En 840D SL Complete Step7 v45

SINUMERIK 840D sl
STEP 7 Basic course

Sinumerik 840D sl
Edition 2013.06
Training Manual
This document was produced for training purposes.

Siemens assumes no responsibility for its contents.
SINUMERIK 840D sl
STEP 7 Basic course
Valid for:
Sinumerik 840D sl Software 4.5

Contents
Start
A060
System
Overview
A002
A150 A026
Service &
Simatic Creating a PLC
Commissioning
Manager Program
Tools A151
Basic functions
of a PLC Pro-
gram
A058
PLC Onboard
Diagnostics
Appendix C A031
A037
PLC PLC Alarms
Alarm Structure
Interface and Messages
End
A060 System Overview
Sinumerik
Operate
Module Description:
The 840D sl Sinumerik Operate system is made up of a variety of hardware components.

This module gives a graphical overview of some of the components and shows where each com-
ponent is connected.
A detailed description of the components is given in the NC61 catalogue.
Module Objective:
Upon completion of this module you will have a basic understanding of the 840D sl Sinumerik Op-
erate system and the components which make up the system.
Content:
Sinumerik
840D sl with TCU

840D sl with PCU50.x and TCU
System Overview SINAMICS S120 / 840D sl
840D sl: NCU and NX
S120 components booksize
S120 Line Modules DC link components
S120 Motor Modules
Sensor Modules
Terminal Modules, DRIVE CLIQ Hub
Operator panels
Drive CLiQ rules
840D sl Sinumerik Operate V4.5 Page 1 This document was produced for training purposes.
A060
A060
A060 Page 2 840D sl Sinumerik Operate

System Overview A060
System Overview:
START
Sensor-
Modules
840D sl with
TCU
Terminal
Modules,
DRIVE CLIQ
Hub
840D sl with
PCU50.x
Operator
panels
840D sl with
PCU50.x and
TCU
Drive CLiQ
rules
System Over-
view S120 /
840D sl
System Overview:
END
840D sl: NCU

and NX
S120
components
booksize
S120 Line
Modules DC
link compo-
nents
S120 Motor
Modules,
booksize
Notes
840D sl Sinumerik Operate Page 3 A060

840D sl with TCU
USB
USB X202 System network.
MCP
Network
hub/switch.
Hand-wheels
via MCP
Connection
kit
X120 system network

Factory
Network Handheld
Digital I/O: Terminal
Sinamics & NC
X120 & X132
DriveCLiQ DMC20
DriveCLiQ DriveCLiQ
DriveCLiQ
Hub
X122
X126 Profibus:
PLC periphery X132
DMS
X120
Scales/encoders
X130 via SMx & DMC
X126 modules.
NCU NX LM MM MM
Filter
Sinamics S120
Booksize
X127
Service
Supply Network
Reactor
Notes

840D sl with PCU50.x
DVI External monitor

X1
Factory network.
OP0xx & PCU50.x
USB
USB
X501
USB
USB X500 System network.
Network
hub/switch.
Hand-wheels
via MCP
Connection
kit
X120 system network

Factory
Network Handheld
Terminal
Digital I/O:
Sinamics & NC
X120 & X132
DriveCLiQ DMC20
DriveCLiQ DriveCLiQ
DriveCLiQ
Hub
X122
X126 Profibus:
PLC periphery X132
DMS
X120
Scales/encoders
X130 via SMx & DMC
X126 modules.
NCU NX LM MM MM
Filter
Sinamics S120
Booksize
X127
Service
Network
Reactor
Notes

840D sl with PCU50.x and TCU
DVI
Factory
OP0xx & PCU50.x Network
USB
USB X501
USB X500 USB X202
USB USB
MCP
Network
hub/switch.
Connection
kit
X120 system network
Handheld
Terminal
Digital I/O:
Sinamics & NC
X120 & X132
X122 DMC20
X126 Profibus: DriveCLiQ
PLC periphery X132 Hub.
X120
X130
X126
NCU NX LM MM
Filter
Sinamics S120 DMS
Booksize Scales/encoders
via SMx & DMC
X127 modules.
Service
Network
Reactor
Notes

System Overview S120 / 840D sl
SINUMERIK and SINAMICS automation system components

.
NCU 710.3
NCU 720.3
NCU 730.3
NX 10.3
NX 15.3
Notes

840D sl: NCU and NX
840D sl: NCU and NX
NCU
SINAMICS S120 Line
NX Motor Module
Property NCU 710.3 PN NCU 720.3 PN NCU 730.3 PN

Cooling ribs No No Yes
DRIVE-CliQ Ports 4 6 6
Axes Up to 8 Up to 31 Up to 31
NX10.3 / 15.3 Up to 2 Up to 5 Up to 5
TCU Up to 2 Up to 4 Up to 4
Notes

Key Data for NCU and NX
Notes

Schematic representation of the NCU 7x0
X150 PROFINET
X126 PROFIBUS DP
X136 PROFIBUS
DP 2
Internal structure of the NCU
SINAMICS
integrated
SOC 2
PROFINET
Notes

Representation of NCU 730.3
position of the measuring sockets

Socket Function Technical data
T0 Measuring socket 1 Resolution: 8 bit, max. output range of the test signal: 0 ... 5 V
T1 Measuring socket 2 Load current: max. 3 mA
T2 Measuring socket 3
M Ground The reference potential is terminal M
The measuring sockets are only suited for banana plugs with a diameter of 2 mm.
Notes

Name Function Status Meaning

RDY Ready Red There is at least one fault (e.g. RESET, watchdog
monitoring etc. ) or the Control Unit is booting up.
Flashing red/orange Error accessing CompactFlash Card

(0.5 Hz)
Orange Accessing CompactFlash Card
Flashing orange (0.5 Hz) Updating the firmware of the connected DRIVE-CLiQ
components
Flashing orange (2 Hz) Firmware update is complete for components. Wait for
POWER ON for the components in question.
Green NC powered up and everything in cyclic mode
Flashing green/orange or LED-supported recognition of connected DRIVE-CLiQ
red/orange (1 Hz) component is activated: (p0124[0] = 1).
RUN PLC Run Grenn PLC ready to operate
STOP PLC Stop Orange PLC stopped
SU/PF PLC FORCE Red FORCE activated
SF PLC SF Red PLC group error
DP BUS1 F Red PROFIBUS group error X126
DP/MPI BUS2 F Red PROFIBUS group error X136
PN PN Fault Red PROFINET IO group error X150
SY/MT PN SYNC Green  Synchronization status (SY) of the onboard PROFINET
IO interface (X150)
 Maintenance status (MT) of the NCU
(presently without function)
OPT BUS3 F Off The PROFINET system runs correctly; data exchange to all
configured IO devices runs.
Rot  Bus fault (no physical connection)
 Incorrect transmission rate
Flashing red  Failure of a connected I/O device.
(2 Hz)  Incorrect or no configuration.
NOTICE
If all the LEDs are flashing, the PLC must be reset via the mode selector (move switch to
position "3" to reboot).
Notes

NX10.3/NX15.3
Notes

Description of LEDs on the NX10.3 / 15.3
LED Color Status Description

RDY Off Electronic power supply outside permissible tolerance range
Green Continuous light NX is ready for operation

Flashing light 2 Hz Writing to CompactFlash Card
Red Continuous light NX is presently booting and at least one fault is present (e.g. RESET,
watchdog monitoring, basic system fault).
Flashing light 0.5 Hz Boot error (e.g. firmware cannot be loaded into the RAM)
Orange Continuous light Firmware loading into RAM
Flashing light 0.5 Hz Unable to load firmware into RAM
Flashing light 2 Hz Firmware CRC fault
DP Off Electronics power supply outside the permissible tolerance range, NX
is not ready to run.
Green Continuous light CU_LINK is ready for communication and cyclic communication is
running.
Flashing light 0.5 Hz CU_LINK is ready for communication and no cyclic communication is
running.
Red Continuous light At least one CU_LINK fault is present.
CU_LINK not ready for operation (e.g., after switching on)
RESET button
The RESET button is on the front of the module under the cover.
NOTICE
When the pushbutton is actuated, the locally connected drive systems are brought to a
standstill with no feedback to the control. In other words, the drive and controller run
asynchronously once the drive has successfully booted up.
Notes

NX10 / NX15: connection DRIVE CLiQ
X105
15
X100
14
DRIVE-CLiQ topology
NX components can be connected to the Control Unit via DRIVE-CLiQ. The following rules apply
for the wiring:
 Only one star topology is permitted between the NX and the Control Unit. This means that
only one NX can be operated per DRIVE-CLiQ port on a Control Unit.
 DRIVE-CLiQ ports not assigned to NX can be wired to other DRIVE-CLiQ components.
 Once an NX has been connected and configured, you cannot simply insert it into a different
DRIVE-CLiQ port, as the addresses of the integrated drives are set permanently from the
point of view of the PLC.
The following table illustrates this relation:

DRIVE-CLiQ Port Drive PROFIBUS addresses
X105 15
X104 14
X103 13
X102 12
X101 11
Notes

S120 Komponenten booksize
840D sl as central control unit
Line Modules for power supply :

 Smart Line Module 400V, to 55 kW
 Base Line Module 400 V to 100 kW
 Active Line Module 400V, to 120 kW
One or several motor modules to control the motors
•Single Motor Modules to 200 A

•Double Motor Modules to 2x18 A
Optional DC link components
 Braking Module
 Brake resistors
 Capacitor Module
Electronic options
Sensor Modules: SMC10 (Resolver)
SMC20 (Encoder)
SMC30 (TTL/HTL)
Terminal Modules: TM15, TM31, TM41
Active/ Smart Line Module

Central power supply to the DC link is provided by Booksize line modules
Single/ Double Motor Module

Booksize motor modules obtain their energy from the DC link and supply
the connected motors.
SMC10/20/30 Cabinet-mounted sensor modules are used when a motor with a DRIVE-
CLiQ interface is not available and when external encoders are required in
addition to the motor encoder.
SME20/25 Measuring systems outside the cabinet can be connected directly to the
Sensor Module External.
Notes

SINAMICS: Connection to the Components
Quicker and easier Start-up with SMI

Automatic detection of motors and encoders
Storage of technical and logistics data
Storage of the equivalent circuit diagram and encoder data in the motor
Integration of direct position measurement systems

Use of measuring systems with DRIVE-CLiQ interface
Use of SMC/SME modules for signal conversion to DRIVE-CLiQ
Third-Party Encoders / Motors

Integration via SMC/SME modules
Parameter assignment via start-up screens
Motion Connect 500 mainly for fix wiring.
Motion Connect 500 plus

for low mechanical load
.
Motion Connect 700 for highly dynamic machines (e.g. Linear drives).
Motion Connect 800 or the high mechanical needs in drag chains.
Notes

S120 Line Modules DC link components
Smart Line Modules

 Autonomous unregulated infeed/regenerative
feedback unit (line-commutated feedback via
IGBTs)
Active Line Modules

 Self-commutated infeed/regenerative feedback
unit (with bidirectional IGBTs)
 Reduced line harmonics with highest drive
dynamics; robust with weak mains systems;
high availability
 Improved utilization of motors via higher,
regulated DC link voltage
 With DRIVE-CliQ for control from the Control
unit CU
Basic Line Modules

 unregulated DC Link Voltage
 No regenerative feedback
 With all BLM: DC-link rails to both sides of line
module
Active Interface Modules for 16 kW, 36 kW, 55 kW und 80
Active Interface Modules

are line-side interfaces for the Active Line
Modules.They contain the following functional
units:
 Line reactors
 Low-frequency/switching frequency filters
 Line filters to EN 61800-3, category C3
Line Reactor for Line Modules

A line reactor is always required.
• On Active line modules, it is absolutely essential for the operation of the step-up converter.
• Is mandatory with Smart Line Modules to reduce the line harmonics and to protect against
high overshoot currents.
Netze All Line Modules are designed for connection to grounded, star (TN, TT) and non-grounded,
symmetrical IT supply systems.
BLM The 100kW module hasn‘t got the integrated braking resistor module control.
Notes

Smart Line Modules 5 kW and 10 kW
Terminal strip X21 for Smart Line Modules 5 kW and 10 kW

Terminal Designation Technical specifications
1 DO: Ready Checkback signal: Smart Line Module ready
The signal switches to high level when the following
conditions have been met:
 Electronics power supply (X24) OK
 DC link is precharged
 Pulses enabled (X21.3/4)
 No overtemperature
 No overcurrent
2 DO: Prewarning DO: Prewarning
High = no prewarning
Low = prewarning
 Overtemperature warning threshold/I2t
5 kW
prewarning: 64°C, overtemperature threshold: 69°C
10 kW
prewarning: 68°C, overtemperature threshold: 73 ℃
 No regenerative feedback capability due to a line fault
[only monitored when feedback is activated (see
terminal X22.2)]
3 EP +24 V (Enable Pulses) Voltage 24 VDC
Current consumption: 10 mA
4 EP M (Enable Pulses) Isolated input
Max. connectable cross-section: 1.5 mm2
Type: Screw terminal 1 (see the chapter titled "Control cabinet installation and EMC/Connection system")
X22 terminals
Terminal strip X22 for Smart Line Modules 5 kW and 10 kW

1 24 V power supply Electronics power supply for controlling digital inputs
X22.2 and 3.
2 DI: Disable Regeneration Deactivate feedback (high active).
No power is supplied back to the network from the DC
link. The regenerative energy of the motors may have
to be reduced using a combination of the Braking
Module and braking resistor.
3 DI: Reset Reset faults (negative edge)
4 Ground Electronics ground
Max. connectable cross-section: 1.5 mm2
X24 24-V- Klemmenadapter
Terminal strip X24

1 24 V power supply Versorgungsspannung DC 24 V
4 Ground Electronics ground
The 24 V terminal adapter is supplied as standard.

Max. connectable cross-section: 6 mm2
Notes

Meaning of the LEDs on 5 kW and 10 kW Smart Line Modules

LED Color Status Description, cause Remedy
RDY Off Electronics power supply is missing or outside —
permissible tolerance range.
Green Continuous light Component is ready to operate. —
Orange Continuous light Pre-charging not yet complete. —
bypass relay dropped out
EP terminals not supplied with 24 VDC.
Red Continuous light Overtemperature, Diagnose fault (via output
overcurrent terminals) and acknowledge it
(via input terminal)
DC LINK — Off Electronics power supply is missing or outside —
permissible tolerance range.
Orange Continuous light DC link voltage within permissible tolerance range. —
Red Continuous light DC link voltage outside permissible tolerance range. Check the line voltage.
Line supply fault.
16 kW to 55 kW Smart Line Modules
Terminal strip X21 (EP terminals) for 16 kW to 55 kW Smart Line Modules

Terminal Function Technical specifications
1 + TEMP Temperature sensors1): KTY 84-1C130/PTC/bimetallic

2 - TEMP switch with NC contact
3 EP +24 V (Enable Pulses) Voltage: 24 VDC

4 EP M (Enable Pulses) Isolated input
Signal propagation times:
L → H: 100 μs
H → L: 1000 μs
1) The temperature sensor type can be selected via parameter p0601; the temperature is displayed via r0035 (see
SINAMICS S120/S150 List Manual).
Temperatures are detected but not evaluated in the Smart Line Module.
Meaning of the LEDs on Smart Line Modules ≥ 16 kW

Status Description, cause Remedy
RDY DC LINK
Off Off Electronics power supply is missing or outside permissible tolerance range. —
Green — The component is ready for operation and cyclic DRIVECLiQ communication is taking —
place.
Orange The component is ready for operation and cyclic DRIVECLiQ communication is taking —
place. The DC link voltage is present.
Red The component is ready for operation and cyclic DRIVECLiQ communication is taking Check line voltage
place. The DC link voltage is too high.
Orange Orange DRIVE-CLiQ communication is being established. —
Red — At least one fault is present in this component. Remedy and
Note: acknowledge
The LED is activated regardless of whether the corresponding messages have been fault
reconfigured.
Green/red — Firmware is being downloaded. —
(0,5 Hz)
Grün/red — Firmware download is complete. Wait for POWER ON. POWER ON durch-
(2 Hz) führen
Green/orange — Component detection via LED is activated (p0124). —
or Note:
Red/orange Both options depend on the LED status when
component recognition is activated via p0124 = 1.
Notes

