axis rotates around 3rd geometry axis (for position pattern only)
Bit 13: Position of the axis for blank selection from active WO (for rotary axes)
Bit 14: Enable spindle for teach-in in axis mode
Page 11
52210 $MCS_FUNCTION_MASK_DISP Function mask Display

Bit 0: Measuring system for programs always in the base system
Bit 1: Front view for turning in school coordinate system
Bit 2: Hide “T,S,M” soft key in JOG area
Bit 3: Generate automatic end-of-program in MDI (with the “Delete blocks” soft key)
Bit 4: Show follow-on tool in T,F,S window
Bit 5: Hide softkey “Actual machine values“
Bit 6: Hide tool radius/diameter in T,F,S window
Bit 7: Hide tool length in T,F,S window
Bit 8: Hide tool icon in T,F,S window
Bit 9: Display selection ”Simple input”
Bit 10: Do not offer channel in job lists
Bit 11: For Work activate the display of the logical spindles
Bit 12: Hide mold making view for G code
Bit 13: Hide channel axes which are currently located in another channel
Bit 14: Display overlay of DRF under machine
Bit 15: Display overlay of tool ($AA_TOFF) under machine

Technology Settings
52211 $MCS_FUNCTION_MASK_DISP _ZOA Function screen for displaying overview of work offsets
Bit 0: Show machine position
Bit 1: reserved
Bit 2: Display DRF offset
Bit 3: Display $AA_OFF position offset
Bit 4: Display $P_PARTFRAME
Bit 5: Display $P_SETFRAME
Bit 6: Display $P_EXTSFRAME
Bit 7: Display $P_ISO1FRAME
Bit10: Display $P_ACTBFRAME
Bit 11: Display $P_IFRAME
Bit 12: Display $P_TOOLFRAME
Bit 13: Display $P_WPFRAME
Bit 14: Display $P_TRAFRAME
Bit 15: Display $P_PFRAME
Bit 17: Display $P_CYCFRAME
Page 12
Bit 18: Display sum of work offsets

Bit 19: Display offset of active tool
Bit 20: Display Work position
Bit 21: Display BCS position
Bit 22: Display $P_GFRAME
Bit 23: Display TOFF
Bit 24: Display overlay $AA_TOFF
52212 $MCS_FUNCTION_MASK_TECH Function mask Cross-technology
Bit 0: Enable swivel plane/align tool with tool carrier
Bit 1: Optimized travel along software limit switches (ShopMill/ShopTurn)
Bit 2: Special approach logic for step drill (ShopTurn)
Bit 3: Call block search cycle for ShopMill/ShopTurn
Bit 4: Approach logic through cycle (ShopTurn)
Bit 5: Call block search cycle for SERUPRO
Bit 6: Work offset ZV cannot be entered as an absolute value (ShopTurn)
Bit 7: Detect the expiry of tool lives (ShopMill/ShopTurn)
Bit 8: Manual machine (ShopMill/ShopTurn)
Bit 9: Selection/deselection of work offset via softkey
Appendix B
Bit 10: Enable swivel plane/align tool using kinematic transformation
Bit 11: Switch off layer check for drilling and milling tools (ShopTurn)
Bit 12: reserved
Appendix B
Bit 13: Approach tool change point Y in Machine (ShopTurn)

Bit 14: With approach logic only check tool position with cutting edge (ShopTurn)
Bit 15: Do not set $MC TOOL_CARRIER_RESET_VALUE after block search
Bit 16: Do not automatically execute swivel plane after block search
Bit 17: Do not automatically execute align turning tool after block search
Appendix B
Appendix B
52214 $MCS_FUNCTION_MASK_MILL Function mask Milling

Bit 0: Enable cylinder surface transformation (ShopMill)
Bit 1: Offer fixed table for blank clamping (at milling machines)
Bit 2: Special handling of slide mill/saw for polyhedron
Bit 3: Enable inside/rear machining (ShopTurn)
Bit 4: Enable spindle clamping (C axis) (ShopTurn)
Bit 5: Enable spindle control of tool spindle via surface
Bit 6: Enable spindle control of turning spindle via surface
Technology Settings
Bit 7: Offer fixed table for blank clamping (on boring mills)
52216 $MCS_FUNCTION_MASK_DRILL Function mask Drilling

Bit 0: CYCLE84 Unhide technology fields
Bit 1: CYCLE840 Unhide technology fields
Bit 2: Thread tapping also without encoder (ShopMill/ShopTurn)
Bit 3: Constant cutting speed in rel. to diameter of centering (ShopMill/ShopTurn)
52218 $MCS_FUNCTION_MASK_TURN Function mask Turning

Bit 0: Enable zoom under manual for tool measurement
Bit 1: Enable parts gripper for cut-off
Bit 2: Enable tailstock
Page 13
Bit 3: Enable spindle control of main spindle via surface

Bit 4: Enable spindle control of counterspindle via surface
Bit 5: Enable spindle control of tool spindle via surface
Bit 6: Enable balance cutting for dual-channel stock removal
Bit 7: Retraction during stock removal along contour with G1
Bit 8: Input spindle chuck data in the program
Bit 9: Additional entry of tailstock data in the program
Bit 10: Enable convex thread
Bit 11: Reserved
Bit 12: Deactivate thread synchronization
Bit 13: Stock rem. contour with CYCLE95 (828D programGUIDE without Advanced Technology)
52229 $MCS_ENABLE_QUICK_M_CODES Enable fast M functions

Bit 0: Coolant OFF
Bit 1: Coolant 1 ON
Bit 2: Coolant 2 ON
Bit 3: Coolant 1 and 2 ON
52230 $MCS_M_CODE_ALL_COOLANTS_OFF M code for all coolants OFF
52231 $MCS_M_CODE_COOLANT_1_ON M code for coolant 1 ON
52232 $MCS_M_CODE_COOLANT_2_ON M code for coolant 2 ON
52233 $MCS_M_CODE_COOLANT_1_AND_2_ON M code for coolant 1 + 2 ON

Technology Settings
52240 $MCS_NAME_TOOL_CHANGE_PROG Tool change program for G code steps
52241 $MCS_TOOL_CHANGE_POS_Y Tool change position Y in the Machine (ShopTurn)
52242 $MCS_TURN_TOOL_FIXING Tool adapter for turning tools
52244 $MCS_SUB_SPINDLE_PARK_POS_Y Parking position of the Y axis with counter spindle
52248 $MCS_REV_2_BORDER_TOOL_LENGTH Limit value of tool length X for 2nd revolver:

Limit value = 0: There is only one revolver
Tool length < limit value: Tool belongs to 1st revolver/multifix
Tool length >= limit value: Tool belongs to 2nd revolver/multifix
52250 $MCS_M_CODE_CHUCK_OPEN M code for Open chuck with non-rotating spindle.

Example: "M34" or "M1=34"
Elements:
[0]: Main spindle
[1]: Counterspindle
Page 14
52251 $MCS_M_CODE_CHUCK_CLOSE_OPEN_ M code for Open chuck with rotating spindle.

ROT Example: "M35" or "M1=35"
Elements:
[0]: Main spindle
[1]: Counterspindle
52252 $MCS_M_CODE_CHUCK_CLOSE M code for Close chuck

Elements:
[0]: Main spindle
[1]: Counterspindle
52253 $MCS_M_CODE_TAILSTOCK_FORWARD M code for quill forward

Elements:
[0]: Quill opposite main spindle
[1]: Quill opposite counterspindle
Appendix B
52254 $MCS_M_CODE_TAILSTOCK_BACKWARD M code for quill backward
Elements:
Appendix B
[0]: Quill opposite main spindle

[1]: Quill opposite counterspindle
52260 $MCS_MACHINE_JOG_INTERRUPT_PRIO Priory for start ASUP under machine JOG

Appendix B
Appendix B
52270 $MCS_TM_FUNCTION_MASK Function mask Tool management

Bit 0: Do not permit Create tool on magazine location
Bit 1: Load/unload disable, if machine is not in reset
Bit 2: Load/unload disable for emergency stop
Bit 3: Load/unload tool or relocate tool to/from spindle disabled
Bit 4: Load directly in spindle
Bit 5: Use grinding configuration file
Technology Settings
Bit 6: Permit relocating to/from spindle despite a block (Bit 3)
Bit 7: Create tool using the T number
Bit 8: Hide Relocate tool
Bit 9: Hide Position magazine
Bit 10: Reactivate tool using Position magazine
Bit 11: Reactivate tool in all monitoring modes
Bit 12: Fade out Reactivate tool
52271 $MCS_TM_MAG_PLACE_DISTANCE Distance between individual magazine locations.

Is used for graphical display of magazine and tools in tool management.
52272 $MCS_TM_TOOL_LOAD_DEFAULT_MAG Default magazine for tool loading
Page 15
0 = No default magazine
52273 $MCS_TM_TOOL_MOVE_DEFAULT_MAG Default magazine for tool relocation
0 = No default magazine
52274 $MCS_TM_TOOL_LOAD_STATION Number of load station
0 = All configured stations are taken into account
52281 $MCS_TOOL_MCODE_FUNC_ON M code for tool-specific function ON
Value -1 means that the M function is not output. If both M commands of a function equal -1, the
corresponding field will not be displayed in the user interface.
52282 $MCS_TOOL_MCODE_FUNC_OFF M code for tool-specific function OFF

Value -1 means that the M function is not output. If both M commands of a function equal -1, the
corresponding field will not be displayed in the user interface.
52290 $MCS_SIM_DISPLAY_CONFIG Location of status display of the channel in the simulation (OP019 only)
Bit 0: Corner left/top
Bit 1: Corner right/top
Bit 2: Corner left/bott
Bit 3: Corner right/bott
52740 $MCS_MEA_FUNCTION_MASK Function mask for measuring cycles, workpiece and tool measuring
Bit 0: Workpiece probe connected at probe input 2
Bit 1: Workpiece, turning technology, measuring in the third geometry axis (Y)
Bit 2: Calc. of correction angle with/without active orientation transformation
Bit 16: Tool probe connected at probe input 2
Bit 17: Tool measurement turning, recording the cutting edge position
Technology Settings
52750 $MCS_J_MEA_FIXPOINT Z value for measuring fixed point
52751 $MCS_J_MEA_MAGN_GLAS_POS Zoom position for tool measurement

[0] = Position in 1st axis
[1] = Position in 2nd axis
52780 $MCS_J_MEA_T_PROBE_APPR_MODE Approach mode tool measurement in JOG
52800 $MCS_ISO_M_ENABLE_POLAR_COORD Polar coordinates

0: OFF
1: ON
52802 $MCS_ISO_ENABLE_INTERRUPTS Interrupt process

0: OFF
1: ON
52804 $MCS_ISO_ENABLE_DRYRUN Machining skipped during tapping G74/G84 at DRY RUN

0: OFF
1: ON
Page 16
52806 $MCS_ISO_SCALING_SYSTEM Basic system

0: not defined
1: METRIC
2: INCH
52808 $MCS_ISO_SIMULTAN_AXES_START Simultaneous approach to the boring position on all programmed axes
0: OFF
1: ON
52810 $MCS_ISO_T_DEEPHOLE_DRILL_MODE Select the type of deep hole drilling

0: deep hole drilling with chip breaking
1: deep hole drilling with stock removal
52818 $MCS_ISO_M_FUNCTION_MASK Function mask for ISO milling mode

Bit 0: Reserved
52819 $MCS_ISO_T_FUNCTION_MASK Function mask for ISO turning mode
Bit 0: Reserved
Appendix B
52840 $MCS_GRIND_FUNCTION_MASK Function mask for grinding
Bit 7: Retraction while profiling with G1
Appendix B
52842 $MCS_GRIND_DIAMETER_LENGTH Number of diameter length
52843 $MCS_GRIND_WIDTH_LENGTH Number of grinding wheel with

Axis Machine Data
Appendix B
Appendix B
53220 $MAS_AXIS_MCS_POSITION Position of axis in the Machine
53230 $MAS_SIM_START_POSITION Axis position at start of simulation
53240 $MAS_SPINDLE_PARAMETER Spindle chuck data

[0]: Chuck dimension
[1]: Stop dimension
[2]: Jaw dimension
Technology Settings
53241 $MAS_SPINDLE_CHUCK_TYPE Spindle jaw type
0 = Clamp from outside
1 = Clamp from inside
53242 $MAS_TAILSTOCK_PARAMETER Tailstock data

[0]: Tailstock diameter
[1]: Tailstock length
53250 $MAS_CLAMPING_TOLERANCE Permissible tolerance when an axis jams

Page 17
General Setting Data

54215 $SNS_TM_FUNCTION_MASK_SET Function mask Tool management
Bit 0: Diameter display for rotating tools
Bit 1: Default direction of rotation for all turning tools is M4
Bit 2: Create tool without name suggestion
Bit 3: Input disable for tool name and tool type in loaded tools
Bit 4: Input disable for loaded tools, if the channel is not in Reset
Bit 5: Calculate tool wear inputs additively
Bit 6: Numerical input of the tool ident.
Bit 7: Fade out tool monitoring parameters
Bit 8: Diameter display for transverse axis - Geometry
Bit 9: Diameter display for transverse axis - Wear
Bit 10: Enable loading/relocating of tools on buffer locations