SINAMICS Power Components : Line Modules
Properties of Infeed
• Supply voltage 3AC 380-480V, 50/60Hz
• IP20 protection
• cooling: Internal and external air cooling
• Ambient temperature: 0-40 °C without derating, to 55°C with derating
• Height: 380mm
• Depth: 270mm
Smart line modules Supply power (kW) / width (mm)
• 5/50 -> without Drive-CLiQ ports
• 10/50 -> without Drive-CLiQ ports
• 16/100
• 36/150
• 50/200
Active line modules Supply power (kW) / width (mm)
• 16/100
• 36/150
• 55/200
• 80/300
• 120/300
ALM Control Modes

Control Modes The active line module can be operated in one of two different control modes,
depending on the parameterized line supply voltage (p210):
Active Mode DC link voltage is controlled with respect to a settable reference value.
The Line Module acts as a Step-up converter with regulated DC link voltage and
sinusoidal supply voltage.
Smart mode The DC link voltage is not regulated, but results from the rectified supply voltage
Notes

ALM Control Modus
SINAMICS: DC Link Components
Braking
Braking Module Module und
and braking Bremswiderstände
resitors
Two braking resitors are available: stehen zur Verfügung:
Zwei Bremswiderstände
Booksize:
Booksize: 0,3 kW braking
0,3 kW continous Dauerbremsleistung
power
(25 kW peak power)
(25 kW Spitzenleistung)
1,5 kW continous
1,5 braking power
kW Dauerbremsleistung
(100 kW peak power)
(100 kW Spitzenleistung)
Capacitor Module
Capacitor modules
Dient zur Erhöhung der Zwischenkreiskapazität um
Is used for increasing the DC link capacity in order
to dealkurzzeitige Netzausfälle
with short power failures zu überbrücken.
Control Supply Modules

Control Supply Module
Supplies
Stellt DC power
DC 24V via the mains or
24-V-Stromversorgung über das Netz oder
via the DC link.
den Zwischenkreis zur Verfügung.
This way it is possible, for example, to perform
Damit
emergency ist es beispielsweise
retraction möglich
motions in a controlled way gezielte
Notrückzugsbewegungen durchzuführen.
Braking Modules/ Braking Resistor

Conversion of DC link energy to thermal loss in the external braking resistor.
As the Smart and Active Line Modules are capable of feedback, braking modules and braking
resistors are not required for normal operation.
These components must only be provided if a machine must be stopped
in a controlled way at power failure (feedback operation no longer possible).
Notes

S120 Motor Modules, booksize
Features Booksize Format

• With the double motor modules two autonomous motor modules are integrated
in one housing (space savings up to 50%)
• Connection via the DC link and DC 24V bus bars integrated in the system.
• Safety Integrated functions such as "safe standstill" (SH/SBH) and
"safe braking control" (SBC).
• Overload capacity of the motor modules similar to SIMODRIVE 611.
• The specified depth of 270mm only applies to devices with air cooling. Models with forced
convection cooling and cold plate cooling have a reduced depth.
• All components in the SINAMICS S system are cULus approved.
The cULus mark is a test mark of Underwriters Laboratories (UL) and indicates compliance
with UL and CSA (Canadian Standard Association) standards.
Properties of the Motor Modules
• Supply voltage DC 510-720V
• IP20 protection
• Cooling: Internal / external air cooling or cold plate cooling
• Ambient temperature: 0-40 °C without derating, up to 55°C with derating
• Height: 380mm
• Depth: 270mm
Single Motor Modules
Rated output current: from 3A to 200A
Maximum output current: from 6A to 282A
Width: from 50mm to 300mm
Double Motor Modules
Rated output current: from 3A to 18A
Maximum output current: from 6A to 36A
Width: from 50mm to 100mm
Notes

X21/X22 EP terminals / temperature sensor Motor Module
Terminal Function Technical specifications
1 + TEMP Temperature sensors 1): KTY 84-1C130/PTC/bimetallic

switch with NC contact
2 - TEMP
3 EP +24 V (Enable Pulses) Supply voltage: 24 V DC (20.4 V to 28.8 V)

Isolated input
4 EP M (Enable Pulses) Signal propagation times:
L → H: 100 μs
H → L: 1000 μs
The pulse inhibit function is only available when Safety
Integrated Basic Functions are enabled.
1) The temperature sensor type can be selected via parameter p0601; the temperature is displayed via r0035 (see
SINAMICS S120/S150 List Manual).
Meaning of the LEDs on the Motor Module
Status Description, cause Remedy

RDY DC LINK
Off Off Electronics power supply is missing or outside permissible tolerance range. —
Green — The component is ready for operation and cyclic DRIVECLiQ communication is taking —
place.
Orange The component is ready for operation and cyclic DRIVECLiQ communication is taking —
place. The DC link voltage is present.
Red The component is ready for operation and cyclic DRIVECLiQ communication is taking Check line voltage
place. The DC link voltage is too high.
Orange Orange DRIVE-CLiQ communication is being established. —
Red — At least one fault is present in this component. Remedy and
Note: acknowledge fault
The LED is driven irrespective of the corresponding messages being reconfigured.
Green/red — Firmware is being downloaded. —

(0.5 Hz)
Green/red — Firmware download is complete. Wait for POWER ON. Carry out a POWER
(2 Hz) ON
Green/orange — Detection of the components via LED is activated (p0124). —
or Note:
Red/orange Both options depend on the LED status when module recognition is activated via
p0124 = 1.
Notes

Sensor Module
Sensor Module Cabinet

The Sensor Module Cabinet-Mounted SMC10, SMC20 and SMC30 be used if a motor with DRIVE-CLiQ interface is
available or if, in addition to the motor encoder further external sensors are required. The SMCs evaluate these
measuring systems and set the values to Drive-CLiQ.
The SMC supplies the power to the encoder; the SMC, however, must be provided separately with 24 VDC power.
SMC10/20
SMC30 The SMCs have the following interfaces:
 1 DRIVE-CLiQ interface
 1 encoder connection, including motor

temperature detection (KTY84-130 or PTC)
via Sub-D connector or terminals
 1 connection for the electronics power supply

via the 24 V DC power supply connector
 1 PE/protective conductor connection
1) Signal cables twisted in pairs and shielded.
Notes

Meaning of LEDs on the SMC 10, SMC 20

RDY — Off Electronics power supply is missing or outside permissible —
READY tolerance range.
Green Continuous light The component is ready for operation and cyclic —
DRIVECLiQ communication is taking place.
Orange Continuous light DRIVE-CLiQ communication is being established. —
Red Continuous light At least one fault is present in this component. Remedy and
The LED is activated regardless of whether the
corresponding messages have been reconfigured.
Green/Red Flashing Firmware is being downloaded. —
0.5 Hz
Flashing Firmware download is complete. Wait for POWER ON Carry out a POWER
2 Hz ON
Green/orange Flashing light Component recognition via LED is activated (p0144). —
or Note:
Red/orange Both options depend on the LED status when component
recognition is activated via p0144 = 1.
Meaning of LEDs on the SMC30

RDY — Off Electronics power supply is missing or outside permissible —
READY tolerance range.
corresponding messages have been reconfigured
0.5 Hz
2 Hz ON
or Note:
OUT > 5 V — Off Electronics power supply is missing or outside permissible —

tolerance range.
Power supply ≤ 5 V.
Orange Continuous light Electronics power supply for encoder system available. —
Power supply > 5 V.
Important:
Make sure that the connected encoder can be operated
with a 24 V power supply. If an encoder that is designed
for a 5 V supply is operated with a 24 V supply, this can
destroy the encoder electronics.
.
Notes

Sensor Module External

Direct encoder systems outside the cabinet can be connected to the Sensor Modules External SME20, SME25, SME120 and
SME125 with protection type (IP67) . The SMEs evaluate these encoder systems and convert the values to DRIVE-CLiQ.
The SME provides the encoder power supply. The power supply for the SME is provided from the connected DRIVE-CLiQ
cable.
SME20/SME25 feature the following interfaces:

SME20 / 25
X500 DRIVE-CLiQ-interface
X100 encoder connector via circular plug
24 V DC electronics power supply via DRIVE-CLiQ link from

the Control Unit/Motor Module
 1 PE/protective conductor connection
SME 20
 Incremental direct encoder systems with SIN/COS (1 Vpp) and reference signal can be
connected.
 KTY/PTC temperature sensors can be used for evaluation of the motor temperature.
 The Sensor Module is only suitable for motors without absolute track signals (C/D track):
– Induction motors (e.g. 1PH)
– Synchronous motors with pole position identification (e.g. 1FN, 1FW, 1FE)
SME 25
 Direct encoder systems with EnDat 2.1 or SSI with SIN/COS (1 Vpp) incremental signals
can be connected, however without reference signal.
Notes

SME120/SME125 have the following interfaces:

SME120 / 125
X300 hall-effect sensor connection via circular connector
(SME120 only)
X100 encoder connection via circular connector
X500 DRIVE-CLiQ-interface
X 200 temperature sensor connection via circular connector
24 V DC electronics power supply via DRIVE-CLiQ link

fromthe Control Unit or Motor Module
1 PE/protective conductor connection
Die SME 120/125 are always used when the temperature signals of the motors do not have protective separation or where this
separation is not possible for certain reasons.SME120/SME 125 is mainly used in linear motor applications.
SME 120
A Hall sensor box can be connected to determine the commutation position of a linear motor.
Incremental direct encoder systems with SIN/COS (1 Vpp) and reference signal can be connected.
SME 125
Direct encoder systems with EnDat 2.1 or SSI with SIN/COS (1 Vpp) incremental signals can be connected, however without
reference signal.
Notes

Terminal Module, DRIVE CLIQ Hub
TM 15
The number of available digital inputs and outputs within a drive system can be
expanded with the TM15 Terminal Module. The TM15 Terminal Module communicates
with a Control Unit via DRIVE-CLiQ.
The following are located on the TM15 Terminal Module:
X500/501 2 DRIVE-CLiQ-sockets
X524 Connection for the DC 24-V electronic power supply
RDY multicolor status-LED
X520 24 bidirectional digital inputs/outputs

X521 (isolation in 3 groups with 8 channels each)
X522 24 green status LEDs for indicating the logical signal status of
the relevant terminal
Notes

TM 31
With the TM31 Terminal Module, the number of available digital inputs and outputs and
the number of analog inputs and outputs within a drive system can be expanded.
The TM31 Terminal Module also features relay outputs with changeover
contact and a temperature sensor input.

X500/501 2 DRIVE-CLiQ-sockets
X 524 Connection for the DC 24-V electronic power supply
S5 current/voltage changeover switch for analog inputs
X521 2 analog inputs
X540 Auxiliary voltage for digital inputs
X522 2 analog outputs

1 temperature sensor input (KTY84-130 or PTC)
X520 4 digital inputs

X530 4 digital inputs
X542 2 relay outputs with changeover contact
Notes

TM 41
Mit dem Terminal Module TM41 lässt sich die Anzahl der vorhandenen Digitaleingänge/-
ausgänge sowie die Anzahl der Analogeingänge innerhalb eines Antriebssystems
erweitern. Die Geberschnittstelle des TM41 liefert TTL-Signale als
Inkrementalgebernachbildung an die Control-Unit.

X500/501 2 DRIVE-CLiQ-Buchsen
X524 Connection for the DC 24-V electronic power supply
X514 connection for the 24 V DC supply to digital outputs (X521)
Z-Pulse LED for signaling zero mark detection for encoder interface
X520 1 interface for simulation of TTL incremental encoder (RS422)
X522 4 digital inputs (with electrical isolation)
X523 1 analog inputs
Notes

Meaning of LEDs on Terminal Module TM 15, TM 31

READY — Off Electronics power supply is missing or outside permissible —
tolerance range.
corresponding messages have been reconfigured.
0.5 Hz
2 Hz ON
or Note:
Meaning of LEDs on Terminal Module TM 41

READY — Off Electronics power supply is missing or outside permissible —
tolerance range.
corresponding messages have been reconfigured
0.5 Hz
2 Hz ON
or Note:
Z pulses — Off Zero marker found; wait for zero marker output; OR —
component switched off.
Red Continuous light Zero mark not enabled or zero mark search. —
Green Continuous light Stopped at zero mark.
Flashing light Zero mark is output at each virtual revolution. —
Notes

DRIVE CLIQ Hub
DMC 20 DRIVE-CLiQ Hub Module Cabinet 20 / External 20

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 re

moved 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

Operator panels
Operator panel fronts

High performance
 Brilliant 8",10" ,12", 15“ and
19"displays“
 USB on the front panel
Rugged
 Front-mounted IP65 with
membrane keyboard
 High MTBF of backlighting
 Temperature up to 55°
Modular
 Can be combined with PCU
or
TCU, keyboard and machine
control panel
Machine Control Panels, Hand-Held Controllers
 SINUMERIK
integrated keyswitch
 Slots for control devices
 Optional connector for

direct keys/handwheel
 Enabling button
 Emergency STOP
 Ergonomic
Notes

PCU 50.5
Fan ON/OFF DC 24V 2x Ethernet 2 x PCI
Profibus 4x USB2.0 RS232 DVI-I

DP/MPI
Interface:
 2 Ethernet 10/100/1000 MBit/s,
 4 external USB ports (USB 2.0 Typ A)
 DVI-I-Interface (VGA-Monitors via optional adapter)
 12 MBit/s PROFIBUS-DP / MPI
 SINUMERIK Operator panel front
Expansion slots:
 PCI-Slot (Slot 1 / Slot 2)
 CompactFlash Card
Multiple Operator Panels on 1 NCU + 1 PCU

 User interface on several
OPs with one TCU each
 NCU 710 up to 2
 PCU 50.5 or
NCU 720/730 up to 4
 Different screen resolutions
possible
 100 m between the switch
and device
 Arbitrary number of panels
through intelligent
displacement with more than
2/4 TCUs
(n x T compared to 1 x M
Notes

Drive CLiQ rules
Obligatory Rules for DRIVE-CliQ
•• Max. 198 DRIVE-CLiQ Teilnehmer pro NCU

Max. 198 DRIVE-CLiQ participants per NCU
• Max.
Max.1414Teilnehmer an einem
participants on oneAnschluss
connnector
•• Max7 8Teilnehmer
Max participants in a row
in Reihe
•• No ring
Keine wiring
Ringverdrahtung
• No Double wiring
• Keine Doppelverdrahtung
No ring wiring
No Double wiring
Optional Rules for DRIVE-CliQ
• Motorgeber
Adherence to these rules
anallows automatic topology
zugehörigem MoModetection.
• For a motor module, the associated motor encoder must also
• Möglichst viele NCU-Ports nutzen
be connected.
• Use as many of the DRIVE-CLiQ connection points on the
NCU as possible as this allows better capacity utilization.
Notes

SINUMERIK 840D sl drive quantity framework
Supplementary conditions
General rules DQ-cycle No. Remark
Only SERVO control
No TMs permitted
No add-ons in addition to linear / rotary safety
125µs 14 axes
Double Motor Modules AC/AC have not been considered
Max. number of DQ count as two components The current hardware configuration determines
nodes / port / DRIVE-CLiQ HUB is not the components to be considered (also
counted*) deactivated DOs / Sensor Modules must be
62,5µs 5
considered in the quantity framework)
NC SI is provided for all axes
Max. number of DQ Double Motor Modules and Tdp >= 2ms / TncSI >= 12 ms
nodes along the -/- 8 DRIVE CLiQ HUB count as The sampling times are set via p112 = 3 (4 kHz)
resp. p112 = 4 (8 kHz)
longest path two components *)
Motor Direct DRIVE-CLIQ

measuring measuring HUB
Quantity frameworks DQ-cycle NCU NX ALM MOMO systems systems
NCU + NX, max 125µs 1 1-5 1 5 5 5 4

125µs 1 6 6 6 4
NX15, max 62,5µs 1 3 3 3 1
31,25µs 1 1 1 1 1
NX10, max 125µs 1 3 3 3 1
*) 840D sl Basic /
NCU710.3 + S120 125µs The SINAMICS S120 Combi counts as 5/6 DRIVE-CLiQ components
Combi, max
Notes

A060 END System Overview
IP-Adressen NCU
X120
IP-Adresse Netzteilnehmer Bemerkung
192.168.214.1 NCU on X120 Default
For additional NCUs with a
fixed IP address on the system
192.168.214.2 – 9 network Unassigned
For additional TCUs,
subsequently for
192.168.214.10 – 240 additional MCPs, MPPs DHCP-Clients
Fixed IP address of the PCU
192.168.214.241 on Eth 2 Default
For additional PCUs with a
192.168.214.242 – 249 fixed IP address Unassigned
For PGs with a fixed IP-
192.168.214.250 – 254 address (service connection) Unassigned
X127
IP-Adresse Netzteilnehmer Bemerkung
192.168.215.1 NCU on X127 Default
For programming devices
192.168.215.2 – 9 with a fixed IP address Unassigned
192.168.215.10 – 30 E.g., for programming device DHCP-Clients
A060: END

A002 Service and Commissioning Tools
Sinumerik
Operate
Module Description:
In order to integrate the Sinumerik 840D sl CNC to a machine tool, various software tools are re-
quired. The tools which enable the machine tool builder to create the PLC program for the machine,
configure the drives etc. Some of the software tools are also used for service tasks.
Software to be installed:
 PLC Toolbox DVD (PLC basic program, Sinumerik Add-on for STEP7, NC Var selector, PLC
symbols generator)
 Start-up Tool - From the Sinucom commissioning/service DVD. (Configuration of Tool Manage-
ment, configuration of drives and running service commands)
 RCS Commander - System card back-up, Remote control (Viewer)
Simatic Manager installation is not covered in this module but is a requirement.
Module Objective:
Upon completion of this module the course participant will be able to do the following:
 Install the software tools from the PLC toolbox DVD.

 Install the RCS Commander software tool.
 Install the Start-up Tool
 Set the network settings of the host computer
 Connect to the controller using each of the software packages.
Content:
Sinumerik
PLC Toolbox Installation.
Start-up Tool Installation
RCS Commander Installation.
Network Settings
Online Connection-RCS Commander
Online Connection-HMI Advanced
Online Connection-Simatic Manager
840D sl SINUMERIK Operate V4.5 Page 1 This document was produced for training purposes.
A002
A002
A002 Page 2 840D sl SINUMERIK Operate

Service and Commissioning Tools A002
Service and
Commissioning
Tools:
START Online
Connection:
SIMATIC Manager
PLC Toolbox
Installation
Service and
Commissioning
Tools:
END
Start-up (IBN)
Tool
Installation
RCS
Commander
Installation
Network Settings
Online
Connection:
RCS Commander
Online
Connection:
Start-up (IBN) Tool
Notes
840D sl SINUMERIK Operate Page 3 A002

PLC Toolbox Installation The Toolbox components need to be selected:
Toolbox content:
PLC Basic Program for 840D sl
Sinumerik Add-on for STEP7
NCVar Selector
PLC Symbols Generator
Installation Process:
Installation is started with the “setup.exe” file.
Double click the “Setup.exe”

file to start the toolbox
installation.
Acknowledge any dialogue boxes and allow the installation to

complete.
The toolbox components will now be installed, starting with A dialogue box will confirm that the installation was success-
the PLC Basic Program. ful:
Notes

Start-up Tool Installation Acknowledge any dialogue boxes and allow the installation to
complete.
The Start-up Tool can be found on the Sinucom Commission-
ing/Service Tools DVD For the 840D sl controller, the “SolutionLine” variant has to be
(Part number for current version: 6FC5250-0AY00-0AG0) selected.
The Start-up (IBN) Tool software must only be used for drive
configuration and tool management set-up.
Installation:
Installation is initialised by running the “Setup.exe” file:
On completion, the computer needs to be restarted in order to

finalise the installation.
Notes

RCS Commander Installation Installation:
RCS Commander allows a remote operation between the To install the RCS Commander software, locate the
828D controller and a computer running windows. “Setup.exe” file in the root of the RCS Commander DVD. Start
the installation by double clicking the file.
Data such as part programs can be transferred between the
remote computer and the controller.
A viewer is included which is used to view and change the

controller settings remotely (Dependant upon access rights).
The software can also be used to write images to compact

flash cards for service and commissioning tasks.
Note:
The RCS commander software is not part of the toolbox.
Double click the

“Setup.exe” file to start
the installation.
Acknowledge any dialogue boxes and allow the installation to

complete.
Network Settings Select the “Network and Sharing Center” option.

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

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

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

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

The PC has been assigned the first available IP address of

192.168.215.2 by the DHCP server of X127.
Online Connection-RCS Commander Set the privilege level to “Run this program as an 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 RCS Commander program and
select “Properties“.
Notes

A dialogue box appears where the choice of connection is

made.
A default connection is available, this is specifically for
connecting to X127 of the controller (IP address
192.168.215.1).
When the program is opened for the first time after the
installation it is necessary to assign a password for encryption
purposes.
It is necessary to login with a password depending on the ac- The access level determines which data can be accessed via
cess level required: RCS Commander.
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 RCS Commander program, this
indicates a successful connection was made.
Online Connection: StartUp (IBN) Tool Administrator Privilege Level

The Toolbox programs should always be run with privileges
During installation a folder is created on the desktop of the set to Administrator.
computer. Within this folder are shortcuts for starting the NC
Connect Wizard and the StartUp Tool. Setting the Administrator Privilege:
Right click on the icon of the StartUp Tool program and se-
lect “Properties“
Note: For Windows 7 version, IBN Start-up in separate Desk-

top is not supported.
Notes

NC Connect Wizard:
The NC Connect Wizard is used to select the interface and
adjust the settings which enable the StartUp Tool to
communicate with the controller.
Choose the 840D solutionline option:
Select the “Engineering Tools (Recommended)” option. Connection/cabling information is provided, a crossover or
This is specifically for connecting via X127 straight cable can be used depending upon the network
adapter of the PG/PC.
Notes

Setting the PG/PC Interface:

X127 has a fixed IP address of 192.168.215.1.
It is also necessary to check the PG/PC interface setting to
ensure that the software is able to communicate. These set-
tings are checked in the “Control Panel” area of the PG/PC.
In the “Control Panel” area, select and open the “Set PG/PC
Interface” program.
The connection setting can be saved under a suitable name

for future use, do not change any other settings.
Select “Finish” to complete the task.
The Access point and network adapter have to be selected.

The Access Point required is the “Sinumerik_CP” option.
Network adaptor example: Intel® 82579LM Gigabit Network
The “Access Point

of the Application”
needs to be
selected from the
list.
(SINUMERIK_CP)
Select the
network adapter
which is in use.
Connect an ethernet cable between the computer and port
X127 of the controller. Run the Start-up tool via the “Start-Up
Tool” shortcut.
Notes

The software will boot to the following screen: Online Connection: SIMATIC Manager
A SIMATIC Manager shortcut icon is placed on the
PC desktop during the installation process.
Administrator Privilege Level

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

Right click on the icon of the SIMATIC Manager program and
select “Properties“
To exit the software, select the F10 key on the PG/PC

keyboard followed by the “EXIT” soft-key.
F10
Set the privilege level to “Run the program as administrator“ Setting the PG/PC Interface:
To allow the program to communicate via Ethernet it is nec-

essary to set the PG/PC interface.
Start the SIMATIC Manager program
The setting for the connection can now be changed. Open the
“Options” menu and select “Set PG/PC Interface.
Notes

A002 END Service and Commissioning Tools
The Ethernet adapter of the computer needs to be selected

from the list.
In the example below, the network adapter is of the type:
Intel® 82579LM Gigabit Network.
Any changes are indicated with an information box.
Checking the online connection: The accessible nodes in this case are:
Ensure that a suitable Ethernet cable is connected between Numerical Control Unit (ncu1)
the PC and X127 of the controller. Thin Client Unit (TCU1)
Machine Control Panel (mcp-ie192)
To check the connection select “Accessible nodes” on the tool
bar.
After a short delay the available Accessible nodes will be dis-

played.
Accessible nodes are the hardware components which are
connected to X120. The internal routing of the controller allows
these to be accessed via X127
Seeing these shows that the connection to the controller has
been established.
A002: END
Notes

A150 SIMATIC Manager
Sinumerik
Operate
Module Description:
The SIMATIC Manager is the main tool in STEP 7. This module provides an overview of the basic
functions of the SIMATIC Manager. The SIMATIC Manager is used to create STEP 7 programs
and for the diagnostics of the PLC (programmable logic controller) when an error occurs.
Module Objective:
At the end of this module, you will be acquainted with the basic functions of the SIMATIC Manager.
You can create a project and will get to know the various programming languages. You will also
learn about the diagnostic options of the SIMATIC Manager.
Content:
Sinumerik
 SIMATIC Manager
 Creating a project
 Hardware configuration
 Blocks in STEP 7
 Program window
 Generating reference data
 Controlling/monitoring variables
A150
A150

SIMATIC Manager A150
SIMATIC Manager:
START
SIMATIC
Manager
Creating a
project
Hardware
configura-
tion
Blocks in
STEP 7
LAD/STL/FBD
programming
languages
Reference
data
Controlling/
monitoring
variables
CPU
diagnostics
SIMATIC Manager:
END
Notes

SIMATIC Manager The SIMATIC Manager opens with the STEP 7 wizard for new
projects.
STEP 7 is the basic programming and configuration software
for SIMATIC. It comprises a number of applications with which
partial solutions can be implemented easily, for example:
 Configuration and parameterization of the hardware
 Creation and testing of the user program
 Configuration of networks and connections
STEP 7 can be expanded through a number of option

packages, e.g. additional language packages such as SCL,
S7-GRAPH or HiGraph.
Graphic access to all these applications is via the
SIMATIC Manager. It combines all the data and settings that
are required for an automation solution into a project. The data
is structured according to topics in this project and displayed
as objects.
Starting STEP 7
After starting Windows, an icon for the
SIMATIC Manager is displayed on the The wizard for the creation of a new project can be switched
Windows user interface. This is the entry off for SINUMERIK projects because SINUMERIK controllers
into the STEP 7 software. are not supported.
Creating a project Enter the name of the project at Name: and confirm with OK
A new project is created via the menu item File > New.
Note: The SIMATIC Manager permits names that have more
than eight characters. However, the name of the project
directory is shortened to eight characters. For this reason,
project names must differ within the first eight characters. No
distinction is made between upper and lower case.
Projects are used to store the data and programs produced

during the creation of an automation solution in an orderly
manner. The project data includes:
 Configuration data about the hardware structure and

parameterization data for modules
 Configuration data for communication via networks
 Programs for programmable modules
The main task during the creation of a project is the provision

of this data and the programming.
Notes

A new SIMATIC station is inserted in order to generate this

project structure.
The project window is split into two sections. The left-hand

section shows the tree structure of the project and the right-
hand section shows the contents of the object selected on the
left in the specified view (large icons, small icons, list or
details).
Hardware configuration
With the hardware configuration, you specify the CPU and all
the modules contained in your controller with the aid of a
module catalog. You can start the hardware configuration by
double-clicking:
During the hardware configuration it is important that the

toolbox with the appropriate add-ons is installed first because
this creates the hardware catalog for the required NCU.
For additional hardware, you require GSD files from the manu-
facturer or corresponding XML files with the appropriate infor-
mation for integration in the hardware. GSD files and XML files
are already stored in the toolbox for Siemens hardware. The
installation is described in “Installation of GSD files”.
Select the required NCU from the hardware catalog by open-

ing the SIMATIC 300 > Sinumerik > 840D sl tab.
Notes

Double-click the appropriate NCU to create the hardware.
The hardware catalog can be hidden and shown via

the following symbol.
The I/O must now be selected. When creating the NCU, you
are first prompted whether a PROFIBUS connection is
available. Confirm this with Yes. The address to be set must
be taken from the hardware plan or, if it is not already
assigned, use the standard address.
Important default settings are made via the object properties

of the NCU.
For example, a clock memory can be set which can be used

to poll the individual clocks in the PLC in order to control a
flashing signal light.
Notes

In this example memory byte 1 has been entered as clock The retentivity for the bit memory, counters and timers can
memory. The individual bits of memory byte 1 are clocked as also be set as a further property of the NCU.
follows by the NCU:
The help is called with “F1”.
The value 16 is the default setting for the memory bytes and
8 for the counters. There is no default setting for the timers.
After the NCU has been created and configured, the

PROFIBUS nodes still have to be set. To do this, the cursor is
placed on the PROFIBUS(1) DP master system. The
connected PROFIBUS nodes can now be selected in the
hardware catalog.
Notes

For additional hardware, you require GSD files from the manu- This is taken over by doubling-clicking the selected module (or
facturer or corresponding XML files with the appropriate infor- by selecting it and dragging it to the PROFIBUS(1) DP master
mation for integration in the hardware. system). The PROFIBUS address set on the module still has
to be entered.
This is performed via Options > Install GSD File…
Setting on the PROFIBUS module via DIP switch (here, for The connected I/O modules can now be entered as of slot 1.
example, 99). To do this, the corresponding folder is opened below the
PROFIBUS node and the connected module installed by
double-clicking it.
If several PROFIBUS nodes are connected, this setting must

be made for each node.
Notes

The complete hardware configuration then looks like this: The address ranges must then be set for the individual I/O
modules. This is performed by double-clicking the module to
open the I/O module properties, selecting the Addresses tab
and entering the address used.
To pack the address range (packing of two or more modules

with bit addresses to one byte address), select the modules
to be packed and click the “Pack Addresses” button.
This is now repeated for all modules.
The address ranges of the modules now looks like this:
The modules on slots 1 and 2 now have the byte 16 address

range.
Notes

The hardware configuration can now be checked for If the consistency check is performed without error, the
consistency. hardware configuration can be compiled and saved.
This checks the current configuration and parameterization of

the automation system for consistency, i.e. whether
configuration data can be created with these entries.
Blocks in STEP 7 There are various types of blocks that you can use within an
S7 user program:
The STEP 7 programming software allows the user program Organization blocks (OB)
to be structured, i.e. to be divided into individual, self-
contained program sections. This provides the following Organization blocks form the interface between the operating
advantages: system and the user program. They are called by the
operating system and control the cyclic and interrupt-driven
 Comprehensive programs can be programmed program execution, the startup behavior of the automation
straightforwardly system and the handling of faults. You can program the
 Individual program sections can be standardized organization blocks and thus determine the behavior of the
 The program organization is simplified CPU.
 Changes to the program can be made more easily
 The program test is simplified because it can be
performed section-by-section
 The commissioning is easier
Block types
Notes

Operating system User program Refer to the documentation of the deployed S7 CPU to see
which interrupt and fault OBs can be used. If an online
Activation connection is established to the NCU, this can also be taken
from the object properties of the CPU.
OB100
Main program
Cyclic
OB1
Interrupt
<Interrupt> Interruption service
routine
OB10 - OB64
<Fault> Interruption Fault service

routine
OB80 - OB88
OB121
Priority of the organization blocks
Organization blocks determine the sequence (start events) in

which the individual program sections are executed. The
execution of an OB can be interrupted by the call of another
OB. Which OB can interrupt another OB depends on the
priority. Higher-priority OBs interrupt lower-priority OBs.
System function blocks (SFB)
A system function block is a function block that is integrated

in the S7-CPU. Since SFBs are part of the operating system,
they are not loaded as part of the program. As with FBs,
SFBs are blocks "with memory". You must also create
instance data blocks for the SFBs and load these as part of
the program to the CPU.
Refer to the documentation of the deployed CPU to see
which SFBs are available.
If an online connection is established to the NCU, this can
also be taken from the object properties of the CPU.
Notes

S7-CPUs provide SFBs for:
 The data exchange via communication function blocks

 The integrated closed-loop control
System functions (SFC)
A system function is a pre-programmed function that is

integrated in the S7-CPU. You can call the SFC from your
program. Since SFCs are part of the operating system, they
are not loaded as part of the program. As with FCs, SFCs are
blocks "without memory".
If an online connection is established to the NCU, this can
also be taken from the object properties of the CPU.
S7-CPUs provide SFCs for the:
 Copy and block functions

 Program monitoring
 Handling of the clock and the operating hours counter
 Transfer of the data blocks
 Handling of time-of-day and time-delay interrupts
 Handling of synchronous fault events, interrupt and
asynchronous fault events
 System diagnostics
 Process image update and the bit array processing
 Addressing of modules
 Distributed I/O
 Global data communication
Notes