Bit 11: Creating of new tools in gripper locations is disabled
Bit 12: Do not unload measuring tools if ”Unload all” function is executed
Bit 13: Do not delete tool wear when inputting the geometry value
Bit 14: Load/relocate tool. Search without pre-assignment of the magazine
54480 $SNS_AST_MMC_HANDLER_NAME Assignment of an HMI Operate instance for AST commands
54481 $SNS_AST_MMC_DEFAULT_IS_PCU Selection of HMI Operate internal (NCU) / external (PCU) for AST
Technology Settings
54600 $SNS_MEA_WP_BALL_DIAM Effective diameter of the probe sphere for the workpiece probe
54601 $SNS_MEA_WP_TRIG_MINUS_DIR_AX1 Trigger point of the 1st measuring axis in negative direction
54602 $SNS_MEA_WP_TRIG_PLUS_DIR_AX1 Trigger point of the 1st measuring axis in positive direction
54603 $SNS_MEA_WP_TRIG_MINUS_DIR_AX2 Trigger point of the 2nd measuring axis in negative direction
54604 $SNS_MEA_WP_TRIG_PLUS_DIR_AX2 Trigger point of the 2ns measuring axis in positive direction
54605 $SNS_MEA_WP_TRIG_MINUS_DIR_AX3 Trigger point of the 3rd measuring axis in negative direction
54606 $SNS_MEA_WP_TRIG_PLUS_DIR_AX3 Trigger point of the 3d measuring axis in positive direction
54607 $SNS_MEA_WP_POS_DEV_AX1 Position deviation of the probe sphere in the 1st measuring axis
Page 18
54608 $SNS_MEA_WP_POS_DEV_AX2 Position deviation of the probe sphere in the 2nd measuring axis
54609 $SNS_MEA_WP_STATUS_RT Calibration status axis positions, reserved for internal use!
54610 $SNS_MEA_WP_STATUS_GEN Calibration status in general, reserved for internal use!
54611 $SNS_MEA_WP_FEED Measuring feed for calibration
54615 $SNS_MEA_CAL_EDGE_BASE_AX1 Calibration groove base of the 1st measuring axis
54617 $SNS_MEA_CAL_EDGE_PLUS_DIR_AX1 Calibration groove edge in positive direction of the 1st measuring axis
54618 $SNS_MEA_CAL_EDGE_MINUS_DIR_AX1 Calibration groove edge in negative direction of the 1st measuring axis
Appendix B
54619 $SNS_MEA_CAL_EDGE_BASE_AX2 Calibration groove base of the 2nd measuring axis
Appendix B
Appendix B
Appendix B
54620 $SNS_MEA_CAL_EDGE_UPPER_AX2 Calibration groove upper edge of the 2nd measuring axis
54621 $SNS_MEA_CAL_EDGE_PLUS_DIR_AX2 Calibration groove edge in positive direction of the 2nd measuring axis
54622 $SNS_MEA_CAL_EDGE_MINUS_DIR_AX2 Calibration groove edge in negative direction of the 2nd measuring axis
54625 $SNS_MEA_TP_TRIG_MINUS_DIR_AX1 Trigger point of the 1st measuring axis in negative direction
Technology Settings
54626 $SNS_MEA_TP_TRIG_PLUS_DIR_AX1 Trigger point of the 1st measuring axis in positive direction
54627 $SNS_MEA_TP_TRIG_MINUS_DIR_AX2 Trigger point of the 2nd measuring axis in negative direction
54628 $SNS_MEA_TP_TRIG_PLUS_DIR_AX2 Trigger point of the 2nd measuring axis in positive direction
54629 $SNS_MEA_TP_TRIG_MINUS_DIR_AX3 Trigger point of the 3rd measuring axis in negative direction
Page 19
54630 $SNS_MEA_TP_TRIG_PLUS_DIR_AX3 Trigger point of the 3rd measuring axis in positive direction
54631 $SNS_MEA_TP_EDGE_DISK_SIZE Tool probe edge length/wheel diameter
54632 $SNS_MEA_TP_AX_DIR_AUTO_CAL Enabling axes and traversing directions for "Automatic calibration" of milling tool probes.
The default setting refers in X and Y to the plus and minus direction respectively, in Z only to the
minus direction.
The parameter is divided into three components the functions of which are to be assigned to
calibration data records 1, 2 or 3!
The calibration data records are firmly assigned to tool measuring in the working planes G17 (1),
G18 (2) and G19 (3)!
Meaning of the parameter components
Decimal position:
Ones: 1st geometry axis (X)
Tens: 2nd geometry axis (Y)

Hundreds: 3rd geometry axis (Z)
Value:
=0: Axis not enabled
=1: Only minus direction possible
=2: Only plus direction possible
=3: Both directions possible
Technology Settings
54633 $SNS_MEA_TP_TYPE Tool probe type cube / wheel
0: Cube
101: Wheel in XY, working plane G17
201: Wheel in ZX, working plane G18
301: Wheel in YZ, working plane G19
54634 $SNS_MEA_TP_CAL_MEASURE_DEPTH Distance between the upper tool probe edge and the lower milling tool edge
54635 $SNS_MEA_TP_STATUS_GEN Calibration status in general, reserved for internal use!
54636 $SNS_MEA_TP_FEED Measuring feed for tool probe calibration in MCS
54640 $SNS_MEA_TPW_TRIG_MINUS_DIR_AX1 Trigger point of the 1st measuring axis in negative direction
54641 $SNS_MEA_TPW_TRIG_PLUS_DIR_AX1 Trigger point of the 1st measuring axis in positive direction
Page 20
54642 $SNS_MEA_TPW_TRIG_MINUS_DIR_AX2 Trigger point of the 2nd measuring axis in negative direction
54643 $SNS_MEA_TPW_TRIG_PLUS_DIR_AX2 Trigger point of the 2nd measuring axis in positive direction
54644 $SNS_MEA_TPW_TRIG_MINUS_DIR_AX3 Trigger point of the 3rd measuring axis in negative direction
54645 $SNS_MEA_TPW_TRIG_PLUS_DIR_AX3 Trigger point of the 3rd measuring axis in positive direction
54646 $SNS_MEA_TPW_EDGE_DISK_SIZE Tool probe edge length/wheel diameter
Appendix B
Appendix B
Appendix B
Appendix B
54647 $SNS_MEA_TPW_AX_DIR_AUTO_CAL Enabling axes and traversing directions for "Automatic calibration" of milling tool probes.
The default setting refers in X and Y to the plus and minus direction respectively, in Z only to the
minus direction.
The parameter is divided into three components the functions of which are to be assigned to cali-
bration data records 1, 2 or 3!
The calibration data records are firmly assigned to tool measuring in the working planes G17 (1),
G18 (2) and G19 (3)!
Meaning of the parameter components
Technology Settings
Decimal position:
Ones: 1st geometry axis (X)
Tens: 2nd geometry axis (Y)
Hundreds: 3rd geometry axis (Z)
Value:
=0: Axis not enabled
=1: Only minus direction possible
=2: Only plus direction possible
=3: Both directions possible
54648 $SNS_MEA_TPW_TYPE Tool probe type cube / wheel

Page 21
0: Cube
101: Wheel in XY, working plane G17
201: Wheel in ZX, working plane G18
301: Wheel in YZ, working plane G19
54649 $SNS_MEA_TPW_CAL_MEASURE_DEPTH Distance between the upper tool probe edge and the lower milling tool edge
54650 $SNS_MEA_TPW_STATUS_GEN Calibration status in general, reserved for internal use!
54651 $SNS_MEA_TPW_FEED Measuring feed for tool probe calibration in WCS
54652 $SNS_MEA_INPUT_TOOL_PROBE_SUB CNC measurement input for tool probe with reference to the counterspindle
=0: Toolsetter no.=n+1, with reference to the main spindle
CNC measurement input corresponds to the value of $MCS_MEA_FUNCTION_MASK, bit16

=10: Toolsetter no.=n+1, with reference to the counterspindle
units digit =0, corresponds to CNC measurement input 1
=11: Toolsetter no.=n+1, with reference to the counterspindle
units digit =1, corresponds to CNC measurement input 2
Technology Settings
54670 $SNS_MEA_CM_MAX_PERI_SPEED Max. permissible peripheral speed of the tool to be measured
54671 $SNS_MEA_CM_MAX_REVOLUTIONS Maximum tool speed for tool measuring
54672 $SNS_MEA_CM_MAX_FEEDRATE Maximum feed for contact of the tool with the probe
54673 $SNS_MEA_CM_MIN_FEEDRATE Minimum feed for 1st contact of the tool with the probe
54674 $SNS_MEA_CM_SPIND_ROT_DIR Direction of spindle rotation for tool measuring
54675 $SNS_MEA_CM_FEEDFACTOR_1 Feedrate factor 1, for tool measuring with rotating spindle
=0: Single probing with the feedrate calculated by the cycle (but at least with the value of
$SNS_MEA_CM_MIN_FEEDRATE)
>=1: First probing with calculated feedrate (but at least with the value of
$SNS_MEA_CM_MIN_FEEDRATE).
Monitoring parameter for tool measuring with rotating spindle.
Page 22
54676 $SNS_MEA_CM_FEEDFACTOR_2 Feedrate factor 2, for tool measuring with rotating spindle
=0:Second probing with the feedrate calculated by the cycle (only effective with
MEA_CM_FEEDFACTOR_1 > 0)
>=1: Second probing with calculated feedrate, feedrate factor 2
Third probing with calculated feedrate (tool speed is influenced by SD54749
$SNS_MEA_FUNCTION_MASK_TOOL, Bit 12)
Notice: - Feedrate factor 2 should be smaller than feedrate factor 1!
- If the value of feedrate factor 2 is 0, a third probing will not be not performed!
Monitoring parameter for tool measuring with rotating spindle.
54677 $SNS_MEA_CM_MEASURING_ACCURAC Required measuring accuracy for tool measuring

Y
54689 $SNS_MEA_T_PROBE_MANUFACTURER Tool probe type (manufacturer)

These indications are required for tool measuring with rotating spindle.
=0: No indication
=1: TT130 (Heidenhain)
Appendix B
=2: TS27R (Renishaw)
Appendix B
Appendix B
Appendix B
54691 $SNS_MEA_T_PROBE_OFFSET Measurement result offset for tool measuring with rotating spindle.
=0: No offset
=1: Cycle-internal offset (only effective with SD54689
$SNS_MEA_T_PROBE_MANUFACTURER<>0)
=2: Offset through user-defined offset table
54692 $SNS_MEA_T_CIRCULAR_ARC_DIST Arc distance for single cutting edge measuring from the radius
Technology Settings
54693 $SNS_MEA_T_MAX_STEPS Max. number of contacts for single cutting edge measuring from the radius
54695 $SNS_MEA_RESULT_OFFSET_TAB_RAD1 Offset table (measure tool radius with rotating spindle)
54696 $SNS_MEA_RESULT_OFFSET_TAB_RAD2 Offset table 1st peripheral speed (radius)
54697 $SNS_MEA_RESULT_OFFSET_TAB_RAD3 Offset table 2nd peripheral speed (radius)
54698 $SNS_MEA_RESULT_OFFSET_TAB_RAD4 Offset table 3rd peripheral speed (radius)

Page 23
54699 $SNS_MEA_RESULT_OFFSET_TAB_RAD5 Offset table 4th peripheral speed (radius)
54700 $SNS_MEA_RESULT_OFFSET_TAB_RAD6 Offset table 5th peripheral speed (radius)
54705 $SNS_MEA_RESULT_OFFSET_TAB_LEN1 Offset table (measure tool length with rotating spindle)
54706 $SNS_MEA_RESULT_OFFSET_TAB_LEN2 Offset table 1st peripheral speed (length)
54707 $SNS_MEA_RESULT_OFFSET_TAB_LEN3 Offset table 2nd peripheral speed (length)

54708 $SNS_MEA_RESULT_OFFSET_TAB_LEN4 Offset table 3rd peripheral speed (length)
54709 $SNS_MEA_RESULT_OFFSET_TAB_LEN5 Offset table 4th peripheral speed (length)
54710 $SNS_MEA_RESULT_OFFSET_TAB_LEN6 Offset table 5th peripheral speed (length)

Technology Settings
54740 $SNS_MEA_FUNCTION_MASK Function mask for measuring cycles, workpiece and tool measuring
Bit 0: Workpiece, measurement repeated if TSA, TDIF are exceeded
Bit 1: Workpiece, repeat measurement with M0 if TSA, TDIF are exceeded
Bit 2: Workpiece, stop at M0 if TUL, TLL are exceeded
Bit 3: Workpiece, accept calibrated probe ball radius in tool data
Bit 4: Workpiece , plane between calibration and measurement can be different
Bit 16: Tool, repeat measurement if TDIF, TSA are exceeded
Bit 17: Tool, repeat measurement with stop at M0 if TDIF, TSA are exceeded
Bit 19: Tool milling, reduction of the spindle speed at the last probing
54750 $SNS_MEA_ALARM_MASK Expert mode for cycle alarms

Bit 0 - 7 Workpiece measurement
Bit 0 =1 Alarms with cycle-internal states and coding are displayed (expert mode)!
Bit 1 - 7 Reserved
Bit 8 -16 Tool measuring
Bit 0 - 7 Reserved
54760 $SNS_MEA_FUNCTION_MASK_PIECE Setting for input screen, measuring cycles in Automatic, workpiece measuring
Bit 1: Selection of display softkey 3D measurement
Page 24
Bit 3: Select probe calibration data field, enable

Bit 4: Select Calibrate Input measuring feed
Bit 6: Enable selection of WO compensation in basic reference
Bit 7: Enable selection of WO compensation in channel-specific basic WO
Bit 8: Enable selection of WO compensation in global basic WO
Bit 9: Enable selection of WO compensation in work offset
Bit 10: Enable selection of WO compensation in course and fine
Bit 11: Enable selection of tool offset wear and geometry
Bit 12: Enable selection of tool offset not inverted and inverted
Bit 13: Enable selection of tool offset radius, length L1, L2, L3
Bit 14: Enable selection of tool offset work offset
Bit 15: Enable selection of tool offset dimensional difference check
Bit 16: Selection of workpiece measurement with spindle reversal
Bit 17: Selection align workpiece probe in switching direction
Bit 18: Select Number of measurements
Bit 19: Select Offset with averaging
Bit 20: Select Empirical values
Bit 21: Select Additive setup offset
Appendix B
Bit 22: Select Calibrate to unknown or known center point
Bit 24: Select Calibrate with or without positional deviation
Bit 25: Selection zero offset when measuring the angularity of the spindle
Appendix B
Bit 26: Tool offset selection not enabled