Function blocks (FB) Functions (FC)
A function block is a block "with memory". It has an assigned A function is a block "without memory". Temporary variables
data block as memory (instance data block). The parameters of the FC are saved to the local data stack. This data is lost
that are transferred to the FB and the static variables are when the processing of the FC is completed. Functions can be
saved to the instance DB. The temporary variables are saved used to save the data of global data blocks.
to the local data stack.
Since an FC does not have any assigned memory, you must
Data that is saved to the instance DB is not lost when the always specify actual parameters for an FC. You cannot
processing of the FB is completed. Data that is saved to the assign any initial values to the local data of an FC.
local data stack is lost when the processing of the FB is
completed. Actual parameters
When a block is called, it can be supplied with block

parameters (constants, operands or variables). These are
called actual parameters.
Data blocks (DB)
In contrast to code blocks, data blocks do not contain any

STEP 7 instructions. They are used to import user data, i.e.
the data blocks contain variable data with which the user
program works.
Creating a new block
Open the Blocks folder and then the “Insert” menu item. A
selection of blocks appears when the cursor is placed on “S7
Block”. Select the function block.
A new window opens in which the properties of the new

block are entered.
Notes

The block can now be opened for editing. The block is

The display name in the header as well as a version ID and selected by double-clicking and opens in the set
the author of the block are entered in the General - Part 2 programming language (STL/LAD/FBD).
tab. The block can also be assigned to a family.
Variable declaration table
The variable declaration table is in the window above the

program section. A distinction is made between different
variable types.
Notes

Variable types in the declaration section:
Variable type Declaratio Block type

n
Input parameter IN - FC FB
Output parameter OUT - FC FB
In/out parameter IN_OUT - FC FB
Static local data STAT - - FB
Temporary local TEMP OB FC FB

data
Function value RETURN - FC -
When calling an FB, the instance DB must also always be

specified. The variables are created in this instance DB.
Notes

LAD/STL/FBD programming languages
Overview of the program window with the opened LAD block
Program elements The most frequently used LAD

operations are displayed in the toolbar
These are only available for LAD
and FBD
Toolbar for FBD
Interface of the function block with input/output

variables as well as static and temporary
variables.
Program editor window
Notes

Program window
With contacts, you poll the binary operands (inputs, bit mem-
The fields for the block title and the block comment are ory, etc.). There are two types of contacts, NO contacts and
displayed in the program window as well as the fields for the NC contacts. With NO contacts you poll the operand for “2”
network title, the comment and the field for the program input and with NC contacts for “0”.
for the first network. These can be adapted individually via The result of the logic operation is inverted with the “NOT”
the default settings of the editor. contact.
Coils
Simple coil
Ladder logic LAD
In the ladder logic programming language (LAD), you

Set
program the control elements by arranging graphic program
elements. These are mainly contacts, coils and boxes that
are interconnected in the form of a circuit diagram.
Reset
With coils, you control the binary operands, such as outputs.

Contacts There are coils with additional functions, such as (S) for set
and (R) for reset. You can also execute individual timer and
NO contact counter functions, and jumps in the program. Please refer to
the SIMATIC Manager documentation for the available
functions.
NC contact
Boxes
Contacts with special
functions
For example: Timer
Timers
Counters
Please refer to the SIMATIC Manager documentation for the

available functions.
LAD represents program elements with digital functions as

boxes . Valid addresses must be entered for all operands
marked with “???”.
Help for the selected function is opened with “F1”.
Notes

The program is structured through single networks in the LAD The networks are mandatory when programming in LAD and
program editor. A title can be entered for each network. A FBD. Whereas with STL, the entire program can be written in
comment to describe the function can also be entered for each one network, which however adversely affects the readability
network. and the documentation. In addition, these networks can no
longer be translated from STL to LAD or FBD.
It is possible to switch between the individual programming

languages (STL, LAD and FBD) in the program editor.
Networks that cannot be translated are displayed in the
programming language in which they were created.
View of the same networks in STL
Please refer to the SIMATIC Manager documentation for the

entire functional scope of STL.
Statement list STL
In the statement list (STL), you program the control tasks

through a sequence of statements. These statements can be
separated by single networks or written continuously.
Comments can be inserted with “//” in the individual networks.

Example of simple binary logic operations:
Notes

Function block diagram (FBD) In the function block diagram programming language (FBD),
you program the control tasks by connecting boxes. FBD
Below is the same view as for LAD and STL in the function provides function boxes for linking signal states, simple boxes
block diagram representation. for the processing of logic operations of signal states, simple
boxes for linking the logic operations and complex boxes for
non-binary functions.
A network always only contains one logic operation. This

comprises coherent, interconnected functions.
With logic operations, a distinction is made between binary,

simple boxes and complex boxes.
Binary logic operations
The linking of binary signal states is implemented in FBD

through the AND, the OR and the exclusive OR functions. At
the input of these functions, you can write the operands whose
signal state you want to poll and link.
AND function
OR function Complex boxes
Complex boxes represent program elements with non-binary

functions.
Example of complex boxes:

Exclusive OR function
Parameterize and start
Time as pulse
Simple boxes
With simple boxes, you control the binary operands, such as

outputs. Generally, simple boxes have only one input.
Add integers
(16-bit)
Example of simple boxes:
Assignment
Count up
Notes

Symbol table
Programming can be symbolic or with the address of the oper-

and. In symbolic addressing, a distinction is made between
“local symbols” and “global symbols”. A local symbol is only
known in the block in which it has been defined. A global sym-
bol is known throughout the entire user program. Global sym-
bols are created in the symbol file.
A global symbol begins with a special character or a letter and

can have up to 24 characters. The symbol comment can have
up to 80 characters.
The data type is also part of the specification of a symbol. It
defines certain properties of the data hidden behind the
symbol (bit, byte, word, etc.).
The symbol file is opened in the S7 program by double- You can also assign a symbol for an operand directly in the
clicking. All the used operands can be entered with a symbol program editor. To do this, the cursor is placed on the operand
and a comment. A data type must be set for each symbol. and a window opened by right-clicking.
Reference data
You can generate and evaluate reference data to facilitate

the testing and changing of your user program. Reference
data is used, for example, as
 An overview of the entire user program

 A basis for changes and tests
 A supplement to the program documentation
The following views are available

 Cross-reference list
 Assignment plan
 Program structure
Select “Edit Symbols…” here to open another window in  Symbols that are not used
which the symbols can be entered.
 Operands without symbols
Notes

Cross references: Operands without symbol

Overview of the use of operands of the memory areas E, A, M, Overview of all absolute addresses (absolute operands and
P, T, Z and DB, FB, FC, SFB and SFC calls within the user blocks) that are used in parts of the user program and for
program. which reference data is available, but for which no symbol is
defined in the symbol table.
Assignment plan
The overview of which bits of the operands of memory areas
E, A and M or which timers and counters within the user To generate the reference data, place the cursor on the
program are already assigned is an important base for Blocks folder in your S7 project and select the Options menu
troubleshooting or for changes in the user program. item. Then select “Reference Data > Generate”.
Program structure
Call hierarchy of the blocks within a user program and
overview of the used blocks and the dependencies.
Symbols that are not used

Overview of all symbols that are defined in the symbol table,
but not used in parts óf the user program for which reference
data is available.
If the reference data is not up to date, a "Generate Reference

Data" prompt appears.
The reference data can be
· updated or
· regenerated.
Select the "updated" option if you want to generate data for

changed or new blocks. The data for deleted blocks is then no
longer displayed.
Select the "regenerate" option if you want to delete available
data and regenerate the complete reference data.
Notes

After the reference data has been generated, it can be dis- “Display S7 reference data” is opened and you are prompted
played via “Reference Data > Display”. as to which data should be displayed.
All the selected symbols are displayed in the cross-reference

list. A selection can be set under “View”. Double-click a sym-
bol at the location to open the corresponding block.
Creating a variable table
All the variables that are to be monitored or controlled are

listed in a variable table (VAT). A new variable table is
created, for example, by opening the block container and
“Insert -> S7 Block > Variable Table”.
Monitoring/controlling variables
If the CPU can be reached online and you have loaded the
hardware configuration to the CPU, then you can address the
inputs and outputs of the configured I/O modules directly, i.e.
without having to change the application.
Notes

A name is assigned to the new variable table. In addition, a Double-clicking the VAT symbol opens the variable table and
comment as well as a version and an author can be entered. the variables to be controlled or monitored can be entered
now.
Comments on the variables can also be inserted in the

variable table.
Notes

A connection must be established to the configured controller in order to display the status values (actual values of the vari-
ables). When the connection is established, the actual status value can be displayed with the symbol. A value can be en-
tered in the “Control value” column which overwrites the status value when the symbol is clicked. Note that all inputs are re-
read in every cycle and set to the input value and all outputs that are used in the PLC assume the value of the PLC again.
Depending on the variable type (bit,

byte, word, etc.), the display format
can be set to the required format.
Danger
Changing the variable values during operation can cause severe damage or injury due to malfunctions or
! program errors!
Make sure that no dangerous states can occur before you execute the "Control" function!
Notes

CPU diagnostics
If a network connection is established to the NCU (see A002),

the module status of the connected CPU can be diagnosed
via “Target System -> Diagnostics/Settings -> Module infor-
mation“.
The various options are displayed here. One of the most If an error occurs, the cause of the error is displayed in the
important is the „Diagnostics“. The status of the CPU is dis- Details.
played.
Notes

A150 END SIMATIC Manager
There is also an overview of the CPU memory. Another important diagnostic item is the display of the cycle
time. A monitoring time of max. 150 ms is preset in the
machine data. If the cycle time of the PLC is greater, an
interrupt is issued.
The operating state of the PLC can also be displayed in

“Diagnostic/Setting”.
The PLC can be stopped and started during the display of the
operating state.
A150: END
Notes

A026 Creating a PLC program
Sinumerik
Operate
Module Description:
The Step 7 PLC Programming package is used to create the machine interface program for the
840D sl Sinumerik Operate.
In order to use the Step 7 package to its upmost, it is necessary to know the structure of the Sinu-
merik controller and the structure of its interface; this knowledge is required in order to produce a
machine tool oriented PLC program which adheres to the relevant safety regulations of the desti-
nation country.
Module Objective:
Upon completion of this module you will know how to use the Step 7 Programming tool to:
 Create a PLC program

 Install the Sinumerik PLC Basic Program
 Configure the PLC Hardware
 Download a PLC project to the controller from a computer
Content:
Sinumerik
S7-300 PLC Cyclic Operation
840D sl Sinumerik Operate PLC
Integrate Basic PLC
Basic PLC Framework
Reserved Functions
Reserved Data
Example Base Program
A026
A026

Creating a PLC program A026
Create
PLC Program:
START
Step 7-300
PLC
840D sl
Sinumerik
Operate PLC
Integrating
the Basic
PLC
Basic PLC
Framework
Reserved
Functions and
Function
Blocks
Reserved
Data Blocks
Example:
Base
Program
Create
PLC Program:
END
Notes

Step7 300 PLC: PLC

Start-up Operating system
PII (Periphery Image Inputs)
PII (Program Image Inputs)
OB 100 (Program startup)

CALL FCxxx FCxxx
.... ....
Statement List Statement List
.... ....
Ladder diagram Ladder diagram
.... ....
BE (Program end) BE (Program end)
PIO (Program Image outputs)
PIO (Periphery Image Outputs)
Step7 300 PLC:

Cyclic operation OB 1 (Program entry Cyclic)
....
CALL FCxxx FCxxx
.... ....
Statement List
Statement List ....
PII (Program Image Inputs) Ladder diagram
....
....
.... BE (Program end)
CALL FBxxx,DBxxx
PII (Periphery Image Inputs) FBxxx DBxxx - Instance
....
Ladder diagram .... ....
.... Statement List ....
.... .... ....
Ladder diagram ....
.... ....
BE (Program end Cyclic) BE (Program end)
PIO (Program Image outputs)
PIO (Periphery Image Outputs)

PLC
Operating system
Notes

840D sl Sinumerik Operate PLC
DB2 Messages
PLC Start-up TO Interface
Operating system
FC 10
PII (Periphery Image Inputs) PLC User IF NCK

FB1 Internal IF
PII (Program Image Inputs) Parameterisation
Startup Functions
OB 100 (Program startup) From
Sinumerik System Interface
CALL FB1,DB7
...... BE (Program end) DB9 Compile Cycles
User Program, here: To
...... TO Interface Interface
Ladder diagram DB7 FROM Interface
...... Basic program
Statement List Parameters
BE (Program end) Settings DB10 Mode Group
....
PIO (Program Image outputs) .... TO Interface
....
PIO (Periphery Image Outputs) FROM Interface
FC 2 Cyclic DB11 NC
to/from
FC2 PLC User / TO Interface
OB 1 (Program entry Cyclic)
Sinumerik System NCK Internal
Sinumerik 840D FROM Interface
CALL FC2
PLC Basic
......
Program
User Program, here: INTERFACE DB19 HMI
Control
...... TO Interface
BE (Program end)
CALL FBxxx,DBxxx FROM Interface
......
Ladder diagram FBxxx
.... DB21 Channel
Or Statement List
.... TO Interface
Statement List Ladder diagram
.... FROM Interface
......
BE (Program end)
BE (Program end Cyclic) DB31 Axis
DBxxx Instance TO Interface
....
.... FROM Interface
PIO (Program Image outputs) ....
....
PIO (Periphery Image Outputs) DB71,72,73
Tool Management
PLC TO Interface
Operating system
FROM Interface NCK Cyclic
to/from
PLC User IF
PII (Periphery Image Inputs)
PII (Program Image Inputs)
Notes

Integrating the Basic PLC
Note: PLC Toolbox installation is described in Module

A002.
In order to create the User PLC program, firstly the PLC Basic
Program has to be installed and implemented.
The Basic Program takes the form of a Step 7 Library which
Installation of Basic program
has to be integrated into the User Project. and additional support tools.
:Sinumerik Addons
Toolbox Installation: : NC Var Selector
: Symbol generator
Toolbox installation
CD
Library Integration and Hardware Configuration:
In order to integrate the Basic program into the User Program,

the necessary “Sinumerik“ hardware components must be
made available for the hardware configuration. This is
achieved through the installation of the “Sinumerik ADDON“.
Hardware configuration displaying the Sinumerik Addon

components:
Hardware configuration
tool:
Open to select the PLC
hardware.
Hardware
Configuratio
Sinumerik
“Addons”
Sinumerik Library:
open and copy to
project.
The PROFINET IO system can be inserted from the context

menu when not activated when inserting the NCU.
Notes

Basic PLC Framework
Upon successful integration of the “Sinumerik Hardware“ and

Machine periphery in the Hardware configuration utility, the
compilation of the hardware components can be started.
Upon completion the S7 Program objects can be found in the
user project.
The library blocks can now be copied into the corresponding
directories of the user program; the symbol table can be
overwritten.
OB1 + OB100
With
Basic Program
Calls
Basic Program
(as Library)
copy to User
program.
The Basic PLC program can be seen by opening OB1 and/or OB100 in the Step 7 editor.
In OB1, the basic program is executed through the call to FC2, and in OB100 with the call to FB1.
Notes

Reserved Functions and Function Blocks
Number Function
FB 15 Basic program
FB 1, FC 2, FC 3, FC 5 Basic program
FC 0 ... 29 Reserved for Siemens
FB 0 ... 29 Reserved for Siemens
FC 30 ... 999 1) Free for user assignment
FB 30 ... 999 1) Free for user assignment
FC 1000 ... 1023 Reserved for Siemens
FB 1000 ... 1023 Reserved for Siemens
FC 1024 ... upper limit Free for user assignment
FB 1024 ... upper limit Free for user assignment
1)
The actual upper limit of the block number (FB/FC) depends on the PLC/CPU on which the selected NCU is located.
Notes

Reserved Data Blocks
Overview of data blocks

DB no. Name Function Package
1 Reserved for Siemens BP

2 ... 5 PLC-MELD PLC messages BP
6 ... 8 Basic program
9 NC-COMPILE Interface for NC compile cycles BP
10 NC INTERFACE Central NCK interface BP
11 Mode group 1 Interface mode group BP
12 Computer link and transport system interface
13 ... 14 Reserved for basic program
15 Basic program
16 PI Service definition
17 Version identifier
18 Reserved for basic program