Bit 27: Select tolerance for linear vectors with kinematic measurement not enabled
Bit 28: Select adapt tool length, enable
Appendix B
Appendix B
54762 $SNS_MEA_FUNCTION_MASK_TOOL Setting for input screen, measuring cycles in Automatic, tool measuring
Bit 4: Select Calibrate Input measuring feed
Bit 5: Select Input feed and spindle speeds for contacting
Bit 7: Select Measure in MCS and WCS
Bit 8: Select Measure absolute and incremental
Bit 9: Select Tool offset Geometry and wear
Bit 10: Select measuring function ”Check teeth individually”
Technology Settings
Bit 11: Selection spindle reversal when calibrating on the plane
Bit 12: Select Number of measurements
Bit 13: Select Empirical values
Bit 14: Select offset correction with selection of direction
54764 $SNS_MEA_FUNCTION_MASK_TURN Setting for input mask, Measuring cycles in Automatic, Workpiece turning
Bit 0: Measure Diameter inside/outside with reversal
Bit 1: Measure Diameter inside/outside “Travel under turning center“?
54780 $SNS_J_MEA_FUNCTION_MASK_PIECE Setting for input screen, Workpiece measurement in JOG

Bit 2: Activate calibration for electronic workpiece probe
Bit 5: Select WO as measuring basis
Page 25
Bit 6: Select WO compensation in basic reference, enable

Bit 7: Select WO compensation in channel basic frame, enable
Bit 8: Select WO compensation in global basic frame, enable
Bit 9: Select WO compensation in settable frame, enable
Bit 16: Selection of workpiece measurement with spindle reversal
Bit 17: Selection align workpiece probe in switching direction
Bit 28: Select adapt tool length, enable
54782 $SNS_J_MEA_FUNCTION_MASK_TOOL Setting for input screen, Tool measuring in JOG
Bit 2: Enable automatic tool measurement
Bit 3: Select tool probe calibration data field, enable
Bit 10: Select measuring function ”Check teeth individually”
Bit 11: Selection spindle reversal when calibrating on the plane
Channel Setting Data
Technology Settings
55200 $SCS_MAX_INP_FEED_PER_REV Feedrate input upper limit for mm/rev
55201 $SCS_MAX_INP_FEED_PER_TIME Feedrate input upper limit for mm/min

55202 $SCS_MAX_INP_FEED_PER_TOOTH Feedrate input upper limit for mm/tooth
55212 $SCS_FUNCTION_MASK_TECH_SET Function mask Cross-technology
Bit 0: Tool preselection active
Bit 1: Calculate thread depth from metric thread lead
Bit 2: Refer to the table for thread diameter and depth
Bit 3: Delete programs generated by contour cycles
55214 $SCS_FUNCTION_MASK_MILL_SET Function mask Milling
Bit 0: Default setting - milling cycles with synchronous operation
Bit 2: Depth calculation in milling cycles without parameter SC
= 0: Depth calculation in milling cycles is carried out between reference plane + safety
clearance and depth
= 1: Depth calculation in milling cycles is carried out without inclusion of the safety clear-
ance
Note: Bit 2 is active with the following milling cycles: CYCLE61, CYCLE71, CYCLE76, CYCLE77,
Page 26
CYCLE79, CYCLE899, LONGHOLE, SLOT1, SLOT2, POCKET3, POCKET4
55216 $SCS_FUNCTION_MASK_DRILL_SET Function mask Drilling

Bit 0: Reverse direction of spindle rotation during tapping
Bit 1: Consider rotation of the tool plane (CYCLE86)
Bit 2: Consider swivelled table kinematics (CYCLE86)
Bit 3: Monitoring spindle MD 31050/31060 (CYCLE84)
Bit 4: Monitoring spindle MD 31050/31060 (CYCLE840)
Bit 5: reserved
Bit 6: Adapt spindle position to the tool orientation (CYCLE86)
Bit 7: Adapt direction of retraction path in the plane to active mirroring (CYCLE86)
55218 $SCS_FUNCTION_MASK_TURN_SET Function mask Turning
Bit 0: New thread table during thread cutting
Bit 1: Reserved (CYCLE93)
Bit 2: Reserved (CYCLE93)
Bit 3: Chamfer in CYCLE930 as chamfer length (CHF)
Bit 4: Retraction from the inside machining (CYCLE951)
Bit 5: Disable new smoothing behaviour in thread cutting cycles
Appendix B
55220 $SCS_FUNCTION_MASK_MILL_TOL_SET Function mask High Speed Settings CYCLE832
Bit 0: Unhide technology fields
Appendix B
Bit 1: Orientation tolerance (OTOL) as a tolerance factor, enter it directly

Bit 2: Mould-making function can be selected in High Speed Settings mask
Bit 3: High Speed Settings mask with Advanced Surface option
Bit 4: Display smoothing selection
Appendix B
Appendix B
55221 $SCS_FUNCTION_MASK_SWIVEL_SET Function mask Swivel CYCLE800
Bit 0: Unhide input field "No swivel"
Bit 1: Selection text for retraction, “fixed point 1” or “fixed point 2”
Bit 2: Show swivel data block "Deselection"
Bit 3: Display active swivel plane in JOG
Bit 4: Positioning in basic position (pole position) of the kinematics
Bit 5: Align tool, absolute (TCOABS)
Bit 6: Do not offer swivel mode “directly” under swivel in JOG
Technology Settings
Bit 7: Swivel plane: Direction selection in initial setting of kinematics
Bit 8: Take into account work offset of rotary axes, swivel data set in Work
Bit 9: Swivel data set TC permanently assigned to the tool
Bit 10: Swivel plane: Display input field “positioning direction”
Bit 11: Swivel plane: Positioning of both solutions AB - display kinematics
Bit 12: Reset behaviour taking into account the rotary axis position
Bit 13: Extended swivel function in pole position
55230 $SCS_CIRCLE_RAPID_FEED Positional feed on circular path
55232 $SCS_SUB_SPINDLE_REL_POS Z retraction position for the counter spindle

Page 27
55260 $SCS_MAJOG_SAFETY_CLEARANCE Safety clearance for machine JOG
55261 $SCS_MAJOG_RELEASE_PLANE Retraction plane for machine JOG
55300 $SCS_EASY_SAFETY_CLEARANCE Simple input: Safety clearance
55301 $SCS_EASY_DWELL_TIME Simple input: dwell time
55305 $SCS_EASY_DRILL_DEEP_FD1 Simple input: percentage 1st federate deep - hole drilling
55306 $SCS_EASY_DRILL_DEEP_DF Simple input: percentage infeed deep - hole drilling
55307 $SCS_EASY_DRILL_DEEP_V1 Simple input: min. depth infeed deep - hole drilling
55308 $SCS_EASY_DRILL_DEEP_V2 Simple input: absolute retraction value deep - hole drilling
55309 $SCS_EASY_THREAD_RETURN_DIST Simple input: return distance thread tapping
55400 $SCS_MILL_ENGRAVE_POINT_RAD Engraving cycle CYCLE60: Circ. path radius for generating the char. ”point”
Technology Settings
55410 $SCS_MILL_SWIVEL_ALARM_MASK Hide and unhide cycle alarms
Bit 0: Display alarm 62186: Active work offset G54 ff. and base (basic reference) contain rotations
Bit 1: Display alarm 62187: Active base and basic reference (G500) contain rotations
Bit 2: Display alarm 61148: Swivel plane not possible with active turning tool
Bit 3: Display alarm 61426: Kinematics measurement with CYCLE9960/996
55420 $SCS_MILL_SWIVEL_RESET_RETRACT Initial setting swivel: retract

= 0: no change
= 1: no
= 2: Z
= 3: Z XY
= 4: Tool direction max.
= 5: Tool direction inc.
55421 $SCS_MILL_SWIVEL_RESET_TRACK Initial setting swivel: tool correction

= 0: no change
= 1: do not correct
= 2: correct
55422 $SCS_MILL_SWIVEL_RESET_MODE Initial setting swivel: swivel mode

Page 28
= 0: axis by axis
= 1: direct
55441 $SCS_MILL_TOL_TECHNO_ROUGH Settings for roughing High Speed Settings cycle CYCLE832 of G group 59
55442 $SCS_MILL_TOL_TECHNO_SEMIFIN Settings for pre-finishing High Speed Settings cycle CYCLE832 of G group 59
55443 $SCS_MILL_TOL_TECHNO_FINISH Settings for finishing High Speed Settings cycle CYCLE832 of G group 59
55446 $SCS_MILL_TOL_VALUE_ROUGH Tolerance value for roughing High Speed Settings cycle CYCLE832
55447 $SCS_MILL_TOL_VALUE_SEMIFIN Tolerance value for pre-finishing High Speed Settings cycle CYCLE832
55448 $SCS_MILL_TOL_VALUE_FINISH Tolerance value for finishing High Speed Settings cycle CYCLE832
Appendix B
Appendix B
Appendix B
Appendix B
55460 $SCS_MILL_CONT_INITIAL_RAD_FIN This data affects the radius of the approach circle during contour pocket finishing.
-1: The radius is selected to maintain a safety clearance to the finishing allowance in the starting
point.
>0: The radius is selected to maintain the value of this setting data to the finishing allowance in the
starting point.
55481 $SCS_DRILL_TAPPING_SET_GG12 Settings for tapping G group 12 cycle CYCLE84 and CYCLE840:
G group 12: Block change behaviour at exact stop (G60)
Technology Settings
0 = Exact stop behaviour, same as before the cycle call
1 = G601
2 = G602
3 = G603
Index[0]: for tool spindle
Index[1]: for main spindle - for drilling in centre
55482 $SCS_DRILL_TAPPING_SET_GG21 Settings for tapping G group 21 cycle CYCLE84:

G group 21: Acceleration profile (SOFT, BRISK, ..)
0 = Acceleration behaviour, same as before the cycle call
1 = SOFT
Page 29
2 = BRISK
3 = DRIVE
55483 $SCS_DRILL_TAPPING_SET_GG24 Settings for tapping G group 24 cycle CYCLE84 and CYCLE840:
G group 24: Feedforward control (FFWON, FFWOF )
0 = Feedforward control, same as before the cycle call
1 = FFWON
2 = FFWOF
55484 $SCS_DRILL_TAPPING_SET_MC Setting for tapping cycle CYCLE84 spindle operation at MCALL
0= Reactivate spindle operation at MCALL
1= Maintain position-controlled spindle operation at MCALL

55489 $SCS_DRILL_MID_MAX_ECCENT Maximum centre offset for centre drilling
55490 $SCS_DRILL_SPOT_DIST Rough drilling depth for drill and thread milling
Technology Settings
55500 $SCS_TURN_FIN_FEED_PERCENT Roughing feedrate for complete machining in %
55505 $SCS_TURN_ROUGH_O_RELEASE_DIST Return distance stock removal for external machining

-1: The distance is specified internally.
55506 $SCS_TURN_ROUGH_I_RELEASE_DIST Return distance stock removal for internal machining

-1: The distance is specified internally.
55510 $SCS_TURN_GROOVE_DWELL_TIME Tool clearance time for grooving at the base (neg. value=revolutions)
- Negative value in spindle revolutions
- Positive value in seconds
55540 $SCS_TURN_PART_OFF_CTRL_DIST Path for cut-off check
55541 $SCS_TURN_PART_OFF_CTRL_FEED Feedrate for cut-off check
55542 $SCS_TURN_PART_OFF_CTRL_FORCE Force for cut-off check, in %
55543 $SCS_TURN_PART_OFF_RETRACTION Retraction path prior to cut-off with counter spindle

Page 30
55550 $SCS_TURN_FIXED_STOP_DIST Counterspindle: path for travel to fixed stop

(see setting data 55551 $SCS_TURN_FIXED_STOP_FEED).
55551 $SCS_TURN_FIXED_STOP_FEED Counterspindle: feedrate for travel to fixed stop
In setting data 55550 $SCS_TURN_FIXED_STOP_DIST you specify the distance after which the
tool travels in this feedrate.
55552 $SCS_TURN_FIXED_STOP_FORCE Counterspindle: force for travel to fixed stop, in %
55553 $SCS_TURN_FIXED_STOP_RETRACTION Counterspindle: retraction path prior to chucking after fixed stop
55580 $SCS_TURN_CONT_RELEASE_ANGLE Counter turning: retraction angle
55581 $SCS_TURN_CONT_RELEASE_DIST Counter turning: retraction value
55582 $SCS_TURN_CONT_TRACE_ANGLE Counter turning: minimum angle for rounding along contour
Appendix B
Appendix B
Appendix B
Appendix B
55583 $SCS_TURN_CONT_VARIABLE_DEPTH Counter turning: percentage for variable cutting depth
55584 $SCS_TURN_CONT_BLANK_OFFSET Counter turning: blank allowance
55585 $SCS_TURN_CONT_INTERRUPT_TIME Counter turning: feed interrupt time (neg. value=revolutions)

- Negative value in spindle revolutions
- Positive value in seconds
Technology Settings
This setting data is effective only if setting data 55586 is 55586
$SCS_TURN_CONT_INTER_RETRACTION = 0.
55586 $SCS_TURN_CONT_INTER_RETRACTION Counter turning: retraction path after feed interrupt