19 HMI interface
Overview of data blocks

DB no. Name Function Package
20 PLC machine data
21 ... 30 CHANNEL 1 ... n Interface NC channels BP
BP
31 ... 61 AXIS 1 ... m Interfaces for axes/spindles
or free for user assignment
62 ... 70 Free for user assignment
71 ... 74 Tool management BP
75 ... 76 M group decoding
77 Data block for MCP signals
78 ... 80 Reserved for Siemens
81 ... 999 Free for user assignment
1000 ... 1099 Reserved for Siemens
1100 ... High Free for user assignment

limit
The actual upper limit of the block number (DB) depends on the PLC/CPU on which the selected NCU is located.
The data blocks of channels, axes/spindles and tool management functions that are not activated may be as-
signed as desired by the user.
Notes

Example: Base Program Integration

Select the Sinumerik controller from menu tree.
Create a New Project e.g. 840Dsl Sinumerik Operate.
Start the Step 7 Hardware configuration.
Configure the Profinet network Periphery not connected to Profinet
Select - not networked -
Notes

Periphery connected to Profinet Change- Name - to Profinet(1) - this step is not necessary but
is logical, as the original name is „Ethernet“ and could cause
confusion later with diagnostics.
Select - New - to Create new active Network
The Profinet Input/Output system can

now be extended with additional
modules from the Profinet branch of
the Hardware catalogue.
Notes

The Profinet periphery PP72/48 will be

inserted and configured in this
example.
The board can be found in the
component list under - PROFINET IO -
I/O - SINUMERIK.
First insert the Object container, and
the individual components can inserted
into the respective slots of the Module
object.
If the Object is not existing in the

Hardware catalogue, it should be
imported from the GSD file .
The PP72/48 is such a case, and can
be found in the PLC Toolbox as shown.
Updating the Profinet Topology
All profinet modules have to be inserted to the network, from

the component list.
The components have to be connected to each other to
create the Profinet Topology, this is carried out using the
Topology editor.
To start the Topology editor, right click one of the Profinet
objects and select the "Profinet IO Topology" from the menu.
The start address can be changed if necessary, this is carried

out by double clicking the slot number to enter the Object
properties, and under the address tab the start address can be
changed.
Notes

The Topology editor con-

sists of the Topology win-
dow on the left side and
the component tree on the
right.
Using the mouse compo-

nents (connections) from
the component list can be
dragged to their respec-
tive position in the Topol-
ogy Windows.
In the above Topology picture an example can be seen of a

PP72/48 connected to Port 1 of the X150 on the NCU board.
It is imperative that the correct ports are connected, in this
case - port-001(X1) is physically connected to Port 1 (X150
P1 R) of the NCU and this has to be replicated in the
Topology as can be seen above.
Notes

In addition to the Topology, a device number and IP have to

be assigned.
To assign the device number you right click the object and
select the Object properties.
In the Object properties dialog box, the device number In addition the Device name has to be changed to reflect
matching the device number set physically on the module the Device number.
(PP72/48 Dip switch S1) should be selected. The Device number has to be therefore appended to the
The default Dip switch settings for the PP72/48 are set for Device name.
Device number 9, therefore the number 9 has to be defined
in the Object properties. In the case of the PP72/48 as default pp72x48pn9 will be
the resulting Device name, which has to be unique on the
bus.
Notes

Dip switches and Device names

Switch S1 - PP72/48 Default device name
Switch S1/S2 Binary Value
Position pp72x48pn xxx
1 1
The switch positions 1 to 8 define the default device name of
2 2
the I/O module. There are up to 128 default device names. If
3 4 these default device names are used, there is no need for
initialization.
4 8
binary value 9 = pp72x48pn9
5 16
6 32 DCP-Mode
Switch S1 to S8 be switched "on".
7 64 In this mode, there is no default device name.
8 128 The device name must be set using initialization and remains
saved on the I/O module. It is first deleted when the factory
9 Profinet=ON setting is restored, e.g. using STEP7.
10 Profinet=ON
Notes

Configure the Profibus network
If the periphery is not connected to the Profibus, select "not

networked" under Profibus (DP X126) Object properties.
If periphery is connected to the Profibus, select New and
create a networked Profibus.
Configure the Profibus network - no changes required Select the newly entered Bus and confirm with ok
Notes

At this point the "PROFIBUS DP

master system" can be seen and
components from the component list
can be inserted onto the Bus.
Notes

A026 END Creating a PLC program
Profibus populated with ET200S
Notes

Adding additional components Additional axes can be added e.g. NX boards
Save and compile the project.
Notes

After a successful compilation, the Step7 Program Objects You can now search for the Library which was installed from
are available to the user. the Toolbox, and open it in the Step 7 editor.
The Library, as it appears in the Step 7 editor. The Library and the user program open in the Step 7 editor.
Notes

Program blocks in the PLC Basic Program. Source code in the PLC Basic Program.
Copying of the Program Blocks from Library to User program. Always overwrite OB1 when copying from the Library,
otherwise the Basic PLC will not be called with FC2.
The Library blocks are now present in the user project.
Notes

Copying of the Source Blocks from Library to User program Copying of the Symbol Table from Library to User program.
After successful integration of the Basic PLC Program, OB1 OB100:

and OB100 should look the same as in the following two
examples.
OB1:
Notes

In order to complete the example, the two parameters in ORGANIZATION_BLOCK OB 100

TITLE =
OB100 / FB1 have to be changed to suit the address and { S7_language := '9(1) English (United States)
type of MCP being used. 13.10.2010 16:56:20' }
VERSION : 1.0
MCP1BusAdr :=192
MCP1BusType :=55 VAR_TEMP
OB100_EV_CLASS : BYTE ;
OB100_STRTUP : BYTE ;
Bus Address is dependant upon the DIP switches on the OB100_PRIORITY : BYTE ;
back of the MCP and is described in Module A008. OB100_OB_NUMBR : BYTE ;
Bus Type can be 5 which determines Ethernet, alternatives OB100_RESERVED_1 : BYTE ;
OB100_RESERVED_2 : BYTE ;
are described in the Module A033 PLC Functions. OB100_STOP : WORD ;
OB100_RESERVED_3 : WORD ;
OB100_DATE_TIME : DATE_AND_TIME ;
END_VAR
BEGIN
NETWORK
TITLE =
CALL FB 1 , DB 7 (
MCPNum := 1,
MCP1In := P#I 0.0,
MCP1Out := P#Q 0.0,
MCP1StatSend := P#Q 8.0,
MCP1StatRec := P#Q 12.0,
MCP1BusAdr := 192,
MCPBusType := B#16#55,
NCKomm := TRUE);
//Insert User program from here
END_ORGANIZATION_BLOCK
Traversing keys
In addition the MCP (Machine Control Panel) has to be trans-
fered Overrides
Function Description: Key-operated switch
The Machine Control Panel signals can be transferred from

the MCP periphery to the corresponding signal at the PLC --> Prerequisites for the Function:
NCK Interface.
If a standard signal transfer is acceptable then one of the MCP Hardware available
following Step 7 Functions can be called, dependant upon
the MCP type. HMI Requirement:
None
FC19 MCP 19“ Milling
FC25 MCP 19“ Turning

Drive requirement (Sinamics):
FC24 MCP small None
FC26 HT6
NCK Requirement:
The following group signals are transferred: None
Mode Groups
PLC Requirement:
Axis selections
Parameterisation of the corresponding Step 7 Function.
WCS/MCS switchover commands
Notes

Steps to achieve running function: Axis sequence for FC19,FC25 etc
Parameterisation of the corresponding Function.

The axis sequence for the FC19 can be found in the
interface DB10 beginning at DBB8 for the first axis, a
Parameter description of FC19 maximum of 9 axis can be configured.
The Machine axis number has to be entered into the
Signal Type Format Range of Remark Interface byte.
values Axis numbers 1 - 9 are entered sequentially as default.
BAGNo I BYTE 0 - b#16#0A No. of mode group to
and which the mode sig-
b#16#10 - nals are transferred. Parameter BAGNo
b#16#1A BAGNo >= b#16#10
means access to the
second machine con- The BAG NO is a parameter with size BYTE.
trol panel. This Byte can be considered as Left and Right nibble(4
ChanNo I BYTE 0 - B#16#0A Channel no. for the bits).
channel signals The left nibble is the BAG No for the 2nd MCP if available,
the right nibble being the BAG no for the 1st MCP.
SpindleIFNo I BYTE 0 - 31 Number of the axis
(B#16#1F) interface declared as a
spindle
FeedHold Q BOOL Feed stop from MCP, MCP 2 MCP 1
modal
Bit 4 - 7 Bit 0 - 3
SpindleHold Q BOOL Spindle stop from
MCP, modal BAGNo BAGNo
With the following logic in OB1, the download to the PLC All Blocks can now be downloaded, System data should
can take place. also be loaded.
CALL FC 24 (
BAGNo := B#16#1,
ChanNo := B#16#1,
SpindleIFNo := B#16#4,
FeedHold := M 100.0,
SpindleHold := M 100.1,
SpindleDir := M 100.2);
After the download, a new start should be carried out.
A026: END
Notes

A151 Basic functions of a PLC program
Sinumerik
Operate
Module Description:
Basic functions of a PLC program with machine control panel and two axes and a spindle.
Module Objective:
At the end of this module, a basic program is created with which a machine, with a framework of
two axes and a spindle, can be operated.
Content:
Sinumerik
Blocks of a basic program

 OB100
 OB1
 FB1
 FC2
 FC19/24
 DB10/DB21/DB31
A151
A151

Basic functions of a PLC program A151
PLC functions:
START
PLC startup
parameterization
Machine
control panel
Spindle
block
Axis block
Loading of the
blocks
Error
messages
Source
PLC functions:
END
Notes

PLC startup parameterization The PLC interface consists of a series of STEP 7 data blocks.
The number and length of the data blocks is specified by the
system during startup.
In a PLC program, OB100 is always run first during the startup
of the controller. Signals and calls of other blocks that only The machine tool manufacturer can influence these and other
have to be run once can be performed in this block (see A026 processes by using the parameterization options of the PLC
Creation of a PLC program). basic program in OB100.
The parameterization is performed through direct

A simple example now shows how a program is inserted for a parameterization of function block 1 in the OB100 startup
machine with two axes and a spindle. The monitoring program; these values are made available to the PLC basic
functions required for a machine, such as limit switches, program through the use of the instance DB (DB7) of FB1.
lubrication, etc. are not taken into account.
The user only has to supply the relevant parameters of FB 1.
A user program is structured through the use of individual FBs The preset values in the associated instance DB 7 do not
and FCs. have to be assigned. The block must only be called in OB 100.
The call of every block can be directly in OB1. There are no
restrictions placed on the programmer.
A new OB1 is always supplied with every toolbox and the
contents must be integrated.
ORGANIZATION_BLOCK OB 100
In addition to the configuration of the interface, various other TITLE =
functions are executed: { S7_language := '9(1) English (United States)
13.10.2010 16:56:20' }
VERSION : 1.0
 Definition of the number of MCPs
VAR_TEMP
 Definition of the address area of the MCPs OB100_EV_CLASS : BYTE ;
OB100_STRTUP : BYTE ;
OB100_PRIORITY : BYTE ;
 Definition of the MCP type OB100_OB_NUMBR : BYTE ;
 Configuration of the handheld unit OB100_STOP : WORD ;
 PLC communication with NCK option OB100_DATE_TIME : DATE_AND_TIME ;
END_VAR
 Interrupt configuration BEGIN
NETWORK
TITLE =
CALL FB 1 , DB 7 (
MCPNum := 1,
Example of OB100 MCP1In := P#E 0.0,
MCP1Out := P#A 0.0,
MCP1StatSend := P#A 8.0,
MCP1StatRec := P#A 12.0,
MCP1BusAdr := 192,
MCPBusType := B#16#55,
NCKomm := TRUE);
//Insert User program from here
END_ORGANIZATION_BLOCK
Notes

Description of the FB1 parameters used here
Signal Type Format Range of values Comment
MCPNum I INT Up to 2 Number of active MCPs

0: No MCPs available
MCP1In I POINTER I0.0 to I120.0 Start address for input signals of the
MCP2In or relevant MCP
M0.0 to M248.0
or
DBn DBX0.0 to DBXm.0
MCP1Out I POINTER Q0.0 to Q120.0 Start address for output signals of the
MCP2Out or relevant MCP
M0.0 to M248.0
or
MCP1StatSend I POINTER Q0.0 to Q124.0 Is currently not relevant
MCP2StatSend or
M0.0 to M252.0
or
MCP1StatRec I POINTER Q0.0 to Q124.0 Is currently not relevant
MCP2StatRec or
M0.0 to M252.0
or
Signal Type Format Range of values Comment
MCP1BusAdr I INT 1 ... 126 DP slave: PROFIBUS address

MCP2BusAdr 192 .. 223 Ethernet MCP: DIP setting
MCPBusType I BYTE Right half of the byte (bits 0...3) for MCP1
Left half of the byte (bits 4...7) for MCP2
B#16#33: PROFIBUS
B#16#44: PROFIBUS on the MPI/DP port
B#16#55: Ethernet
B#16#66: PROFINET
NCKomm I BOOL PLC-NC communication services
(FB 2/3/4/5/7:
Put/Get/PI_SERV/GETGUD)
TRUE: Active
A complete description of FB1 is contained in the DOConCD or refer to the help of STEP 7.
Notes

OB1 Machine control panel
OB1 is then run cyclically. The user program is integrated in OB1 is opened by double-clicking it in the Blocks folder. The
this organization block. connected machine control panel should now be called and
OB1 has the lowest processing priority and can be interrupted parameterized here as first user program component.
by all interrupt and fault events. The priority cannot be
changed.
FC2 must be called in OB1. The user program is inserted after

the call of FC2.
Three functions are available in the PLC toolbox to integrate With FC MCP_IFM2 (M variant, slimline machine control
the Siemens machine control panel. panel, e.g. MCP 310), the following are transferred from the
machine control panel (MCP) to the appropriate signals of
 FC19 Milling variant the NCK/PLC interface:
 FC24 slimline machine control panel
 FC25 Turning variant  Operating modes
 Axis selections
One of these functions is called depending on the machine  WCS/MCS switchover
control panel.  Traversing keys
 Overrides or override simulation
The slimline machine control panel is connected and FC24 is
called. Feedrate override:
 The feedrate override is transferred on the interface of

the selected channel and the interface of the axes.
 In addition to the interface byte "Rapid traverse
override" (DBB 5), the feedrate override signals are
also transferred to the NC channel when the HMI
signal "Feedrate override for rapid traverse active" is
set (exception: Switch position "Zero"). "Rapid
traverse override" is also still set with this HMI signal.
Notes

Machine function INC and axis traversing keys:
 When the MCS is selected, the signals are transferred

on the interface of the selected machine axis.
 When the WCS is selected, the signals are transferred

on the geometry axis interface of the parameterized
channel.
 At a switchover from MCS to WCS, generally the

previously selected axis is deselected.
Parameterization of FC24 The following is an extract from the elementary data types.
Type and Size in Formal Range

description bits options
BOOL (bit) 1 Boolean TRUE/FALSE

text
BYTE (byte) 8 Hexadeci B#16#0 to B#16#FF
mal
number
WORD 16 Pure 2#0 to
(word) binary 2#1111_1111_1111_1111
number
With this parameterization, the signals are transferred to the Hexadeci W#16#0 to W#16#FFF
first mode group, the first channel and to all axes. In addition, mal
the spindle override is transferred in the fourth axis/spindle number
interface. The feed hold signal is transferred to bit memory
100.0 and as spindle hold signal to bit memory 100.1. BCD C#0 to C#999
The spindle direction signal is transferred to bit memory
M100.2.
The formal parameters and their type as well as the range of

values can be taken from the following table.
Notes

Formal parameters for the FC24 function: Signal For Type Range of Remark
ma values
t
Signal For Type Range of Remark
ma values FeedHol Q BOOL 0,1 Feed hold from MCP,
t d modal
BAGNo I BYTE B#16#00- Mode group no. in Spindle Q BOOL 0,1 Spindle hold from MCP,
B#16#0A which the operating Hold modal
und mode signals are
B#16#10– transferred. Spindle Q BOOL 0,1 Spindle direction of
B#16#1A BAGNo =B#16#10 Dir rotation
means access to the 0: Corresponds to +
second machine control (CCW)
panel 1: Corresponds to -
(CW)
ChanNo I BYTE B#16#00 - Channel no. for the
B#16#0A channel signals
SpindelI I BYTE 0 - 31 Number of the axis

FNo (B#16#1F) interface that is
declared as spindle
Notes

Spindle block
At least these signals are required:
First a new FB is generated. For example, the Blocks folder is right-clicked to open a new window via “Insert New Object” ->
“Function Block”. FB152 is selected as the name of the new FB and FB_spindle entered at Symbolic Name.
Notes

The new block has now been created below Blocks and is Network 1 is created in the block for the controller enable.
opened by double-clicking. Input I16.2 is connected here to the data block of the spindle
with address DB34.DBX2.1. Bit memory M0.1 is connected to
the pulse enable in the second network and a measuring
system selected in the third network. In this case, the first
measuring system.
The input and the bit memory as well as the data block have
been declared previously in the symbol table.
 UDTs can be used like elementary data types or

compound data types in the variable declaration of
code blocks (FC, FB, OB) or as data type for variables
in a data block (DB). This has the advantage that you
only have to define a special data structure that is to be
used several times once and then assign it to any
number of variables.
 UDTs can be used as a template for the creation of

data blocks with the same data structure, i.e. you only
create the structure once and then generate the
required data blocks through simple assignment of the
UDTs (recipes as an example: the structure of the DB
is always the same, only the quantities are different).
User-defined data types (UDT)
User-defined data types are special data structures created

by the user that can be used in the entire S7 user program
after their definition.
Notes

The new block can only be called in OB1. The block is as- Axis block
signed to a free DB.
Next a general block should be created for the axes which can
If the data block does not exist, you are prompted as to be called separately for all axes. This has the advantage that
whether you want to generate it. Click “Yes” to generate the only one block exists for all axes and that changes only have
data block. to be made at one place. The minimum signal requirement is
the same as for the spindle.
As for the spindle, the block is first created and then opened
by double-clicking it.
Notes

The interface of the block is declared first. Two inputs are A network title can be entered for the individual networks. A
required here for the measuring systems and one input each comment can also be entered for the networks. The
for the controller enable and the pulse enable. comment is also selected here in the display.
The new variables are now linked in the block to the

appropriate signals of the used axis data block.
A prompt appears when saving the block that the interface

has been changed. Confirm this with “Yes”.
Notes

If the interface of the block has been changed, the data block
must be recreated and loaded so that interface parameters
can be regenerated.
The new block can now be called in OB1. A free DB is

assigned to the block.
If the data block does not exist, you are prompted as to

whether you want to generate it. Click “Yes” to generate the
This can now be repeated with all the axes to be used.
data block. The formal parameters can then be entered.
Notes

Loading of the blocks If you want to power up the controller the first time, then the
following sequence of operations must be performed for a
When all blocks have been created and called in OB1, they memory reset of the NCK and PLC:
can be loaded to the CPU and tested.
Before the blocks and the hardware configuration are 1. Turn the startup switches on the front of the NCU to the
reloaded, the PLC should be switched to a defined state. This following switch positions:
is performed through a memory reset of the PLC. The – NCK startup switch: Switch position "1"
following steps are required for this: – PLC startup switch: Switch position "3"
2. Initiate a power on reset by switching the controller off

and on or by pressing the Reset button on the front of
the NCU. The NCU is stopped and restarted with the
memory reset prompt.
LED display Effect:
– "STOP" LED flashes
– "SF" LED is lit up
7-segment display 3. Turn the PLC mode selector switch to switch position
"2" and then back to switch position "3".
Reset button Effect:
NCK startup switch – "STOP" LED flashes first at approx. 2 Hz and is then
lit up steadily
– "RUN" LED is lit up
Diagnostics PLC mode selector
button DIAG switch
(no function)
4. When the "STOP" LED is lit up steadily, turn the PLC A block must not be selected.
mode selector switch back to "0".
Effect: The icon to load the block is then clicked.
– "STOP" LED is extinguished
5. Turn the NCK mode selector switch back to switch The following prompt appears:
position "0".
To load the blocks and the hardware configuration, the cursor

is positioned on the Blocks folder.
Notes

This prompt is confirmed with “OK”. When loading new When all blocks have been loaded you are prompted as to
blocks to a running system, it is important to follow the cor- whether the system data should also be loaded. The system
rect sequence as otherwise the system may crash. data contains the hardware configuration. This prompt should
A new window is opened showing the block loading probe confirmed with “Yes”.
gress.
This is followed by another prompt concerning the system Finally a prompt concerning a restart appears which should
data which should also be confirmed with “Yes”. also be confirmed with “Yes”.
Notes

Error messages error messages are displayed on the HMI until they have been
acknowledged by the user even when the signals are no
FC10 must be called in the user program (e.g. in OB1) in longer present.
order to display error messages from the PLC. The "ToUserIF" parameter can be used to transfer the group
signals for feed, read-in and NC start disable as well as feed
stop on the available axis, spindle and channel interfaces. The
group signals are transferred directly from the status
information of DB 2 to the user interface irrespective of the
acknowledgement of an alarm.
An error message should now be displayed based on the

feedback of “Position controller active” (DB31.DBX61.5) of the
X axis. If the feedback is “0”, a message should be displayed,
and with “1”, the message should be cleared again via the
FC10 after acknowledgement.
The signals entered in DB 2 are evaluated with FC AL_MSG

and displayed on the HMI as incoming and outgoing error and
operational messages.
The incoming signals (positive edge) are immediately
displayed not only for the error messages, but also for the
operational messages. Outgoing signals (negative edge) are
only cleared immediately for operational messages; error
messages that are no longer pending are only cleared after
they have been acknowledged with the "Ack" parameter, i.e.
For this purpose, FB151 should be expanded with an output The output can now be programmed.
signal. First of all, the output is entered in the interface of the
block.
Notes

FB151 is now shown in red in OB1 because of the change to The new output can now be written directly on a message.
the interface and has to be called again. The message DB is DB2 and the general PLC messages
start at DB2.DBB180 (see Appendix C).
As long as the controller enable (E16.1) is not set to “1”,

message 700000 is displayed on the HMI. Module A031 con-
tains a description of how text is entered for this interrupt.
Source
A source can be generated from the block with the “Generate

Source” function. If the source has been generated with sym-
bolic operands, the absolute addresses in the symbol file can
be changed and, after compilation, a program is obtained
with changed inputs and outputs. In this way, the program
can be adapted to a different hardware configuration.
Notes

The source then appears as follows: NETWORK

TITLE =pulse enable
FUNCTION_BLOCK "FB_axis"
TITLE =FB axis A #enable_pulse;
{ S7_language := '9(1) Englisch (USA) 08.02.2012 = DBX 21.7;
08:07:41' } NETWORK
VERSION : 0.1 TITLE =position measuring system 1
A #enable_PM1;
VAR_INPUT = DBX 1.5;
axis_DB : BLOCK_DB ; //axis data block NETWORK
enable_CE : BOOL ; //controller enable TITLE =position measuring system 2
enable_pulse : BOOL ; //pulse enable
enable_PM1 : BOOL ; //position measuring system 1 A #enable_PM2;
enable_PM2 : BOOL ; //position measuring system 2 = DBX 1.6;
END_VAR NETWORK
VAR_OUTPUT TITLE =position controller active
pos_controller_active : BOOL ; //position controller
active A DBX 61.5;
END_VAR = #pos_controller_active;
BEGIN END_FUNCTION_BLOCK
NETWORK
TITLE =open axis DB
OPN #axis_DB;
NETWORK
TITLE =controller enable
A #enable_CE;
= DBX 2.1;
This source can then be exported and imported into another The file can then be saved, for example, in an “External
project. To do this, the source must be selected in the sources STEP 7” folder.
Sources folder and then “Export Source” can be selected in
the “Edit” menu.
Notes

External sources are imported via the menu item “Insert -> A window is opened in which the external source can be se-
External Source”. lected.
The new source is inserted in the “Sources” folder in the The source still has to be compiled so that the blocks can be
opened project. used.
To do this, the source is selected, right-clicked to open the
context menu and the command “Compile” selected.
The blocks are compiled and are then in the “block container”.
Notes

A151 END Basic functions of a PLC program
The blocks can now be called in the program.
A151: END
Notes

A058 PLC Onboard Diagnostics
Sinumerik
Operate
Module Description:
The 840D sl SINUMERIK controller has onboard PLC diagnostic capabilities to aid users with the
fault finding procedure.
It is possible to monitor the status of external inputs and outputs and also internal system signals.
It is also possible to trace the status of variables over defined time periods using the NC/PLC
Trace function
Module Objective:
Upon completion of this module you will be able to:
 Check the status of user PLC Variables

 Check the status of user system variables
 Use the NC/PLC Trace function
Content:
Sinumerik
User PLC Variables
System Variables
Onboard Diagnostics: Detailed Description
NC/PLC Trace function
A058
A058

PLC Onboard Diagnostics A058
PLC Onboard
Diagnostics:
START
User PLC
Variables
System
Variables
Onboard
Diagnostics:
Detailed
Description
NC/PLC Trace
Function
PLC Onboard
Diagnostics:
END
Notes

User PLC Variables
Address Formats
The format that a variable (Operand) is entered on the diagnostics screen will be dependent on the type of data being diagnosed.
The format can be in single bit, byte, word & double word format.
Bit- This refers to a single element of logic e.g. I4.0, Q5.5, M100.6, DB31.DBX2.1. The Bit part is the number after the decimal
point. The value of a bit is either 1 or 0.
Byte- A Byte is a collection of 8 bits of logic in the same group. e.g.

Input Byte 4 (IB4) contains the bits I4.0, I4.1, I4.2, I4.3, I4.4, I4.5, I4.6, I4,7.
When working with bytes it must be remembered that the numbering counts up from the right as shown below.
IB4
Bit no 7 6 5 4 3 2 1 0
Value 1 0 1 0 0 1 0 1
In this example I4.1, I4.2, I4.5 & I4.7 are equal to 1. Another term for being equal to 1 is that these bits are High.
The bits equal to 0 are termed as being Low.
Output Bytes (QB), and Marker Bytes (MB) can also be used in the same way.
Word– A Word is a collection of 16 bits of logic which encompasses two

consecutive Bytes.
A Word can only be addressed as 0 or an even number (IW0, IW2, IW4 etc) odd numbers are not allowed.
As with the Byte format the numbering starts from the right.
Example IW4
IB4 IB5
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
In this example I4.0, I4.1, I4.4, I4.5, I4.6, I5.0, 5.2, I5.5, I5.7 are equal to 1.Output Words (QW) and Marker Words (MB) can also
be used in the same way.
Double Word– A Double Word is a collection of 32 bits of logic which encompasses two consecutive Words (Four consecutive
Bytes).
A Double Word can only be addressed as 0 or as a number which is a multiple of four, (ID0, ID4, ID8, ID12 etc) odd numbers
are not allowed.
Example ID4
IB4 IB5 IB6 IB7
Bit no 7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0
Value 1 0 1 0 0 1 0 1 0 1 1 1 0 0 1 1 1 0 1 0 0 1 0 1 0 1 1 1 0 0 1 1
Output Words (QD) and Marker Words (MD) can also be used in the same way.
Data Blocks (DB):-

System Data Blocks are used for interfacing between different areas of the controller and the User PLC, Module A034 describes
this in more detail.
The user can also create Data Blocks.
Data Blocks can be written in different formats e.g. :

DB31.DBX0.0 Data Block 31, Data Block Bit 0.0
DB31.DBB1 Data Block 31, Data Block Byte 1
DB31.DBW10 Data Block 31, Data Block Word 10
DB31.DBD12 Data Block 31, Data Block Double Word 12
Notes

To locate the PLC Diagnostics screen use the following soft- The status of the PLC variable to be checked should typed into
key sequence: the “Variable” column (Bit, byte, word, double word).
Example, using inputs to show the different format possibilities
The following screen will be displayed, it is possible that there

are entries already present on the screen.
Format
The variable value can be viewed in different formats. The for-

mat has to be selected from the list:
Format description: Variable Possible Format
Formats Description Inputs Ix.x, IBx, IWx, IDx
B Binary Outputs Qx.x, QBx, QWx, QDx
H Hexadecimal Bit memory Mx.x, MBx, MWx, MDx
D Decimal without sign Timers Tx
±D Decimal with sign Counters Cx
F Floating point number (for double words) Data Blocks DBx.DBXx.x, DBx.DBBx, DBx.DBWx,
DBx.DBDx
A ASCII characters
Timers can only be viewed in the “Decimal” format.
The variable will be displayed in the selected format: Counters can be viewed “Decimal”, Binary” and Hexadecimal”
format.
PLC variables are the most commonly checked during fault

finding, e.g. inputs from switches, outputs to coils etc.
The following table shows the PLC variables that can be moni-
tored: Entries can be edited by using the Insert, and Cursor keys
found on the NC keyboard.
Notes

System Variables The types of variable available for selection are:

A list of available system variables is displayed via the “Insert System variables
variable” soft-key. NC
The available variables are listed when the soft-key is se- Axis
lected. Channel
Mode groups
Global user data
PLC
The filter is used to narrow down the variables on view.
The search window can be used to locate the required variable.

Partial or whole names can be entered.
The variable used in this example is an axis variable, therefore

an axis has to be chosen.
Choose the variable from the list, e.g. “aaRef Axis
Notes

The chosen variable will appear on the screen. Onboard Diagnostics: Detailed Description
Operand +/-:
The “Operand +” and “Operand -”soft-keys are used for

locating operands (Variables) within the same group.
The values within the square brackets identify the individual

variables e.g:
or
Display Comments:
[U1= Channel No. , 1 = Axis No.]
Further information about the variable can be displayed by
selecting the “Display Comments” and “Details” soft-key.
Change:
For test purposes it may be necessary to manually change

(Force) an operand. This is achieved with the “Change” soft
The comments can be edited if necessary. In the case of user key.
PLC inputs and outputs, the comments will require adding.
The operand in question has to be highlighted and the new

Details: value entered and confirmed with the “OK” soft key.
The details of the variable can be viewed:
Notes

Enter the new value e.g. 1 Delete All:
The “Delete all” soft-key will delete all entries in the list.
Note:
It is useful to have this function in the commissioning stages.
After data loss, it may also be necessary to enter values into
Data Blocks using this method. This depends upon the ma-
chine manufacturer.
Caution should be taken when attempting to manually enter
data as unwanted movements may occur.
It is not possible to force operands which are being addressed
by the PLC program.
Individual entries can be cleared via the ”Delete” soft-key

found on the NC keyboard.
Further functions The file can be saved locally or externally to a USB device or
networked PC. It is always useful to have the file stored
Further functions are available when the “Menu extension/ locally.
page right” soft-key is pressed: Choose a suitable destination e.g. User\Variable masks.
Save screen:
The variables that are listed can be saved to a file. This is

useful if a set of operands have been selected which relate to
a certain area of the machine e.g. the toolchanger.
The file can be loaded each time the toolchanger signals need
to be monitored.
Notes

Load mask:
When required, the saved file can easily be loaded.
Enter a suitable name for the file, e.g. Toolchange signals:
The variable will now appear on the status screen. NC/PLC Trace Function
The “NC/PLC trace” function is used to trace the status of

variables over a given time. The results of the trace are dis-
played on the screen in a graph format.
To locate the NC/PLC Trace screen, follow the soft-key se-

quence:
Load symbols:
If a symbols file (*.snh) is available, this can be loaded with the

“Load symbols” soft-key.
The following screen will be displayed. The variables can be
typed directly or selected from the list displayed when the
“Choose variable” soft-key is selected.
Note: Symbols files are created with the Step7 software pack-
age. They then have to be converted into files with the “.snh”
extension, in readiness for loading via the “Load symbols” soft-
key.
Notes

A058 END PLC Onboard Diagnostics
Colour of Show/hide
trace. trace
Style of
trace line
The trace time and various other settings can be modified:
Example: Tracing the status of I16.0 over a 10 second period.
Enter the variable into column marked “Variable”. A comment

will automatically be entered.
The colour of the trace and the trace line can be selected.
After the set time has elapsed, the trace will be automatically
displayed.
The example shows that the input I16.0 switched from 0 to 1
on three occasions during the 10 second period
The trace can now be started:
The trace can be examined in detail using the zoom functions.