>0: Retraction path after feed interrupt (setting data 55585
$SCS_TURN_CONT_INTERRUPT_TIME is ineffective!)
=0: No retraction path
55587 $SCS_TURN_CONT_MIN_REST_MAT_AX1 Counter turning: minimum difference dimension residual machining axis 1
Example:
If this MD is set to 50% and if the finishing allowance is 0.5 mm, the residual material which is
thinner than 0.25 mm is not removed in a separate machining step, but during finishing.
Page 31
55588 $SCS_TURN_CONT_MIN_REST_MAT_AX2 Counter turning: minimum difference dimension residual machining axis 2
Example:
If this MD is set to 50% and if the finishing allowance is 0.5 mm, the residual material which is
thinner than 0.25 mm is not removed in a separate machining step, but during finishing.
55595 $SCS_TURN_CONT_TOOL_BEND_RETR Counter plunge turning: retraction path due to tool bending
In this setting data you specify the lateral distance to the last cut, by which each next cut will be
shortened.
55596 $SCS_TURN_CONT_TURN_RETRACTION Counter plunge turning: retraction path prior to turning

Technology Settings
55613 $SCS_MEA_RESULT_DISPLAY Selection of measurement result display

=0: No measurement result display
=1: The measurement result is displayed until cycle end
=2: The measurement result is displayed until the start/call of the next cycle
=3: With the measurement result display, the cycle is stopped by an internal M0, with NC start,
the measuring cycle is continued and the measurement result display is deselected
=4: The measurement result display is only shown for cycle alarms 61303, 61304, 61305, 61306
Same behavior as with setting 3!
55614 $SCS_MEA_RESULT_MRD Program control of the display of the measurement result display MRD
=0: Hide measurement result display
=1: Show measurement result display
55618 $SCS_MEA_SIM_ENABLE Setting measuring cycles under a simulated environment

= 0: Measuring cycles are not executed (measuring cycle is skipped internally)
= 1: Measuring cycles are executed; real axes are required!
During calibration no values are entered in the probe data fields,
no measurement result is displayed,
the measuring cycle is not logged,
the travel is performed without collision detection.
Page 32
55619 $SCS_MEA_SIM_MEASURE_DIFF Value for simulated error of measurement

Provided that SD55618 $SCS_MEA_SIM_ENABLE=1 is used and that the measuring cycles are
executed in a simulated environment of HMI Advanced or ShopMill / ShopTurn, a measurement
difference can be entered in this parameter. The value of the measurement difference must be
smaller than the measuring path in parameter _FA!
Otherwise cycle alarm 61301 "Probe does not switch" is output during active simulation.
55622 $SCS_MEA_EMPIRIC_VALUE_NUM Number of empirical values
55623 $SCS_MEA_EMPIRIC_VALUE Empirical value memory

Using parameter $SCS_MEA_EMPIRIC_VALUE_NUM the number of memory elements can be
defined! Currently, however, these 20 memory elements can-not be changed!
In the empirical value memory, empirical values can be stored which are cleared with the currently
calculated difference between the setpoint and the actual value.
Using parameter _EVNUM the empirical value element to be cleared is addressed!
Appendix B
55624 $SCS_MEA_AVERAGE_VALUE_NUM Number of mean values
Appendix B
Appendix B
Appendix B
55625 $SCS_MEA_AVERAGE_VALUE Mean value memory
Using parameter $SCS_MEA_AVERAGE_VALUE_NUM the number of memory elements can be
defined! Currently, however, these 20 memory elements can-not be changed!
In the mean value memory, the mean values calculated in connection with functionality "Automatic
tool offset with mean value creation" are stored.
Using parameter _EVNUM the mean value element to be used is addressed!
55628 $SCS_MEA_TP_FEED_MEASURE Feed for calibrating a tool probe
Technology Settings
55630 $SCS_MEA_FEED_MEASURE Feed for calibrating a workpiece probe
55631 $SCS_MEA_FEED_MEASURE_DEG Measurement feedrate of workpiece probe during positioning of a rotary axis
55632 $SCS_MEA_FEED_RAPID IN_PERCENT Rapid traverse velocity in per cent for intermediate positioning
55634 $SCS_MEA_FEED_PLANE_VALUE Traverse velocity for intermediate positioning in the plane

Page 33
55636 $SCS_MEA_FEED_FEEDAX_VALUE Positioning velocity in the infeed axis
55637 $SCS_MEA_FEED_POS_DEG Feedrate when positioning a rotary axis between individual measurements
55638 $SCS_MEA_FEED_FAST_MEASURE Rapid measuring feed

The use of "Rapid measuring feed" depends of SD55740 $SCS_MEA_FUNCTION_MASK Bit4!
55640 $SCS_MEA_FEED_CIRCLE Circular feed for measuring circle segment
55642 $SCS_MEA_EDGE_SAVE_ANG Additional safe angle for measuring corner

Set $SCS_MEA_EDGE_SAVE_ANG=10 for compatibility programs.
Technology Settings
55644 $SCS_MEA_KIN_DM_TOL Measure kinematics: Tolerance of diameter of calibration ball
55645 $SCS_MEA_KIN_MODE Free component of the linear vector
55646 $SCS_MEA_KIN_VALUE Measure kinematics completely: value of the linear vector
55647 $SCS_MEA_KIN_MIN_ANG_TRIANGLE Minimum interior angle of the measurement triangle
55648 $SCS_MEA_KIN_MIN_ANG_POS Minimum angle when positioning a rotary axis
55649 $SCS_MEA_KIN_BALL_VEC Perform complete kinematics measurement: Vector of the ball mounting
55730 $SCS_MEA_PROTOCOL_USER_EXT File extension for application protocol
55740 $SCS_MEA_FUNCTION_MASK Function mask for measuring cycles, workpiece and tool measuring
Bit 0: Workpiece, collision monitoring for intermediate positioning
Page 34
Bit 1: Workpiece, coupling spindle with coordinate rotation around infeed axis
Bit 2: Workpiece, for coupling of spindle pos., reverse positioning direction
Bit 3: Workpiece, do not repeat if the probe does not switch
Bit 4: Workpiece, 1st probing for each measurement with fast measuring feedrate
Bit 5: Workpiece, fast retraction after measurement
Bit 6: Workpiece, deactivate probe during spindle positioning
Bit 7: Kinematics, normalization based on the input values of rotary axis vectors
Bit 8: Kinematics, measurement with active swivel (TCARR) or active TRAORI
Bit 9: Kinematics, user-specific scaling of rotary axis vectors
Bit 10: Complete kinematics measurement with reference
Bit 11: Kinematics, number of measuring points for measuring the calibration ball
Bit 15: Workpiece, calib. Radius with start point at venter of ring, only in JOG
Bit 16: Tool, collision monitoring for intermediate positioning
Bit 17: Tool, do not repeat if the probe does not switch
Bit 19: Tool, fast retraction after measuring
Bit 28: Continuous standard protocol for measurement in JOG (append)
Bit 29: Table format for standard protocol for measurement in JOG
Appendix B
55774 $SCS_J_MEA_PROTOCOL_FILE Name and path of protocol file for measurement in JOG
Appendix B
Appendix B
Appendix B
55800 $SCS_ISO_M_DRILLING_AXIS_IS_Z Selection of the drilling axis

0: Drilling axis is vertical to the active plane
1: Drilling axis is always "Z", independently of the active plane
55802 $SCS_ISO_M_DRILLING_TYPE Tapping type

0: Tapping without compensating chuck
1: Tapping with compensating chuck
Technology Settings
2: Deep hole tapping with chip breakage
3: Deep hole tapping with stock removal
55804 $SCS_ISO_M_RETRACTION_FACTOR Factor for retraction speed (0...200%)
55806 $SCS_ISO_M_RETRACTION_DIR Retraction direction for precision drilling and reverse counter-sinking G76/G87
0: G17(-X) G18(-Z) G19(-Y)
1: G17(+X) G18(+Z) G19(+Y)
2: G17(-X) G18(-Z) G19(-Y)
3: G17(+Y) G18(+X) G19(+Z)
4: G17(-Y) G18(-X) G19(-Z)
Page 35
55807 $SCS_ISO_M_TAPPING_SET_MC Setting tapping G84: Spindle mode/position control
55808 $SCS_ISO_T_RETRACTION_FACTOR Factor (1-200%) for retraction speed at tapping G84/G88
55810 $SCS_ISO_T_DWELL_TIME_UNIT Dwell time evaluation for deep hole drilling G83/G87
0: Seconds
1: Revolutions
55818 $SCS_ISO_M_FUNCTION_MASK Function mask for ISO milling mode

Bit 0: Reserved
55819 $SCS_ISO_T_FUNCTION_MASK Function mask for ISO turning mode
Bit 0: Without complete residual corner cut
Bit 1: Stock removal roughing without tool nose radius compensation
Technology Settings
55820 $SCS_FRICT_OPT_RADIUS Circle radius for optimizing friction compensation
55821 $SCS_FRICT_OPT_RADIUS_ROT Circle radius for optimizing friction compensation for rotary axes
55822 $SCS_FRICT_OPT_FEED Feedrates for optimizing friction compensation
55823 $SCS_FRICT_OPT_FEED_ROT Feedrates for optimizing friction compensation for rotary axes
55824 $SCS_FRICT_OPT_STEP Step number for optimizing friction compensation
55826 $SCS_FRICT_OPT_ACT_STEP Current step number for optimizing friction compensation
55828 $SCS_FRICT_OPT_DIR_MINUS Direction of rotation for optimizing friction compensation
55844 $SCS_GRIND_MEA_KIN_TOL Kinematic measurement: Tolerance of kinematic vectors

Page 36
55880 $SCS_GRIND_CONT_RELEASE_ANGL Grinding - profiling: retraction angle

E
55881 $SCS_GRIND_CONT_RELEASE_DIST Grinding - profiling: retraction value
55884 $SCS_GRIND_CONT_BLANK_OFFSET Grinding - profiling: blank allowance
Appendix B
Appendix B
Appendix B: END
Anhang A PLC Interface
Sinumerik
Operate
PLC Interface:
START
DB3000
DB3100
Operating
Mode Signals
Machine
Control
Panel
DB3200
DB3300
NC
Channels
DB1000
DB1100
User Area
DB3400
ASUP
Signals
DB1200
DB1400
PI Services
DB3700
DB3800
DB3900
Axis/Spindle
DB1600
PLC User
Alarms
DB4000
Tool
Management
DB1700
DB1800
DB1900
HMI Signals
DB4500
PLC
Machine
Data
DB2500
AUX
Functions
Sinumerik
DB9900
User
Interface
DB2600
DB2700
NC
Signals
PLC Interface:
END
DB2800
DB2900
Fast NC I/O
Siemens assumes no responsibility for its contents. Appendix C
Appendix C PLC Interface Structure
Machine Control Panel
Machine Control Panel MCP483 PN

During commissioning the MCP address range is set to start at Input and output Bytes 112.
MCP483 PN Signals from machine control panel (keys)

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

QB112
INC 1000 INC 100 INC 10 INC 1 JOG TEACH IN MDA AUTO
QB113 Feed Feed NC Start NC Stop REPOS REF INC var. INC 10000
start stop
Direction X 4th axis 7th axis Single Spindle start Spindle stop
QB114 Minus R1 R4 R7 R10 block
R13
Z 5th axis MCS/WCS 8th axis 6th axis Direction

QB115 R3 R5 R11 R9 R8 R6 Plus
R15
Unassigned customer keys Y
QB116
T9 T10 T11 T12 T13 T14 T15 R2
QB117
T1 T2 T3 T4 T5 T6 T7 T8
QB118 Reset R14
QB119 KT6 KT5 KT4 KT3 KT2 KT1
Notes :
Appendix C Page 2 SINUMERIK 828D

PLC Interface Structure Appendix C
Machine Control Panel MCP310 PN
During commissioning the MCP address range is set to start at Input and output Bytes 112.
MCP310 PN Signals from machine control panel (keys)

IB112 *NC Stop Spindle - Spindle 100% Spindle + Single block JOG MDA AUTO
IB113 NC Start Spindle right *Spindle stop Spindle left Key-switch REF REP Teach IN
position 3
Feed start *Feed stop INC var. Key-switch posi-
IB114 tion 0
INC 1000 INC 100 INC 10 INC 1
Feedrate override
IB115 Reset Key- Key-switch E (16) D (8) C (4) B (2) A (1)
switch position position 1
2
Direction keys
IB116
+ - Rapid traverse KT5 (X52.2) KT4 (X52.1) KT3 (X51.3) KT2 (X51.2) KT1(X51.1)
Axis selection
IB117 T16 KT6(X52.3) 6th axis 5th axis 4th axis Z Y X
IB118 T9 T10 T11 T12 WCS MCS T13 T14 T15

IB119 T1 T2 T3 T4 T5 T6 T7 T8
IB123 KT9
Spindle override
IB125
E (16) D (8) C (4) B (2) A (1)
MCP 310 PN Signals to machine control panel (LEDs)

QB112 NC Stop Spindle Dec. Spindle 100% Spindle Inc. Single Block JOG MDA AUTO
QB113 NC Start Spindle right Spindle Stop Spindle left RESET REF REPOS Teach In
QB114 Feed Start Feed Stop INC var. INC 1000 INC 100 INC 10 INC 1
QB115
QB116 Minus Plus Rapid trav- KT5 KT4 KT3 KT2 KT1
Direction Direction erse
QB117 T16 KT6 6th axis 5th axis 4th axis Z Y X
QB118 T9 T10 T11 T12 MCS/WCS T13 T14 T15
QB119 T1 T2 T3 T4 T5 T6 T7 T8
Notes :
SINUMERIK 828D Page 3 Appendix C

User Area (DB1000, DB1100)
User Data Areas

There are two areas set aside for free use within the user PLC.
DB1000-
User Data 1 [r/w]
DB1001
0000
User Data
up to
0011 User Data
Input image for MCP483 USB, MCP310 USB and MCP416 USB
DB1000-
User Data 1 [r/w]
DB1001