Up to 16 variables can be traced at once.
Traces can be saved and loaded from external sources in
“xml” format.
A058: END
Notes

A037 Alarm Structure
Sinumerik
Operate
Module Description:
The 840D sl SINUMERIK 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 840D sl
system.
Content:
Sinumerik
NCK Alarms and Messages Structure
Alarm Display Description
Alarm Acknowledgement
Alarm Log
Suppress Alarm Function
A037
A037

Alarm Structure A037
NCK Alarms and

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

Messages:
END
Notes

NCK Alarms and Messsages: Structure 102000 - 102999 Services
The NCK alarm structure is divided into three areas. Each area 103000 - 103999 Machine
has been assigned a separate range of alarm/message 104000 - 104999 Parameter
numbers.
105000 - 105999 Programming
Message/Alarm 106000 - 106999 Reserved
Function range
Nr.
107000 - 107999 OEM
NCK-Alarms/Messages
108000 - 108999 HiGraph
000000 - 009999 General alarms
109000 - 109999 Distributed systems (M to N)
010000 - 019999 Channel alarms
110000 - 110999 Cycles
020000 - 029999 Axis/spindle alarms
111000 - 111999 ShopMill, ShopTurn
060000 - 064999 Cycle alarms SIEMENS
113000 - 113999 Expanding User Interface (Easy screen)
065000 - 069999 Cycle alarms user
114000 - 114999 HT6
070000 - 079999 Compile cycles Manufacturer and OEM
119000 - 119999 OEM
HMI-alarms/messages
120000 - 129999 HMI advanced messages
100000 - 100999 Basic system
130000 - 139999 OEM
101000 - 101999 Diagnosis
142000 - 142099 RCS Host/Viewer
149000 - 149999 ePS
Message/Alarm Nr. Function range 231000 - 231999 Drive CLiQ component encoder 1
232000 - 232999 Drive CLiQ component encoder 2
SINAMICS-Alarms
233000 - 233999 Drive CLiQ component encoder 3
201000 - 203999 Control unit (CU)
234000 - 234999 Reserved
204000 - 204999 Reserved
235000 - 235999 Terminal Module 31 (TM31)
205000 - 205999 Power Unit
236000 - 236999 Reserved
206000 - 206999 Infeed
240000 - 240999 Controller extension (NX32)
207000 - 207999 Drive
241000 - 248999 Reserved
208000 - 208999 Option board
249000 - 249999 Sinamics GM7SM7GL
209000 - 209999 Reserved
250000 - 250999 Communication board (Comm Board)
213000 - 213002 Licence
250500 - 259999 Reserved
230000 - 230999 Drive CLiQ 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 that one alarm is present (Indicated by the arrow) they

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

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

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

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

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

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

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

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

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

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

Alarm Log
A log of alarms that have occurred can be seen by selecting

the “Alarm protocol” soft key.
This shows the time when the alarm occurred and when it
was cleared.
The “Display new” soft key is used to refresh the list and
display any alarms that have recently occurred.
There are a number of options which can be selected by us-

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

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

Write mode file: Time controlled:

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

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

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

A037: END
Notes

A037 END Alarm Structure

A031 PLC 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
Alarm Configuration
Entering the Alarm Text
User Help Files
A031
A031

PLC Alarms and Messages A031
PLC Alarms
and
Messages:
START
General
Information
Alarm
Configuration
User Help
Files
PLC Alarms
and
Messages:
END
Notes

General information *1)
The PLC alarms/messages are sub-divided into the following Messages/alarms within these ranges are activated via the
ranges: user PLC. Each message/alarm has an interface bit within
DB2 to facilitate the activation of each individual alarm.
Message/Alarm No. Function The reaction of the machine to alarms within the
500000/600000 range is predefined by the system.
400000 - 499999 *
2)
PLC-messages in general Alarms within the 700000 range do not have any effect on the
machine unless they are configured to do so via the user PLC
program.
1)
500000 - 599999 * PLC-messages for channel
*2)
1)
600000 - 609999 * PLC-messages for axis and spindle Messages/alarms within these ranges are system generated
and cannot be configured by the user.
1)
700000 - 709999 * PLC-messages for user
2) PLC-messages for sequence chains/

800000 – 899999 *
graphics
2)
810000 - 810009 * PLC system messages
As soon as a fault occurs on the machine, the corresponding Alarms/messages appear at the top of the screen
alarm will be displayed in the message line at the top of the
screen.
The alarm number, acknowledgement method and a short text
description will be displayed.
Further alarms are indicated by a downward pointing arrow, to

the right of the alarm number.
The alarms/messages can be displayed in red or black. Red is

traditionally used to indicate a more serious alarm and black is
used for a message.
The alarm/message text can be input via the controller or cre-

ated offline.
Alarm/message details.
Notes

Alarm/ The alarms and messages are categorised and accessed via
message different soft-keys
Alarm
number clearance
The “Alarm list” screen displays serious alarms
The “Messages” screen displays less serious

alarms .
Indication that Alarm/

further alarms are message
active. description.
A list of active alarms/messages can be viewed.
The alarms displayed at the top of the screen can be made to Alarm Configuration
cycle in turn after a set time.
This is controlled by Display Machine Data 9056. The alarm/messages list can be entered directly on the con-
troller:
With values of less than 500 there is no rotation cycle. Values

of 500 to 10000 set the time that each alarm/message is dis-
played for.
The units are milliseconds.
The machine data is activated with an NC reset.
Notes

Alarm/ The file name is:

Alarm/ message oem_alarms_plc_eng.ts. The “eng” part of the name is the
message Colour language identifier.
number. selection
Language identifier examples:
eng = English
deu = German
fra = French
ita = Italian
esp = Spanish
Alarm/ Selection of a chs = Chinese (Simplified)
message pop-up box cht = Chinese (Traditional)
description. when alarm kor = Korean
is active. ptb = Portuguese (Brazil)
The file can be edited on the controller or saved externally for

editing/forwarding elsewhere. Select the “Open” soft-key to
open the file.
When the texts have been completed it is necessary to switch
the controller off/on to activate the changes.
The data is now saved to an xml file in the following location:

NCU: SystemCF card\oem\sinumerik\hmi\lng
PCU50: F:\HMI\hmisl\oem\sinumerik\hmi\lng
NCU: Location of the alarm text file. PCU: Location of the alarm text file.
Notes

The entries made previously on the controller can be seen in User PLC Requirements
the file.
PLC Interface signals (DB2)
DB2 is used for activating the alarms/messages.

Each alarm number has its own interface bit which, when set
high will activate the alarm.
Whether an alarm behaves as a an Error Message (EM) or

Operator Message (OM) is pre-defined for all PLC user alarm
in the 500000 and 600000 ranges.
Exception:
Setting FB1 parameter - ExtendALMsg:= True
With this setting the alarm reaction can be configured using
DB5
A list of all the interface signals is found in Module Appendix C

PLC Interface.
To make the alarm system operational it is necessary to call Channel Alarms 510000 to 511315:
and parameterize FC10 in the user PLC program.
The following table is a sample of DB2. This shows the inter-
Calling FC10 face signals for alarms 510000 to 511315. These are alarms
for channel 1. (See Module Appendix C for additional channel
signals)
See below for description The red text denotes that the alarm is classed as an Error
Message. Alarms in the blue text classifies them as Operator
Messages.
Declaring the alarm clear signal. Error messages, when activated, will appear on the “Alarm
(e.g. I3.7 (MCP reset button) list” screen and require an acknowledgement to clear.
(FC10 “Quit” function e.g. I3.7)
FC10 parameter : ToUserIF:=TRUE Operator Messages will appear on the “Messages” screen
Error messages/alarms in the 500000 and 600000 ranges and remain displayed until the interface bit is set to 0.
(Set via DB2) will be displayed. The controller will automati- The effect of a message on the system is also shown for each
cally issue feed-hold, read-in disables etc. byte. This is only if FC10 parameter ToUserIF:= True.
FC10 parameter : ToUserIF:=FALSE

Error messages/alarms in the 500000 and 600000 ranges
(Set via DB2) will be displayed. The controller will not auto-
matically issue feed-hold, read-in disables etc. This is the
responsibility of the OEM.
Notes

Following is an Example assuming the parameter

"ExtendALMsg:=" False
DB2 interface signals for alarms 510000 to 511315: DB2

Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
Byte
510231 510230 510229 510228 510227 510226 510225 510224
DB2 9
Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 Read-in disable-Operator message (OM)
Byte 510307 510306 510305 510304 510303 510302 510301 510300
510007 510006 510005 510004 510003 510002 510001 510000
10
NC start disable-Error message (EM)
0
Feed and read-in disable-Error message (EM)
510315 510314 510313 510312 510311 510310 510309 510308
510015 510014 510013 510012 510011 510010 510009 510008
11
NC start disable-Operator message (OM)
1
Feed and read-in disable-Operator message (OM)
511107 511106 511105 511104 511103 511102 511101 511100
510107 510106 510105 510104 510103 510102 510101 510100
12
Feed stop Geometry axis-Error Message (EM)
2
511115 511114 511113 511112 511111 511110 511109 511108
510115 510114 510113 510112 510111 510110 510109 510108
13
Feed stop Geometry axis-Operator message (OM)
3
511207 511206 511205 511204 511203 511202 511201 511200
510123 510122 510121 510120 510119 510118 510117 510116
14
Feed stop Geometry axis-Error Message (EM)
4
Feed and read-in disable-Operator message (OM)
511215 511214 511213 511212 511211 511210 511209 511208
15
510131 510130 510129 510128 510127 510126 510125 510124 Feed stop Geometry axis-Operator message (OM)
5
Read-in disable-Operator message (OM)
511307 511306 511305 511304 511303 511302 511301 511300
16
510207 510206 510205 510204 510203 510202 510201 510200 Feed stop Geometry axis-Error Message (EM)
6
Read-in disable-Error message (EM)
511315 511314 511313 511312 511311 511310 511309 511308
17
510215 510214 510213 510212 510211 510210 510209 510208 Feed stop Geometry axis-Operator message (OM)
7
Read-in disable-Error message (EM)
510223 510222 510221 510220 510219 510218 510217 510216

8
Read-in disable-Operator message (OM)
Axis and Spindle Alarms 600000 - 609999 User PLC Alarms 700000 - 709999
Alarms in the 600000 - 699999 range are used for creating a Alarms in the 700000 - 709999 range are free for configuring
feed/spindle stop. in the user PLC program.
Two bytes are reserved for each axis/spindle. The first of The effect the alarm has on the system is entirely the respon-
which is defined as error messages (EM) while the second sibility of the machine manufacturer.
byte is defined as operator messages (OM). The alarms are separated into error messages (EM), and
operator messages (OM)
DB2 interface signals for alarms 600100 to 600415: DB2 interface signals for alarms 700000 to 700063:
DB2 Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 DB2 Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
Byte Byte
144 600107 600106 600105 600104 600103 600102 600101 600100 180 700007 700006 700005 700004 700003 700002 700001 700000
Feed stop/spindle stop for axis/spindle 1
181 700015 700014 700013 700012 700011 700010 700009 700008
145 600115 600114 600113 600112 600111 600110 600109 600108
146 600207 600206 600205 600204 600203 600202 600201 600200 182 700023 700022 700021 700020 700019 700018 700017 700016
Feed stop/spindle stop for axis/spindle 2 183 700031 700030 700029 700028 700027 700026 700025 700024
147 600215 600214 600213 600212 600211 600210 600209 600208

184 700039 700038 700037 700036 700035 700034 700033 700032
148 600307 600306 600305 600304 600303 600302 600301 600300

185 700047 700046 700045 700044 700043 700042 700041 700040
149 600315 600314 600313 600312 600311 600310 600309 600308 186 700055 700054 700053 700052 700051 700050 700049 700048
150 600407 600406 600405 600404 600403 600402 600401 600400

187 700063 700062 700061 700060 700059 700058 700057 700056
151 600415 600414 600413 600412 600411 600410 600409 600408
Notes

Alarm Activation When the interface signals are high, the alarms/message will
be displayed on the relevant screen.
The interface signals have to be set in the user PLC.
The following example shows how alarms 700000 (EM) and
700032 (OM) can be activated.
Notes

Following is a Function diagram base upon"ExtendALMsg:=" False

and FC9 parameter ToUserIF True and False
cancel alarm display

Error message
Quit := I3.7
CALL FC10
ToUserIF := True
Quit : = I 3.7
FC35 - Alarm Block
A I 88.4
= DB2.DBX0.0 Error Message
A I 88.5
= DB2.DBX1.0 Operator Message Interface signal to
ToUserIF := True NCK
Group Signal
Transfer
Feed Hold
ToUserIF := False
No Signal Transfer CALL FC10
CALL FC10 ToUserIF := True
ToUserIF := False Quit : = I 3.7
Quit : = I 3.7
Notes

Following is a Function diagram base upon"ExtendALMsg:=" True

and FC9 parameter ToUserIF True and False
Without Alarm no
display
CALL FC10
ToUserIF := True
Quit : = I 3.7
FC35 - Alarm Block
A I 88.4
= DB2.DBX0.0 Feed hold effect
without alarm
A I 88.5 Interface signal to
= DB2.DBX1.0 Feed hold effect NCK
ToUserIF := True
without alarm
Group Signal
Transfer
Feed Hold
ToUserIF := False
No Signal Transfer Controlled directly from
CALL FC10 customer PLC when
ToUserIF := False ToUserIF:= False
Quit : = I 3.7
With alarm no
display
CALL FC10
ToUserIF := True
Quit : = I 3.7
FC35 - Alarm Block
A I 88.6
= DB2.DBX310.0 Error Message
A I 88.7
= DB2.DBX311.0 Operator Message Interface signal to
ToUserIF := True NCK
Group Signal
Transfer
Feed Hold
ToUserIF := False
No Signal Transfer Controlled directly from
CALL FC10 customer PLC when
ToUserIF := False ToUserIF:= False
Quit : = I 3.7
Notes

Additional Functions with "ExtendALMsg:=" True
 The user messages can be parameterized in the sec-  The alarms / messages also get the 16-bit integer addi-
ond decade of the message number in the numerical tional value (%Z parameter in the alarm text) in addi-
range 0 to 9. The display value of the second decade tion to the alarm number for the user area 0. The user
must be written by the user in the DB5 in the array vari- must write the 16-bit integer values in the DB 2 in the
able UserDek2No. A number can be defined for each Array variable ZInfo0 parallel to setting an alarm bit. An
user area, see DB 5 in the basic program. integer value is available for each bit in the user area 0.
The second digit can therefore be changed:

Alarm 700000 or 710000 or 750000, it can be used to identify  The structuring of the DB 2 in UDT1002 can be recog-
a logical station on the machine. nized (basic program). In case of new alarm functions,
the UDT1002 must be assigned symbolically to the
DB2.
L6
T ALMSG_DB.ZInfo0[8]
Alarm : 700008 "Axis No %Z Temperature Fault"

L5
T DB5.UserDek2No[0] Result: 700008 "Axis No 6 Temperature Fault"
Notes

User Help Files
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 (Hyper Text Mark-up Language) and needs to be stored in a specific directory.
File location for English language:
NCU: System CF-Card\oem\sinumerik\hmi\hlp\eng\sinumerik_alarm_plc_pmc
PCU: F:\HMI\hmisl\oem\sinumerik\hmi\hlp\eng\sinumerik_alarm_plc_pmc
The italicised text denotes folders that require creating. Separate folders are required for each language where the Help file is to
be utilised.
Examples:
English - eng\sinumerik_alarm_plc_pmc
German - deu\sinumerik_alarm_plc_pmc
The HTML file name:

sinumerik_alarm_oem_plc_pmc.html
A separate file needs to be created and stored in each of the language folders.
HTML script language

Once the file is created the HTML code can be entered. HTML uses tags, each tag has a specific function.
Tags have to be opened and closed in the correct manner, example:
<html> Opening the “html” tag

Information/more tags entered here etc.
</html> Closing the “html” tag
Table of Common HTML Tags:
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

Example help file

Below is an example help file for alarm 700000. The text has been coloured to assist with understanding the contents.
<html>
<head><meta http-equiv="Content-Type" content="text/html; charset="UTF-8"/><title></title></head>
<body>
<table>
<tr>
<td width="15%"><a name="700000">700000</a></td>
<td width="85%">Hydraulic Pressure Low</td>
</tr>
<tr>
<td valign="top" width="15%">Parameter:</td>
<td width="85%">N/A</td>
</tr>
<tr>
<td valign="top" width="15%">Explanation:</td>
<td width="85%">I8.1 is low.</td>
</tr>
<tr>
<td valign="top" width="15%">Reaction:</td>
<td width="85%">Emergency Stop Initiated</td>
</tr>
<tr>
<td valign="top" width="15%">Remedy:</td>
<td width="85%">The hydraulic unit has indicated a fault. Check oil level. Check pressure switch. Clean filter if necessary.</td>
</tr>
<tr>
<td valign="top" width="15%">Part number:</td>
<td width="85%">Hydraulic oil type: AAA. Pressure switch type: BBB Filter type CCC</td>
</tr>
<tr>
<td valign="top" width="15%">Program continuation:</td>
<td width="85%">Machine restart required</td>
</tr>
</table>

</body>
</html>
The “a” tag is known as an anchor.