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

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

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

2) For MCP310USB, preassigned with ”Coolant”, for MCP483 USB and MCP416 USB freely assignable customer key.
3) Key not available for MCP310 USB, for MCP483 USB and MCP416 USB freely assignable customer key.
Notes :

User Data Areas-continued
DB1100- User Data 2 [r/w]

DB1101
0000
up to User Data
0015
User Data
Output image for MCP483 USB, MCP310 USB and MCP416 USB
DB1100-
User Data 2 [r/w]
DB1101
Operating mode
0000
JOG Teach IN MDA AUTO
Feed start Feed stop NC start NC stop Machine function -

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

0003 mand in
MCS/WCS
0004
S18 S40 (res.) 2) S7 1) S21 - - - S32
0005
S10 S11 S12 S13 S14 S15 S16 S17
0006 - - - - - - Reset S23
0007 - - - - - - - -
0010 - - - - - - - -
0011 - - - - - - - -
DP
0012
- - - - - - DP2 DP1
0013
0014 User data
0015 User data
1) For MCP310 USB, preassigned with ”Coolant”, for MCP483 USB and MCP416 USB freely assignable customer key.
2) Key not available for MCP310 USB, for MCP483 USB and MCP416 USB freely assignable customer key.
Notes :

7-Segment display
The MCP USB has a 2-position 7-segment display. To output a character, write the ASCII code as hexadecimal value of the
character to the output image. For the signs q, b, r, d, t, y, n, o, only the code works for the capital letters
Example: To display the number “2“, you must write hexadecimal value 32 and for "p" the hexadecimal value 50 write to
the output image.
The representable signs are yellow marked.
DB1100/DB1101.DBB8 7-segment-display left

DB1100/DB1101.DBB9 7-segment-display right
ASCII-character table
Notes :

PI Services (DB1200)
Reading/Writing of NC data
It is possible to read/write data too/from the NC &PLC. Variables are available to facilitate this function.
Below:- Defining read or write, how many variables and setting the start Signal.
DB1200 PLC NC [r/w]
0000 Read:0 Start

Write:1
0001 Number of variables to be read/written
Below:-Information regarding the variable has to be written to the following areas. Up to eight sets of data can be moved in one
go.
DB1200- PLC NC [r/w]

DB1207
1000 Variable Index
1001 Area Number
1002 Line index for NC variable x (Word)
1004 Column index for NC variable x (Word)
1006
1008 Writing data to NC variable x (1 to 4 bytes) *1)
1012
1016 Writing data to NC variable x (REAL) *2)
1020 Writing data to NC variable x (DWORD / DINT) *2)
1024 Writing data to NC variable x (WORD / INT) *2)
1026 Writing data to NC variable x (BYTE) *2)
1027 Writing data

to NC varia-
ble x (BOOL)
*2)
*1) Only for predefined variables of the "Read/write NC variable" user interface
*2) Only for variables from DB9910, DB9911, DB9912 NC_DATA
Notes :

Results:-The results of the task are output to the following areas:-

DB1200 NC PLC [r]
2000 Error in job Request

Complete
2001
DB1200- NC PLC [r]

DB1207
3000 Fault Valid Variable
3001 Access result

0: No error, 3: Access to object is not permitted, 5: Invalid address, 10: Object does not exist
3002
3004 Reading data from NC variable x (1 to 4 bytes) *1)
3008
3012
3016 Reading data from NC variable x (REAL) *2)
3020 Reading data from NC variable x (DWORD / DINT) *2)
3024 Reading data from NC variable x (WORD / INT) *2)
3026 Reading data from NC variable x (BYTE) *2)
3027 Reading data

from NC
variable x
(BOOL) *2)
*1) Only for predefined variables of the "Read/write NC variable" user interface
*2) Only for variables from DB9910, DB9911, DB9912 NC_DATA
PI Services
DB1200 PLC NC [r/w]
4000 Start
4001 PI-Index
4002
4003
4004 PI-Parameter 1
4006 PI-Parameter 2
etc
4022 PI-Parameter 10
Notes :

PI Services:- Result
5000 Fault Finished
5001
5002
Retentive Data Area
DB1400 Retentive Data [r/w]
User area
0000
User area
0001
etc
User area
0127
PLC User Alarms (DB1600)

DB1600 Activating alarms (Alarm number range 700000 to 700247) PLC HMI [r/w]
0000 700007 700006 700005 700004 700003 700002 700001 700000
0001 700015 700014 700013 700012 700011 700010 700009 700008
0002 700023 700022 700021 700020 700019 700018 700017 700016
0003 700031 700030 700029 700028 700027 700026 700025 700024
etc
0030 700247 700246 700245 700244 700243 700242 700241 700240
DB1600 Variable for alarm PLC HMI [r/w]
1000 Variable for alarm 700000 (4 bytes)
etc
Notes :

DB1600 Active alarm response HMI PLC [r]
Channel 1
2000 Acknowledge Acknowledge PLC Stop Em. Stop Feed disa- Read-in NC start
with power ON with DB1600. ble disable disable
DBX3000.0
Channel 2
2001 Feed disa- Read-in NC start

ble disable disable
DB1600 Alarm acknowledgement PLC HMI [r/w]
3000 Acknowledg
e
Extended User Alarms

DB1600 Activating alarms (Alarm number range 701000 to 701247) PLC HMI [r/w]
4000 701007 701006 701005 701004 701003 701002 701001 701000
4001 701015 701014 701013 701012 701011 701010 701009 701008
4002 701023 701022 701021 701020 701019 701018 701017 701016
4003 701031 701030 701029 701028 701027 701026 701025 701024
etc
4124 701999 701998 701997 701996 701995 701994 701993 701992
DB1600 Variable for alarm PLC HMI [r/w]
etc
Notes :

HMI Signals (DB1700, DB1800, DB1900)
Program Control Signals

DB1700- HMI signals HMI PLC [r]
DB1701
0000 Test run M01 DRF

Feedrate Selected Selected
selected
0001 Program test Feedrate over-

selected ride
(Rapid) selected
0002 Skip Skip block 6 Skip block 5 Skip block 4 Skip block 3 Skip block 2 Skip Skip block
block 7 selected selected selected selected selected block 1 0
selected selected selected
0003 Skip Skip

block 9 block 8
selected selected
0007 Reset NC stop NC start
Program selection
DB1700- Interface PLC HMI [r/w]
DB1701
1000 Part program Disable teach
selection transfer
1001 Always 1 Part program handling: Number of the control data base for user file names
1002 Part program handling: Index of the file to be transferred from the user list
DB1700- Interface HMI PLC [r]

DB1701
Part program handling status

2000
Selection Loading Unloading Active Error OK
2001 Error program handling
SMS Messenger
DB1700- Interface SMS messenger PLC [r]
DB1701
3000 Variable-Settable via SMS
Notes :

Signals from HMI
DB1800 HMI PLC [r]
0000 Reset JOG mode MDA mode AUTO

mode
0001 Machine Machine Machine

function:- function:- function:-
REF REPOS TEACH IN
Note:- Signals present for only one plc cycle.
Signals from PLC

DB1800 Signals from PLC [r]
1000 Start-up ar- Power up Power up

chive was with saved with default
read in data values
1002
1004 PLC cycle time in micro seconds (Double Integer)
1008 Year (Tens) BCD Year (Units) BCD
1009 Month (Tens) BCD Month (Units) BCD

1010 Day (Tens) BCD Day (Units) BCD
1011 Hour (Tens) BCD Hour (Units) BCD
1012 Minute (Tens) BCD Minute (Units) BCD
1013 Second (Tens) BCD Second (Units) BCD
1014 Millisecond (Hundreds) BCD Millisecond (Tens) BCD

1015 Millisecond (Units) BCD Weekday BCD (1, 2…….7) 1 = Sunday
1016 Configured number of mode groups
1018 Maximum channel number
1020 Maximum axis number
1022 Current channel distribution
Channel 2 Channel 1
1023 Reserved
1024 Current axis distribution
Axis 8 Axis 7 Axis 6 Axis 5 Axis 4 Axis 3 Axis 2 Axis 1
1025 Current axis distribution
Axis 12 Axis 11 Axis 10 Axis 9
1026 Reserved
Notes :

Maintenance Planner
DB1800 PLC HMI Deactivate Maintenance Task [r/w]
Deactivate Maintenance Task

2000
8 7 6 5 4 3 2 1
2001
16 15 14 13 12 11 10 9

2002
24 23 22 21 20 19 18 17
2003
32 31 30 29 28 27 26 25
DB1800 HMI PLC Alarm for Maintenance Task [r]
Alarm for Maintenance Task

3000
8 7 6 5 4 3 2 1
3001
16 15 14 13 12 11 10 9
3002
24 23 22 21 20 19 18 17
3003
32 31 30 29 28 27 26 25
DB1800 PLC HMI Maintenance task acknowledgement [r/w]
Maintenance Task acknowledgement

4000
8 7 6 5 4 3 2 1
4001
16 15 14 13 12 11 10 9
4002
24 23 22 21 20 19 18 17
4003
32 31 30 29 28 27 26 25
Notes :

Maintenance Planner-continued
DB1800 PLC HMI Disable Maintenance task acknowledgement [r/w]
Disable Maintenance task acknowledgement

5000
8 7 6 5 4 3 2 1
5001
16 15 14 13 12 11 10 9
5002
24 23 22 21 20 19 18 17
5003
32 31 30 29 28 27 26 25
Signals from operator panel

0000 Switch over Simulation Cancel
MCS/WCS active
0001 Active HMI area
0002 Channel number displayed by the HMI software
0003 Proximity Screen Data transfer Keyboard has

sensor active change ac- active been used
tive
0004 Active JobShop area
0006 Reserved
0008 Reserved
0010 Reserved
0011 bis Error code for function selection number

0015 Function selection from DBB5021
0016 Reserved
0018 Reserved
0020 Simulation state
Error code for function selection number:

0 No error
1 Function selection number is missing (DBB5021 Bit 0 … 5)
2 Invalid parameter
3 Internal error
10 Channel does not exist
Notes :

Signals from operator software, Sidescreen - Interface for MCP function
Customer keys
0022
8 7 6 5 4 3 2 1
Customer keys
0023
16 15 14 13 12 11 10 9
Customer keys
0024
24 23 22 21 20 19 18 17
Customer keys
0025
32 31 30 29 28 27 26 25
Customer keys
0026
40 39 38 37 36 35 34 33
Customer keys
0027
48 47 46 45 44 43 42 41
Customer keys
0028
56 55 54 53 52 51 50 49
Customer keys
0029
64 63 62 61 60 59 58 57
0030 Reserved
0031 Reserved
Signals from operator software

Channel number for hand-wheel 1
1000
C B A

1001
C B A

1002
C B A
Notes :

Signals from operator software-continued

Hand-wheel 1 Axis number for hand-wheel 1
1003
Machine axis Hand-wheel Contour hand C B A
selected -wheel

1004
selected -wheel

1005
selected -wheel
1006 Reserved
1007 Language ID of the HMI software
Collision avoidance: Deactivate protection zone group
1008 For operating mode: JOG For operating mode::AUTO
Workpiece Workholder Tools Machine Workpiece Workholder Tools Machine
Signals to operator software

DB1900 PLC HMI [r/w]
5000 Actual values Key disable Screen dark

in WCS
(0=MCS)
5001 External External view-

viewer monitor- er not
ing only permitted
5002
5003 PLC Hardkeys (Range of values 1….255, 0 is start position
5004
5006 Analog spindle 1, utilization as a percentage
5007 up to Reserved
5020
5021 Busy Strobe Function selection number from PLC

function function
5022 Parameter 1 for function selection number, function selection from DBB5021
5025 Reserved
Notes :

Signals to operator software, Sidescreen - Interface for MCP function
DB1900 PLC HMI [r/w]
Customer LED
5026
8 7 6 5 4 3 2 1
Customer LED
5027
16 15 14 13 12 11 10 9
Customer LED
5028
24 23 22 21 20 19 18 17
Customer LED
5029
32 31 30 29 28 27 26 25
Customer LED
5030
40 39 38 37 36 35 34 33
Customer LED
5031
48 47 46 45 44 43 42 41
Customer LED
5032
56 55 54 53 52 51 50 49
Customer LED
5033
64 63 62 61 60 59 58 57
Customer key deactivated

5034
8 7 6 5 4 3 2 1

5035
16 15 14 13 12 11 10 9

5036
24 23 22 21 20 19 18 17

5037
32 31 30 29 28 27 26 25
5038
40 39 38 37 36 35 34 33

5039
48 47 46 45 44 43 42 41

5040
56 55 54 53 52 51 50 49

5041
64 63 62 61 60 59 58 57
5042 Reserved
5043 Reserved
Notes :

Auxiliary functions (DB2500)
Auxiliary functions from NC channel

DB2501
0000 up to
0003
0004 M fcts.5 M fcts.4 M fcts.3 M fcts.2 M fcts.1

change change change change change
0005
0006 S fcts.1
change
0007
0008 T fcts.1
change
0009
0010 D fcts.1
change
0011
0012 H fcts.3 H fcts.2 H fcts.1

change change change
0013 up to
0019
Decoded M signals (M0-M99)

DB2501
1000 Dynamic M functions

M1=5 M1=4 M1=3
M7 M6 M5 M4 M3 M2 M1 M0
M15 M14 M13 M12 M11 M10 M09 M08
M23 M22 M21 M20 M19 M18 M17 M16
etc
Dynamic M functions
1012
M99 M98 M97 M96
1013 up to
1015
Note:- Signals present for only one plc cycle.
Notes :

Transferred T functions

DB2501
2000 T function 1 (DINT)
2004
up to
2007
Transferred M functions

DB2501
3000 M function 1 (DINT)
3004 Extended address of M function 1 (Byte)
Transferred S functions
DB2501
4000 S function 1 (REAL)
4004 Extended address of S function 1 (Byte)
4008 S function 2 (REAL)
4012 Extended address of S function 2 (Byte)
4016
4020
Transferred D functions

DB2501
5000 D function 1 (DINT)
5004
Notes :

Transferred H functions

DB2501
6000 H function 1 (REAL)
6004 Extended address of H function 1 (Byte)
NC Signals (DB2600, DB2700)
General Signals to NC
Protection level: Key-operated switch position 0 to 3 Acknowledge Emergency Braking on

emergency stop the contour
0000 stop with emer-
4 5 6 7 gency stop
Request axis Request INC inputs in
distances to Actual values mode signal
0001 go (*1) (*1) range active
Collision avoidance: Deactivate protection zone group
0002 For operating mode: JOG For operating mode::AUTO
Workpiece Workholder Tools Machine Workpiece Workholder Tools Machine
0003
(*1) Used in conjunction with Data blocks DB5700 to DB5711.
Notes :

General Signals to NC-continued

Collision avoidance: Activate protection zone

0004
7 6 5 4 3 2 1 0

0005
15 14 13 12 11 10 9 8

0006
23 22 21 20 19 18 17 16

0007
31 30 29 28 27 26 25 24

0008
39 38 37 36 35 34 33 32

0009
47 46 45 44 43 42 41 40

0010
55 54 53 52 51 50 49 48

0011
63 62 61 60 59 58 57 56
Signals from the roboter

1000 Roboter status byte 0
Notes :

General Signals from NC

0000 Emergency
stop active
0001 INCH measur- Probe 2 Probe 1

ing system actuated actuated
NC Ready Drive ready Drives in HMI ready

0002 cyclic opera-
tion
0003 Air temp. NC alarm is

alarm active
0004
0005
0006
0007
0008
0009
0010
0011
0012 Change counter for motions of hand-wheel 1
0015 Change counter, inch metric unit system
0016
0017
0018
0019
Notes :

General Signals from NC-continued

Collision avoidance: Protection zone active

0020
7 6 5 4 3 2 1 0

0021
15 14 13 12 11 10 9 8

0022
23 22 21 20 19 18 17 16

0023
31 30 29 28 27 26 25 24

0024
39 38 37 36 35 34 33 32

0025
47 46 45 44 43 42 41 40

0026
55 54 53 52 51 50 49 48

0027
63 62 61 60 59 58 57 56
Signals from the roboter

Notes :

Fast NC I/O (DB2800, DB2900)
Signals to fast inputs and outputs
Disable digital NC inputs

0000
Input 8 Input 7 Input 6 Input 5 Input 4 Input 3 Input 2 Input 1
Values from the PLC for digital NC inputs
0001
Disable digital NC outputs
0004
Output 8 Output 7 Output 6 Output 5 Output 4 Output 3 Output 2 Output 1
Overwrite mask for digital NC outputs
0005
Values from the PLC for digital NC outputs
0006
Setting mask for digital NC outputs
0007
Disable external digital NC inputs
1000
Input16 Input15 Input14 Input13 Input 12 Input11 Intput10 Input 9
Values from the PLC for the external digital NC inputs
1001
Input16 Input15 Input14 Input13 Input12 Input11 Input10 Input 9
Disable external digital NC outputs
1008
Ouput16 Output15 Output14 Output13 Output12 Output11 Output10 Output9
Overwrite mask for external digital NC outputs
1009
Output16 Output15 Output14 Output13 Output12 Output11 Output10 Output 9
Values from PLC for the external digital NC outputs
1010
Setting mask for external digital NC outputs
1011
Notes :

Signals from fast Inputs & Outputs

DB2900 PLC NC [r]
Actual values for digital NC inputs
0000
Set-points for digital NC outputs
0004

Actual values of external digital NC inputs
1000
Set-points of external digital NC outputs
1004
Output16 Output15 Output14 Output13 Output12 Output11 Output10 Output9
Operating Mode Signals (DB3000, DB3100)
DB3000- PLC NC [r/w]

DB3001
Mode group Mode group Mode group Mode change Operating mode
reset *1) stop axes & stop *1) disable
0000 spindle *1)
JOG MDA Auto
Single block Single block Machine function

0001 Type A Type B
REF REPOS Teach in
Machine function (to use the INC function DB2600.DBX1.0 must be set to 1)
0002 Continuous INC var. INC 10000 INC 1000 INC 100 INC 10 INC 1
travel
0003

DB3101
All channels Mode group Mode group Active operating mode
0000 in the reset reset ready
state *1) executed *1)
JOG MDA Auto
Active Machine function

0001
REF REPOS Teach in
0002 Continuous INC var. INC 10000 INC 1000 INC 100 INC 10 INC 1
travel
0003
(*1) Signals only available/valid with multi-channel configuration.
Notes :

Channel-specific Signals (DB3200, DB3300)

Signals to NC channel
DB3201

Activate dry run Activate M01 Activate single Activate DRF Activate feed Activate re-
0000 feedrate block (*1) forward verse travel
Activate program Enable protec- Activate

0001 test tion zones referencing
Activate skip Activate skip Activate skip Activate skip Activate skip block Activate skip Activate skip Activate skip
0002 block 7 block 6 block 5 block 4 3 block 2 block 1 block 0
Feed-rate override (31 position gray code)

0004
H G F E D C B A
Rapid traverse override (31 position gray code)

0005
H G F E D C B A
Feed-rate Rapid traverse Limited path Program level Delete number of Delete dis- Read-in disable Feed-rate
0006 override override active velocity abort subroutine cycles tance to go disable
active (*2)
Reset Suppress NC stop axis plus NC stop NC stop at NC start NC start lock
0007 Start Lock spindle block limit
Activate machine related protection zone

0008
Area 8 Area 7 Area 6 Area 5 Area 4 Area 3 Area 2 Area 1
Activate machine related protection zone

0009
Area 10 Area 9
Activate channel specific protection zone

0010
Activate channel specific protection zone

0011
Area 10 Area 9
0012
Do not lock Deactivate Activate fixed Activate fixed Activate fixed Activate fixed
0013 tool workpiece feedrate 4 feedrate 3 feedrate 2 feedrate 1
counter
No tool change Jog circles Activate associ- Neg. direction for Sim. contour hand Activate contour hand wheel
commands ated M01 sim. contour wheel ON (bit/binary-coded)
h/wheel
Handwheel Handwheel Handwheel
0014 3 2 1
Activate skip Activate skip Invert contour

0015 block 9 block 8 hand wheel
direction of
rotation
0016 Control
program
branching
(GOTOS)
0017 Value from PLC for NC grinding inputs $AC_IN_KEY_G[1…8]
0018 Blocking the digital NC grinding inputs from the PLC
0019 Status of the digital NC grinding outputs from the PLC $AC_IN_KEY_G_RUN_IN[1…8]
(*1) Select single block type (SBL1, SBL2) via soft-key.

(*2) Even if feed-rate override is not active (=100%) the 0% is still effective.
Notes :

Control signals to geometry axis (Axis in WCS)

DB3201
Geometry axis 1 (Axis 1 in WCS)

1000
Traversing keys Rapid trav- Traversing key Feedrate stop Activate handwheel (*1)
erse override lock
+ - 3 2 1
1001
Machine function (*2)
Continuous Inc var INC10000 INC1000 INC100 INC10 INC1
travel
1002
1003 Invert hand-

wheel direc-
tion of rot.
1004
erse override lock
+ - 3 2 1

1005
travel
1006
1007 Invert hand-

wheel direc-
tion of rot.
1008
erse override lock
+ - 3 2 1

1009
travel
1010
1011 Invert hand-

wheel direc-
tion of rot.
(*1) The type of numbering for the hand-wheel is determined by machine data
11234 HANDWH_VDI_REPRESENTATION (0=bit coded, 1=binary coded).
(*2) Machine function:- Only if DB2600.DBX1.0 is not set.
Notes :

Signals from NC channel

DB3301
Last action M0/M01 Approach Action block Forward Reverse travel Program
block active Active block activate Travel active active execution
active from
0000
external ac-
tive
Program test Transfor- M2/M30 Block search Hand-Wheel Rev. Referencing
0001 active mation active active active override feed-rate active
active active
0002
Channel status Program status
0003 Reset Interrupted Active Aborted Interrupted Stopped Wait Running
NC alarm Specific NC Channel All axes sta- All axes ref- Stop Start
with alarm is ac- ready tionary erenced Request request
0004 processing tive
stop present
Contour hand - wheel active

(Bit/binary coded)
0005 H-wheel H-wheel H-wheel
3 2 1
Contour Protection
handwheel zones not
direction of guaranteed
0007
rotation
inverted
Machine related protection zones pre-activated
0008
Machine related protection zones pre-activated
0009 Area 10 Area 9
Channel specific protection zones pre-activated
0010 Area 8 Area 7 Area 6 Area 5 Area 4 Area 3 Area 2 Area 1
Channel specific protection zones pre-activated
0011
Area 10 Area 9
Machine related protection zones violated
Machine related protection zones violated
0013 Area 10 Area 9
Channel specific protection zones violated
Channel specific protection zones violated
0015 Area 10 Area 9
Notes :

Status signals from geometry axis (Axis in WCS)
DB3300- NC  PLC [r]
DB3301

1000
Motion Command Travel request Active Hand-wheel (*1)
Plus Minus Plus Minus 3 2 1
Active machine function

1001
travel
Invert hand-
1003 wheel direc-
tion of rot.

1004

1005
travel
Invert hand-
1007 wheel direc-
tion of rot.

1008

1009 Continuous Inc var INC10000 INC1000 INC100 INC10 INC1
travel
1011 Invert hand-

wheel direc-
tion of rot.
(*1) The type of numbering for the hand-wheel is determined by machine data 11234 (0=bit coded, 1=binary coded).
Additional status signals from NC channel

DB3301

4000 G00 active
Travel request Work-piece set- External

4001 for drive test point reached language
present mode active
4002 Dry run feedrate Associated M01/ Stop ASUP is

is active M00 active delayed stopped
No tool change Delay Delay

4003 commands active FST suppress FST
Prog Event Display
4004 Start after Power up Operator panel Part program Part program
block search reset end start from
reset
Notes :

Additional status signals from NC channel-continued

DB3301

4005 Jog circles Retract data JOG retract Stop condition Coll avoid-
active available active ance stop
4006 Silent ASUP ASUP is

active active
4008 Active transformation number
4010 ´Status of the enable for the digital NC grinding inputs to the PLC $AC_IN_KEY_G_ISENABLE[1...8]
4011 ´Status of the function of the digital NC grinding inputs to the PLC $AC_IN_KEY_G_RUN_OUT[1...8]
ASUP Signals (DB3400)

DB3401

0000 Asup 1 start
0001 Asup 2 start
0002 Asup 3 start
0003 Asup 4 start
ASUP result
DB3401

Asup 1 start Asup 1 num- Asup 1 run- Asup 1
1000 not possible ber not possi- ning finished
ble

ble

1002 not possible ber not possi- ning Finished
ble

ble
G functions from NC channel

DB3501

0000 Active G function of group 1 (8 bit Integer)
etc
Notes :

Axis/Spindle Signals (DB3700, DB3800, DB3900)
M/S functions, axis specific-spindle specific

DB3711

0000 M function for spindle (Double Integer)
0004 S function for spindle (Real)
Signals from operating software
DB3700- HMI PLC [r]

DB3711

1000 Activate pro- Suppress
gram test program test
Signals to axis/spindle
DB3811

Feedrate override
0000 H G F E D C B A
Override active Measuring Measuring Follow up mode Axis/spindle Sensor for fixed Acknowledge
system 2 system 1 disable stop fixed stop
0001 reached
Reference point value Clamping in pro- Distance to go/ Controller

gress spindle reset enable
0002 4 3 2 1
Axis/spindle enable Velocity/spindle Activate fixed feedrate Enable

0003 program test speed limiting approach to
Feedrate 4 Feedrate 3 Feedrate 2 Feedrate 1 fixed stop
Traversing keys Rapid traverse Traverse key lock Feedrate stop/ Activate Hand-wheel
0004 override spindle stop
Plus Minus 3 2 1
Machine function (only if DB2600.DBX1.0 = 0)

travel
Invert hand-
0007 wheel direction
of rotation
Request PLC axis/ Activation signal Request NC

0008 spindle when signal when this axis/spindle
byte is changed
Parameter set-Servo
0009
C B A
Delay reference Modulo Limit 2nd software limit switch Hardware limit switch
point approach Reached
1000 Plus Minus Plus Minus
Jogging to position Jog fix-point Jog fix-point Jog fixpoint

1001 position 2 position 1 position 0
Activate Suppress
1002 program test program test
Notes :

Signals to spindle
DB3811
Clear S value Spindle:-No Spindle resynchro- Spindle resynchro- Gear changed Actual gear stage
speed moni- nise 2 nise 1
2000 toring for gear C B A
change.
Invert M3/M4 Resynchronise spin- Feedrate

2001 dle during override valid
positioning for spindle
Setpoint direction of rotation Oscillation speed Oscillation via PLC

2002
CCW CW
Spindle override
2003
H G F E D C B A
Signals to PLC axis

DB3811
Start position- Start spindle Start spindle Start spindle

3000 ing axis positioning rotation oscillation
3001 Stop spindle Stop spindle

rotation oscillation
Automatic Constant cut- Direction of Handwheel Traversing Path Path
3002 gear ting speed rotation-same override dimension condition: condition:
selection as M4 on Inch Shortest path Incremental
(DC) (IC)
Abs. path Abs. path
3003 Indexing posi- condition: condition:
tion Positive di- Negative
rection direction
(ACP) (ACN)
3004 Position (REAL, with indexing axis: DINT)
3008 Feedrate (REAL)

If < 0, the value is taken from MD32060 $MA_POS_AX_VELO
Note:- IC, DC, ACP, ACN only one signal can be selected at any one time. If no signal is selected AC is active by default.
Signals to drive
DB3811
Open holding
4000
brake
Pulse Speed control- Motor being Parameter set selection
4001 enable ler integrator selected
disable C B A
Notes :

Signals to technology functions
DB3811

Activate Master/ Torque equalisa- Control axis
5000 Slave tion controller ON
Activate
dynamic
5001 backlash
compensation
Enable following
5002 axis overlay
Stop HIAxMove Stopp corr Stop DEPBCS Stop DEPMCS Resume HIAx- Resume corr Resume DEP- Resume
5003 Move BCS DEPMCS
PLC controlled Stop along Stop at next Change reversal Set reversal point Continue Reset External
5004 axis braking ramp reversal point point oscillation
reversal
Disable auto- Start gantry

5005 matic synchro- synchronisation
nisation
Positioning the Automatic gear Specified direc- Specified direc- Spindle

5006 spindle stage change tion of rotation tion of rotation STOP
CCW CW
Delete synchronism Track synchro- Disable syn- Resynchroniza-

5007 correction nism chronization tion
General signals from axis/spindle

DB3911

Position reached Referenced/ Referenced/ Encoder limit Spindle/no
synchronised 2 synchronised 1 frequency ex- axis
0000 With exact stop- With exact stop- ceeded
fine coarse
Current controller Speed controller Position con- Axis/spindle sta- Follow up mode Axis ready Axis alarm Drive test
0001 active active troller active tionary active travel request
(n < nmin)
Power fixed stop Fixed stop Activate travel to Measurement Rotational feder- Hand-wheel
0002 limited reached fixed stop active ate active override active
Axis stop
0003 Ready for opera-
tion
Travel command Travel request Active hand-wheel

0004

travel
Invert hand-
wheel direc-
0007 tion of rota-
tion
PLC axis/spindle Neutral axis/ Exchange New type from Current assignment of the NC
spindle possible PLC requested axis/spindle in the channel
0008
2 1
Notes :

General signals from axis/spindle-continued

DB3911

Servo parameter set
0009
C B A
DRV Safety
0010 Integrated with
SIC/SCC active
PLC axis perma- Position re- Position restored

0011 nently assigned stored 1 2
Signals from axis

DB3911

Modulo limit
1000 Enabled active
Jog position Indexing axis in Jog fix point posi- Jog fix point posi- Jog fix point posi- Act jog fix Act jog fix point Act jog fix point
1001 reached position tion reached 2 tion reached 1 tion reached 0 point position position1 position 0
2
Rotary axis in Indexing axis in Positioning axis Path axis Lubrication

1002 position position pulse
Velocity re-
1003 duced by Colli-
sion check
Signals from spindle

DB3911

Change gear Set gear stage
2000 stage
C B A
Actual Speed monitoring Spindle in Set- Supporting Geometry Set-point Set-point speed Speed limit
2001 direction is clock- point range range limit vio- monitoring speed in- limited exceeded
wise lated creased
Active spindle mode Tapping with GWPS active Constant cut-

compensation ting velocity
2002 Control mode Oscillation mode Positioning mode Synchronous chuck active active
mode
Spindle in posi- Tool with dy-

2003 tion namic response
limitation
Signals from PLC axis

DB3911
Positioning axis Position reached Error Axis

3000 active during travers- cannot be
ing started
3002 Reserved
3003 Error number
Notes :

Signals from drive

DB3911

Drive enabled Holding brake Drive autonom Ramp function
4000 open motion active generator disa-
ble active
4001 Pulses Speed control- Motor being Active motor / parameter set
enabled ler integrator selected
disabled E D C B A
nact = nset nact < nx nact < nmin Md < Mdx Ramp up com- Temperature pre-warning
4002 pleted
Heat Sink Motor
4003 Generator op Vdclink <

min speed Vdclinkx
undershot
4004 Reserved
4006 Reserved
Interface as- Active motor / parameter set

4008 signment valid
(Bit 0-4) E D C B A
Signals from technology functions

DB3911

Master/slave Torque compen- Master/slave Master/
5000 active satory controller coarse slave fine
on
5001 Reserved
ESR Acceleration Velocity Superimposed Actual Synchronism Synchronism
reaction initiat- warning warning motion coupling coarse fine
5002 ed threshold threshold
reached reached
Maximum Maximum Synchronisation Axis is Synchro- Following Leading spin-

5003 acceleration velocity running accelerating nism over- spindle active dle active
reached reached ride travel
Oscillation ac- Oscillation Sparking out Error during Oscillation Oscillation

5004 tive movement active oscillation cannot start reversal is
active movement active
Gantry axis Gantry lead- Gantry group- Synchronisation Gantry warning Gantry shut-
5005 ing axis ing is syn- ready threshold down limit
chronising reached reached
Position Position Clamping Dynamic

measuring measuring tolerance backlash
5006 system 2 system 1 exceeded compensation
activated activated active
Synchronism Synchronism 2 Synchronism

2 coarse fine correction is
5007 taken into
account
Active infeed axis

5008
Axis 6 Axis 5 Axis 4 Axis 3 Axis 2 Axis 1
Notes :

Signale von SMI24 Spindel

DB3911
Sensor configuration
Sensor S6 Sensor S5 Sensor S4 Sensor S1 Sensor avail-
available available available available able
7000 (angular (piston end (clamped
position of position) state)
the motor
shaft)
Sensor configuration
Status value
7001 is generated
7002 Status of the clamping system (sensor S1)
7004 Analog measured value of the clamping system (sensor S1)
Status digital sensors

Sensor S5 Sensor S4
7006 available available
(angular (piston end
position, position)
motor shaft)
7007
Tool Management (DB4000)
User interface loading, unloading, relocating
DB4000- PLC NC Signals to TM [r/w]

DB40xx (*1)
Acknowledge- Acknowledge- Acknowledge- Acknowledge- Acknowl- Acknowl- Acknowledge- Total

y000 ment step 7 ment step 6 ment step 5 ment step 4 edgement edgement ment step 1 acknowl-
step 3 step 2 edgement
Acknowledge- Acknowledge- Acknowledge- Acknowledge- Acknowl- Acknowl- Acknowledge- Acknowl-

y001 ment step 15 ment step 14 ment step 13 ment step 12 edgement edgement ment step 9 edgement
step 11 step 10 step 8
Acknowledge- Acknowledge- Acknowledge- Acknowledge- Acknowl- Acknowl- Acknowledge- Acknowl-

y002 ment step 23 ment step 22 ment step 21 ment step 20 edgement edgement ment step 17 edgement
Acknowledge- Acknowledge- Acknowledge- Acknowl- Acknowl- Acknowledge- Acknowl-

y003 Reserved ment step 30 ment step 29 ment step 28 edgement edgement ment step 25 edgement
y004 Multitool: Location number (Int)
Status3 for total Reset

acknowledge- acknowl-
y009
ment edgement
error
(*1) xx = Loading position, y = TO unit
Notes :

Jobs for loading, unloading, relocating, positioning the magazine
DB4100- NC PLC Signals from TM [r]

DB41xx (*1)

y000 Multitool: Job
Data in the
multitool range
Multitool: Multitool: Job from NC Positioning Relocating Unloading Loading

y001 Job from NC Positioning program
program
y006 Source magazine no. (Integer)

y008 Source location no. (Integer)
y010 Target magazine no. (Integer)
y012 Target location no. (Integer)
Load/unload
y014 without mov-
HMI to PLC ing magazine
y056 Multitool: Distance coding (Int)
y058 Multitool: Number of locations (Int)
y060 Multitool: Tool distance (Real)
y064 Multitool: Number (Int)
y068 Multitool: Spindle/tool number (Int)
Feedback signal

DB41xx (*1)
Acknowl- Acknowl-
y100 edgement edgement OK
error
y102 Reserved
y104 Error status (Word)
y106 Reserved
y108 Acknowledge- Acknowledge- Acknowledge- Acknowledge- Acknowledge- Acknowl- Acknowl- Total
ment step 7 ment step 6 ment step 5 ment step 4 ment step 3 edgement edgement acknowledge-
step 2 step 1 ment
y109 Acknowledge- Acknowledge- Acknowledge- Acknowledge- Acknowledge- Acknowl- Acknowl- Acknowl-

ment step 15 ment step 14 ment step 13 ment step 12 ment step 11 edgement edgement edgement
y110 Acknowledge- Acknowledge- Acknowledge- Acknowledge- Acknowledge- Acknowl- Acknowl- Acknowl-

ment step 23 ment step 22 ment step 21 ment step 20 ment step 19 edgement edgement edgement
y111 Acknowledge- Acknowledge- Acknowledge- Acknowledge- Acknowl- Acknowl- Acknowl-

Reserved ment step 30 ment step 29 ment step 28 ment step 27 edgement edgement edgement
Notes :

Job status

DB41xx (*1)

y120 Reserved
y122 Reserved
y124 Current magazine number of the tool (Integer)
y126 Current location number of the tool (Integer)
y128 Target magazine number of the tool (Integer)
y130 Target location number of the tool (Integer)
y132 to
y138 Reserved
User interface tool change
DB4200- PLC NC Signals to TM [r/w]

DB42xx (*1)

Acknowledge- Acknowledge- Acknowledge- Acknowl- Acknowl- Acknowl- Acknowl- Total
y000 ment step 7 ment step 6 ment step 5 edgement edgement edgement edgement acknowl-
step 4 step 3 step 2 step 1 edgement
Acknowledge- Acknowledge- Acknowledge- Acknowledge- Acknowl- Acknowl- Acknowl- Acknowl-

y001 ment step 15 ment step 14 ment step 13 ment step 12 edgement edgement edgement edgement
step 11 step 10 step 9 step 8
Acknowledge- Acknowledge- Acknowledge- Acknowl- Acknowl- Acknowl- Acknowledge- Acknowl-

y002 ment step 23 ment step 22 ment step 21 edgement edgement edgement ment step 17 edgement
Acknowledge- Acknowledge- Acknowl- Acknowl- Acknowl- Acknowledge- Acknowl-

y003 Reserved ment step 30 ment step 29 edgement edgement edgement ment step 25 edgement
y004 to
y008 Reserved
Status3 for Reset

total acknowl-
y009 acknowledge- edgement
ment error
y010 to Reserved
y024
(*1) xx = Tool holder, y = TO unit
Notes :

Jobs for tool change preparing and execute

DB43xx (*1)

y000 Multitool: Job
Data in the
multitool range
Tool Manual tool Manual tool No old tool T0 Prepare Change tool Fixed location
y001 remains in unload load change (Initiated by coded
spindle M06)
y002 Reserved
y004 Reserved
y006 Source magazine no. for new tool (Integer)
y008 Source location no. for new tool (Integer)
y010 Reserved
y012 Reserved
y014 Reserved
y016 Reserved
y018 Target magazine no. for old tool (Integer)
y020 Target location number for old tool (Integer)
y022 Location type (Integer)
y024 Size, left (Integer)
y026 Size, right (Integer)
y028 Reserved
y030 Reserved
Tool status for new tool
y032 Tool has been Tool is fixed Tool being Pre warning Measure tool Tool Tool Active tool
in use location coded changed limit reached disabled enabled
Tool status for new tool
y033 Manual tool 1:1 change Master tool To be loaded To be Disabled, but Tool in the
unloaded ignore buffer
y034 New tool: Internal T no. of NC (Integer)

y036 Reserved (Double word)
y040 Reserved (Double word)
y044 User defined parameter 1 (Double word)
Notes :

Feedback signal
DB43xx (*1)
Acknowl- Acknowl-
y100 edgement edgement
error OK
y102 Reserved
y104 Error status (Word)
y106 Reserved
Acknowledge- Acknowledge- Acknowledge- Acknowledge- Acknowl- Acknowl- Acknowl- Total

y108 ment step 7 ment step 6 ment step 5 ment step 4 edgement edgement edgement acknowl-
step 3 step 2 step 1 edgement


Acknowledge- Acknowledge- Acknowledge- Acknowl- Acknowl- Acknowl- Acknowl-

y111 Reserved ment step 30 ment step 29 ment step 28 edgement edgement edgement edgement
Job status
DB4300- NC PLC Job status [r]

DB43xx (*1)

y120 Reserved
y122 Reserved
y124 Current magazine no. for new tool (Integer)
y126 Current location no. for new tool (Integer)
y128 Target magazine no. for new tool (Integer)
y130 Target location no. for new tool (Integer)
y132 Current magazine no. for old tool (Integer)
y134 Current location no. for old tool (Integer)
y136 Target magazine no. for old tool (Integer)
y138 Target location no. for old tool (Integer)
Notes :

PLC Machine Data (DB4500)

INT values (MD14510 USER_DATA_INT)
0000 Int values (Word/2 bytes)

Up to
HEX values (MD14512 USER_DATA_HEX)

1000 Hex value (Byte)

Up to
FLOAT values (MD14514 USER_DATA_FLOAT)

2000 Float value (Real/4 bytes)

Up to
User alarm Configuration (MD14516 USER_DATA_PLC_ALARM)

3000 Alarm reaction/cancellation criterion-Alarm 700000

Up to
Synchronised actions
DB4600- PLC  HMI [r/w] Deactivate synchronised action with ID...

DB4601
0000 ID8 ID7 ID6 ID5 ID4 ID3 ID2 ID1

Notes :

Signals from channel

DB4700- NC  PLC [r] Synchronised action with ID... can be blocked from the PLC
DB4701
Reading and writing PLC variables
DB4900 PLC interface [r/w]

0000 Offset 0
0001 Offset 1
0002 Offset 2
Up to Offset 4095
4095
Tool management functions from NC channel

Change signals for tool management functions
DB5301
Tool limit Tool
value warning
0000
reached limit
reached
Transferred tool management functions

DB5301
1000 T number for tool warning limit (Double integer)
1004 T number for tool limit value (Double integer)
1008
1012
Notes :

Axis actual values and distances to go

Signals from axis/spindle
DB5711
0000 Axis actual value (Real)
0004 Axis distance to go (Real)
Used in with: DB2600.DBX1.1 Request axis actual value, DB2600.DBX1.2 Request axis distance to go
Drive-based Safety Integrated

Signals to axis
DB6000- PLC Drive [r/w]

DB6011

Test stops for
0000 extended func-
tions
0001
0002
External Torque 1 or 2 Direction of Test with Start Select
0003 brake closed rotation brake 1 or 2 brake test safe brake test
Signals from axis

DB6100- Drive PLC [r]
DB6111

Safety error ESR requested Bit 1 Bit 0
active Safety limited Safety limited
0000 speed limit speed limit
value value
Safety error Safe limited Safe operat- Safe limited Safe operat- Safe stop 2 Safe stop 1 Safe torque of
0001 with Stop A speed selected ing stop select- speed active ing stop active
ed
Test stop re- Test stop active Safe direction Safe direction
0002 quested negative positive
Safety limited Bit 0

position is for Safety lim-
0003 selected ited position
area
0004 Velocity limit

Acceptance Acceptance
test Safety test Safety
0008 limited position limited position
active selected
Load torque Close external Brake test

negative sign brake
0009 Completed OK active With brake 2 Setpoint specifi- Safe Brake
cation during Test (SBT)
SBT in the drive
Notes :

User interface (DB9900)
Tool management user interface
DB9900 Constant transfer step table [r]

0000 Transfer step 1 Source magazine no. (Integer)
0002 Transfer step 1 Source location no. (Integer)
0004 Transfer step 1 Target magazine no. (Integer)
0006 Transfer step 1 Target location no. (Integer)
etc
DB9901 Variable transfer step table [r/w]

etc
Notes :

Tool management user interface-continued
DB9902 Acknowledgement step table [r]

0000 Acknowledgement step 1 Transfer step for new tool. (Byte)
0001 Acknowledgement step 1 Transfer step for old tool. (Byte)
0002 Acknowledgement step 1 Acknowledgement status. (Byte)
0003 Acknowledgement step 1 Reserved
etc
Maintenance planner user interface
DB9903 Initial data table [r]

0000 Interval 1 [Hours]
0002 Time of first warning 1 [Hours]
0004 Number of warnings to be output 1
0006 Reserved 1
0014 Reserved 2
etc
0254 Reserved
Notes :

Maintenance planner user interface-continued
DB9904 Actual data table [r]
0002 Number of warnings output 1
0004 Reserved_1 1
0006 Reserved_2 1
0012 Reserved_1 2
0014 Reserved_2 2
etc
0252 Reserved_1 32
0254 Reserved_2 32
Easy Extend user interface
DB9905 HMI PLC [r/w]
Deactivate Activate Enable

0000
1 1 1
0001
Error Activated
0002
1 1
0003 Device ID_1

0004
2 2 2
0005
Error Activated
0006
2 2
0007 Device ID_2
etc

0252
64 64 64
0253
Error Activated
0254
64 64
0255 Device ID_64
Notes :

Ctrl Energy user interface
DB9906 Energy saving profiles

Control signals
n+0
Set time to Immediately
prewarning limit activate energy
saving profile
Control signals (HMI PLC)

n+1
Immediately
activate energy
saving profile
Signals to check energy saving profile

n+2
PLC user signal Master com-
puter signal
n+3 Reserved
Control signals
n+4
Activation time energy saving
T1 has expired profile active
n+5 Reserved
n+6 Actual value: Actual value T1
n+8 Actual value: Actual value T2
Effectiveness profile
n+10
Disable energy Energy saving
saving profile profile config-
ured
State conditions (HMI PLC)

n+11
Screen change Data transfer Operator panel
active active

n+12
Machine
control panel
used

n+13
NC Channel
1 in reset
n+14

n+15
PLC user Master com-
signal puter signal
n+16 State conditions (HMI PLC) Activation time T1
n+18 State conditions (HMI PLC) Prewarning time T2
Profile instances: Energy profile 1 (n=0): DB9906.DBB0 … DBB19

Energy profile 2 (n=20): DB9906.DBB20 … DBB39
etc
Energy profile 8 (n=140): DB9906.DBB140 … DBB159
Notes :

Ctrl Energy user interface-continued
DB9907 SENTRON PAC

0000 Regenerative Infeed energy: Regenerative Infeed energy SENTRON PAC Display
PLC HMI energy: Integration energy is read is read by represents the manual value
Integration using FW by SENTRON SENTRON machine
using FW PAC PAC
0001 PLC FW
should perform
measurement
0002 Measurement
HMI PLC in progress
0003 Power dis-

play on
0004 Manual value (REAL) to HMI
0008 Total active power (REAL) to HMI
0012 Measured drawn active energy in kWh (REAL) to HMI
0016 Measured supplied active energy in kWh (REAL) to HMI
0020 Total active power in watts (REAL) from SENTRON
0024 Drawn active energy at taritf1 (F) in Wh (REAL) from SENTRON
0028 Supplied active energy at tariff1 (F) in Wh (REAL) from SENTRON
0032 Drawn active energy in kWh per day (REAL) to HMI
0036 Supplied active energy in kWh per day (REAL) to HMI
0040 Drawn active energy in kWh per previous day (REAL) to HMI
0044 Supplied active energy in kWh per previous day (REAL) to HMI
0048 Drawn active energy in kWh per month (REAL) to HMI
0052 Supplied active energy in kWh per month (REAL) to HMI
0056 Drawn active energy in kWh per previous month (REAL) to HMI
0060 Supplied active energy in kWh per previous month (REAL) to HMI
0064 Drawn active energy in kWh per annum (REAL) to HMI
0068 Supplied active energy in kWh per annum (REAL) to HMI
0072 Drawn active energy in kWh per previous year (REAL) to HMI
0076 Supplied active energy in kWh per previous year (REAL) to HMI
0096 Production Act (PLC HMI)
0097 Value invalid Value invalid Value invalid

DBD0028 DBD0024 DBD0020
0098 Value invalid Value invalid Value invalid Value invalid Value invalid Value invalid Value invalid Value invalid
DBD0384 DBD0344 DBD0304 DBD0264 DBD0224 DBD0184 DBD0144 DBD0104
0099 Value invalid Value invalid

DBD0464 DBD0424
Notes :

Ctrl Energy user interface-continued
DB9907 SENTRON PAC

Control/Command bits
n+100
Reset data Input-Mode: Different val- Energy meas- Read energy Process
structure (energy or ues when urement run- actual value device
power) measuring ning update
energy
n+101 Reserved
n+102 Reserved
n+104 Active power or active energy of the auxiliary unit [kW] or [kWh]
n+108 Drawn active energy of the auxiliary unit [kWh]
n+112 Active energy supplied by the auxiliary unit [kWh]
n+116 Active energy drawn by the auxiliary unit at the measurement start [kWh]
n+120 Active energy supplied by the auxiliary unit at the measurement start [kWh]
n+124 Active energy drawn by the auxiliary unit at the measurement end [kWh]
n+128 Active energy supplied by the auxiliary unit at the measurement start end [kWh]
n+132 Reserved
n+136 Reserved
Auxiliary units instances:
Auxiliary units 1 (n=0): DB9907.DBB100 … DBB139

etc
Notes :

Spindle temperature sensor user interface
DB9908 ISM_TS
n+0 Sensor installation location
n+2 Reserved
n+4 Temperature sensor actual value [C]
n+8 Temperature sensor warning threshold value [C]
n+12 Number of alarm limit value violations
n+14 Last alarm limit value violation: Year
n+15 Last alarm limit value violation: Month
n+16 Last alarm limit value violation: Day
n+17 Last alarm limit value violation: Hour
n+18 Last alarm limit value violation: Minute
n+19 Last alarm limit value violation: Seconds
n+20 Duration of the warning limit value violations
n+24 Temperature sensor fault threshold value [C]
n+28 Number of fault limit value violations
n+30 Last fault limit value violation: Year
n+31 Last fault limit value violation: Month
n+32 Last fault limit value violation: Tag
n+33 Last fault limit value violation: Day
n+34 Last fault limit value violation: Minute
n+35 Last fault limit value violation: Seconds
n+36 Duration of the fault limit value violation
Spindle/temperature sensor instances:
Spindle 1, temperature sensor 1 (n=0): DB9908.DBB0000 … DBB0039

Notes :

Selecting NC variables user interface
DB9910- Selected NC data [r]

DB9912
0001 Syntax ID
0002 Area
0003 Unit
0008 Block
0010 Type
0011 Length
0013 Syntax ID
0014 Area
0015 Unit
0020 Block
0022 Type
0023 Length
etc
0493 Syntax ID
0494 Area
0495 Unit
0500 Block
0502 Type
0503 Length
Notes :

PLC Alarms user interface
DB9913 Alarm configuration [r]
0000 Alarm response / cancel criterion, channel assignment alarm 701000
etc
Access to SINAMICS Signals via PLC user interface
DB9914 ALM_IF [r/w]

n+0 STW1.15 STW1.14 STW1.13 STW1.12 STW1.11 STW1.10 STW1.9 STW1.8
Control by
PLC
n+1 STW1.7 STW1.6 STW1.5 STW1.4 STW1.3 STW1.2 STW1.1 STW1.0

Acknowledge Disable gen- Disable motor Enable opera- No OFF2 ON/OFF1
faults erator opera- operation tion “0/1“
tion
n+2 ZSW1.15 ZSW1.14 ZSW1.13 ZSW1.12 ZSW1.11 ZSW1.10 ZSW1.9 ZSW1.8

Line contactor Precharging Control re-
closed completed quest to PLC
n+3 ZSW1.7 ZSW1.6 ZSW1.5 ZSW1.4 ZSW1.3 ZSW1.2 ZSW1.1 ZSW1.0
Alarm active Switching on No OFF2 Fault active Operation Ready to oper- Ready to
inhibited active enabled ate start
ALM instances:
ALM 1 (n=0): DB9914.DBB0 … DBB3

ALM 2 (n=4): DB9914.DBB4 … DBB7
Appendix C: END
Notes :

EN - 828D Service 0408 - 2019-03

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SINUMERIK 828D

This document was produced for training purposes.

Service Manual for

Sinumerik 828D Software 4.8

Sinumerik 828D SW4.8

Electrical Cabinet Protocol attached

Filename of Cabinet protocol

Machine Test Protocol Sinumerik 828D

Copyright © Siemens AG 2016 All Rights Reserved.

1 RESPONSIBLE PERSONS: ................................................................................................................................................................................ 4

1.1 Schedule ..................................................................................................................................................................................................................................................................................... 4

1.2 Participants carrying-out the test ............................................................................................................................................................................................................................................ 4

2 SUMMARY AND RESULT ................................................................................................................................................................................... 5

2.1 Summary .................................................................................................................................................................................................................................................................................... 5

2.2 Result ......................................................................................................................................................................................................................................................................................... 5

2.3 Release Siemens ......................................................................................................................................................................................................................................................................... 5

2.4 Release from Machine Tool Builder ........................................................................................................................................................................................................................................ 5

3.1 Modified data ............................................................................................................................................................................................................................................................................ 6

3.2 Data Backup .............................................................................................................................................................................................................................................................................. 6

4 CHANGE LOG ..................................................................................................................................................................................................... 7

4.1 Changes to the machine. ........................................................................................................................................................................................................................................................... 7

5 SYSTEM DESCRIPTION ..................................................................................................................................................................................... 8

5.1 Machine ..................................................................................................................................................................................................................................................................................... 8

5.2 Control ....................................................................................................................................................................................................................................................................................... 8

Copyright © Siemens AG 2016 All Rights Reserved.

6 TEST OBJECTIVE ............................................................................................................................................................................................... 9

6.1 Note ............................................................................................................................................................................................................................................................................................ 9

8.1 Machine area ........................................................................................................................................................................................................................................................................... 11

8.2 Parameter ................................................................................................................................................................................................................................................................................ 25

8.3 Geometry ................................................................................................................................................................................................................................................................................. 28

8.4 Safety Integrated ..................................................................................................................................................................................................................................................................... 28

8.5 Startup ..................................................................................................................................................................................................................................................................................... 29

8.6 Password protection ............................................................................................................................................................................................................................................................... 30

Doc-Nr Page 3/32 Protocol version 1.2

Copyright © Siemens AG 2016 All Rights Reserved.

Test carried out at (OEM Name):

1.2 Participants carrying-out the test

Name Company / Department

Doc-Nr Page 4/32 Protocol version 1.2

Copyright © Siemens AG 2016 All Rights Reserved.

2 Summary and result

2.2.1 Exception List

2.3 Release Siemens

2.4 Release from Machine Tool Builder

Doc-Nr Page 5/32 Protocol version 1.2

Copyright © Siemens AG 2016 All Rights Reserved.

3.2 Data Backup

- ____________ (NCPLC Archive)

Doc-Nr Page 6/32 Protocol version 1.2

Copyright © Siemens AG 2016 All Rights Reserved.

4.1 Changes to the machine.

Date Change Reason Tested Responsible person Signature

Doc-Nr Page 7/32 Protocol version 1.2

Copyright © Siemens AG 2016 All Rights Reserved.

Doc-Nr Page 8/32 Protocol version 1.2

Copyright © Siemens AG 2016 All Rights Reserved.

The test plan extends the commissioning documentation of 828D.