The system is able to cross reference the highlighted alarm with the entry within the “a” tag.
<td width="15%"><a name="700000">700000</a></td>
When an alarm is selected and the help key is pressed the system uses the anchor to locate and display the correct table contents
for the selected alarm.
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 not be changed. This determines the content type and text format.
Notes

Creating the help files/directories on the controller NCU “hlp” folder location:
The folders can be created directly on the controller or by using

the RCS Commander software package.
Creating the help file folders on the controller:
Locate the directory where the folders are to be created.

NCU: System CF-Card\oem\sinumerik\hmi\hlp
PCU50: F:\HMI\hmisl\oem\sinumerik\hmi\hlp
PCU “hlp” folder location: Select the “Directory” soft-key, this is usually already selected
by default.
Enter the directory name, this is the language directory.

Several will have to be created if help files are to be available
for more than one language. See previous page for language
specific folder names.
Below: Creating a folder for English help files.
Cursor to the “hlp” directory and select the “New” soft-key.
Notes

Highlight the “eng” folder and select the “New” soft-key.
Type in the help file name

“sinumerik_alarm_oem_plc_pmc.html“.
Enter the mandatory name for the new directory:
“sinumerik_alarm_plc_pmc”.
Creating the help file:

Cursor to “sinumerik_alarm_plc_pmc” directory and select the
“New” soft-key followed by the “Any” soft-key.
The file will automatically open in readiness for the HTML code NCU:
to be entered. System CF card\user\sinumerik
\hmi\hlp\eng\sinumerik_alarm_plc_pmc
The file is closed with the “exit” soft-key: “System CF card\oem\sinumerik
\hmi\hlp\eng\sinumerik_alarm_plc_pmc
PCU50:
F:\HMI\hmisl\user\sinumerik\hmi\hlp\eng\
sinumerik_alarm_plc_pmc
Creating the help files/directories on an external PC F:\HMI\hmisl\oem\sinumerik\hmi\hlp\eng\
sinumerik_alarm_plc_pmc
It is also possible to create the directories/help files offline using
an ASCII editor (e.g. Notepad®).
This is usually a more comfortable method than stood at the
controller.
These files have to be transferred to the controller and placed in
the correct folders using the USB /CF Interfaces or with the
RCS Commander software.
The file needs to be placed in certain folders on the controller.

The “sinumerik_alarm_oem_plc_pmc.html” file has to be
placed in one of the following directories:
Notes

Testing the help file on the controller If several alarms exist, cursor to the correct one.
To test the Help file the alarm specified in the Help file should
be activated.
Alarm 700000 is activated by DB2.DBX180.0
With the alarm active locate the “Alarms/Messages” screen.
The alarm will appear in either the “Alarmlist” or “Messages”

screen depending how it has been configured.
Or
The HELP function is activated by the “HELP” key.
A031: END
Notes

A031 END PLC Alarms and Messages
A031: END

Appendix C PLC Interface
Sinumerik
Operate
PLC Interface:
START
DB21-30
NC
Channels
Machine
Control
Panel
DB31-61
Axis/Spindle
DB2
PLC
Messages
DB71-74
Tool
Management
DB10
NCK
Interface
DB77
MCP
Signals
DB11
Mode
Group
PLC Interface:
END
DB18
SI
Signals
DB19
Sinumerik
HMI
Interface
DB20
PLC
Machine
Data
Appendix C
Appendix C PLC Interface Structure
Interface Description
Signals from/to Operator Component
Machine control panel, M version
Signals from machine control panel (keys)

Input display
Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0

IB n + 0 Spindle speed override Operating mode
D C B A JOG TEACH IN MDA AUTO
IB n + 1 Machine function
REPOS REF Var. INC 10000 INC 1000 INC 100 INC 10 INC 1 INC
IB n + 2 Key- Key- Spindle start *Spindle stop Feed *Feed NC Start *NC Stop
switch switch posi- start stop
position 0 tion 2
IB n + 3 Reset Key- Single block Feedrate override
switch posi-
tion 1
E D C B A
IB n + 4 Direction keys Keyswitch Direction keys

position 3
plus minus Rapid trav- X 4th axis 7th axis
R15 R13 erse R1 R4 R7 R10
R14
IB n + 5 Axis selection
Y Z 5th axis Traverse 9th axis 8th axis 6th axis
R2 R3 R5 command R11 R9 R8 R6
MCS/WCS
IB n + 6 Unassigned customer keys
T9 T10 T11 T12 T13 T14 T15

T1 T2 T3 T4 T5 T6 T7 T8
Notes
Appendix C Page 2 840D sl SINUMERIK Operate

PLC Interface Structure Appendix C
Signals to machine control panel (LEDs)

Output display
QB n + 0 Machine function Operating mode
1000 INC 100 INC 10 INC 1 INC JOG TEACH IN MDA AUTO
QB n + 1 Feed *Feed NC Start *NC Stop Machine function

start stop
REPOS REF Var. INC 10000 INC
QB n + 2 Direction key Axis selection Single block Spindle start *Spindle stop
minus
R13 X 4th axis 7th axis
R1 R4 R7 R10
QB n + 3 Axis selection Direction key
plus
Z 5th axis Travel com- R11 9th axis 8th axis 6th axis R15
R3 R5 mand R9 R8 R6
MCS/WCS
R12
QB n + 4 Unassigned customer keys Y
T9 T10 T11 T12 T13 T14 T15 R2
QB n + 5 Unassigned customer keys
T1 T2 T3 T4 T5 T6 T7 T8
Notes
840D sl SINUMERIK Operate Page 3 Appendix C

Machine control panel, T version
Signals from machine control panel (keys)

Input display

D C B A JOG TEACH IN MDA AUTO
IB n + 1 Machine function
REPOS REF Var. INC 10000 INC 1000 INC 100 INC 10 INC 1 INC
IB n + 2 Keyswitch Keyswitch Spindle start *Spindle stop Feed start *Feed stop NC Start *NC Stop
position 0 position 2
IB n + 3 Reset Keyswitch Single block Feed override
position 1
E D C B A
IB n + 4 Direction keys Keyswitch Direction keys
position 3
+Y -Z -C
R15 R13 R14 R1 R4 R7 R10
IB n + 5 Direction keys
+X +C Rapid Travel com- -Y -X +Z
R2 R3 traverse mand MCS/ R11 R9 R8 R6
override WCS
R5 R12
T9 T10 T11 T12 T13 T14 T15
T1 T2 T3 T4 T5 T6 T7 T8
Signals to machine control panel (LEDs)

Output display

QB n + 0 Machine function Operating mode
1000 INC 100 INC 10 INC 1 INC JOG TEACH IN MDA AUTO
QB n + 1 Feed start *Feed stop NC Start *NC Stop Machine function
REPOS REF Var. INC 10000 INC
QB n + 2 Direction keys Single block Spindle start *Spindle stop
+Y -Z -C
R13 R1 R4 R7 R10
QB n + 3 Direction keys
Travel com- -Y -X +Z
R3 R5 mand R11 R9 R8 R6 R15
QB n + 4 Unassigned customer keys Direction key

+X
T9 T10 T11 T12 T13 T14 T15 R2
T1 T2 T3 T4 T5 T6 T7 T8
Notes

Machine control panel, slimline

Signals from slimline machine control panel (Keys and switches)
Input display

*NC Stop SP - SP 100% SP + SINGLEB JOG MDA AUTO
IB n + 1 Spindle Keyswitch Machine function

NC Start SP right *SP Stop SP left SS 3 REF. REPOS Teach in
IB n + 2 Feedrate Keyswitch Machine functions

Start *Stop Var. INC SS 0 1000 INC 100 INC 10 INC 1 INC
IB n + 3 Keyswitch Feed override

RESET SS 2 SS 1 E D C B A
IB n + 4 Direction keys Optional customer keys

plus minus Rapid trav-
R15 R13 erse R14 KT4 KT3 KT2 KT1 KT0
IB n + 5 Axis selection
T17 KT5 6 5 4 Z Y X
IB n + 6 Unassigned customer keys MCS/WCS Unassigned customer keys

T9 T10 T11 T12 T14 T15 T16

T1 T2 T3 T4 T5 T6 T7 T8
Signals to slimline machine control panel (LEDs)

Output display
QB n + 0 NC Stop Spindle speed override Operating mode
SP - SP 100 % SP + SINGLEB JOG MDA AUTO
QB n + 1 NC Start Spindle Machine function

SP right SP Stop SP left unassigned REF. REPOS Teach in
QB n + 2 Feedrate Machine functions

Start Stop Var. INC unassigned 1000 INC 100 INC 10 INC 1 INC
QB n + 3 unassigned
unassigned unassigned unassigned unassigned unassigned unassigned unassigned unassigned
QB n + 4 Direction keys Optional customer keys

plus minus Rapid trav-
R15 R13 erse R14 KT4 KT3 KT2 KT1 KT0
QB n + 5 Axis selection
T17 KT5 6 5 4 Z Y X
QB n + 6 Unassigned customer keys Unassigned customer keys

T9 T10 T11 T12 MCS/WCS T14 T15 T16

T1 T2 T3 T4 T5 T6 T7 T8
Notes

Signals from/to handheld unit (HHU, HT 2)
Signals from handheld unit (keys)

Input display

IB n + 0 Reserved Identifier
HT 2
IB n + 1 Reserved
IB n + 2
T9 T7 T6 T5 T4 T3 T2 T1
IB n + 3
T16 T15 T14 T13 T12 T11 T10 T9
IB n + 4
T24 T23 T22 T21
IB n + 5 Acknowl- Rapid traverse/feed override switch

edgement
Keyswitch E D C B A
Digital dis-
play
Notes

Signals to handheld unit (LEDs)

Output display

QB n + 0 always 1
New data for Line selection
QB n + 1 selected line
QB n + 2
L8 L7 L6 L5 L4 L3 L2 L1
QB n + 3
L16 L15 L14 L13 L12 L11 L10 L9
Digital display of handheld unit
QB n + 4 1st character (right) of the selected line
QB n + 5 2nd character of the selected line
QB ...
QB n + 18 15th character of the selected line
QB n + 19 16th character (left) of the selected line
Notes

Signals from/to handheld programming unit (HT 8)
Signals from machine control panel simulation

Interface HT 8  PLC

IB n + 0 Function key block
REF TEACH AUTO MDA JOG QUIT RESET WCS/MCS
IB n + 1 Function key block
Cntr Panel U4 U3 U2 U1 INC REPOS
Func (CPF)
IB n + 2 Change over Travel keys (JOG) positive direction
axes
Ax7-Ax12 Ax6 Ax5 Ax4 Ax3 Ax2 Ax1
Ax1-Ax6
IB n + 3 Travel keys (JOG) negative direction
Ax6 Ax5 Ax4 Ax3 Ax2 Ax1
IB n + 4
U9 U10 U11 U12 U13 U14 U15 U16
IB n + 5
U8 U7 U6 U5 SBL
IB n + 6 Start key block

Reserved HT 8 SF2 SF1 SF4 SF3 Start Stop
IB n + 7 Feedrate override
E D C B A
Notes

Signals to machine control panel simulation

Interface PLC  HT 8

QB n + 0 Function key block
REF TEACH AUTO MDA JOG QUIT RESET WCS/MCS
QB n + 1 Function key block
U4 U3 U2 U1 INC REPOS
QB n + 2 Travel keys (JOG) positive direction
Axes 7n Ax6 Ax5 Ax4 Ax3 Ax2 Ax1
QB n + 3 Travel keys (JOG) negative direction
For WCS: Ax6 Ax5 Ax4 Ax3 Ax2 Ax1
No MCS
QB n + 4
U9 U10 U11 U12 U13 U14 U15 U16
QB n + 5
U8 U7 U6 U5 SBL
QB n + 6 Start key block
Display travel SF2 SF1 SF4 SF3 Start Stop
keys
QB n + 7
Notes

PLC alarms / messages

FC 10 alarms in DB2 (FB1-Parameter "ExtendAlMsg"=False)
Channel areas (Parameter "ExtendAlMsg"=False)
DB2 Signals for PLC messages (PLC  HMI)

Byte (Message Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
type)
Channel 1
0 (EM) 510007 510006 510005 510004 510003 510002 510001 510000
Feed disable (alarm no.: 510000-510015)
1 (OM) 510015 510014 510013 510012 510011 510010 510009 510008
2 (EM) Feed and read-in disable byte 1 (alarm no.: 510100-510107)
4 (OM) Feed and read-in disable byte 3 (alarm no.: 510116-510123)
6 (EM) Read-in disable byte 1 (alarm no.: 510200-510207)
8 (OM) Read-in disable byte 3 (alarm no.: 510216-510223)
10 (EM) NC Start disable byte 1 (alarm no.: 510300-510307)
11 (OM) NC Start disable byte 2 (alarm no.: 510308-510315)
12 (EM) Feed stop GEOaxis 1 byte 1 (alarm no.: 511100-511107)
13 (OM) Feed stop GEOaxis 1 byte 2 (alarm no.: 511108-511115)
Notes

type)
Channel 2
18 (EM) 520007 520006 520005 520004 520003 520002 520001 520000
19 (OM) 520015 520014 520013 520012 520011 520010 520009 520008
Notes


(Message
type)
Channel 3
36 (EM) 530007 530006 530005 530004 530003 530002 530001 530000
37 (OM) 530015 530014 530013 530012 530011 530010 530009 530008
Notes


(Message
type)
Channel 4
54 (EM) 540007 540006 540005 540004 540003 540002 540001 540000
55 (OM) 540015 540014 540013 540012 540011 540010 540009 540008
Notes


(Message
type)
Channel 4
54 (EM) 540007 540006 540005 540004 540003 540002 540001 540000
55 (OM) 540015 540014 540013 540012 540011 540010 540009 540008
Notes


(Message
type)
Channel 6
90 (EM) 560007 560006 560005 560004 560003 560002 560001 560000
91 (OM) 560015 560014 560013 560012 560011 560010 560009 560008
Notes


(Message
type)
Channel 7
108 (EM) 570007 570006 570005 570004 570003 570002 570001 570000
109 (OM) 570015 570014 570013 570012 570011 570010 570009 570008
Notes


(Message
type)
Channel 8
126 (EM) 580007 580006 580005 580004 580003 580002 580001 580000
127 (OM) 580015 580014 580013 580012 580011 580010 580009 580008
Channel 9 and 10 not realized
Notes

Axis areas in DB2 (Parameter "ExtendAlMsg"=False)
type)
axis/spindle
144 (EM) 600107 600106 600105 600104 600103 600102 600101 600100
Feed stop/spindle stop for axis/spindle 1 (alarm no.: 600100-600115)
145 (OM) 600115 600114 600113 600112 600111 600110 600109 600108
146 (EM) Feed stop/spindle stop for axis/spindle 2 byte 1 (alarm no.: 600200-600207)
147 (OM) Feed stop/spindle stop for axis/spindle 2 byte 2 (alarm no.: 600208-600215)
159 (OM) Feed stop/spindle stop for axis/spindle 8 (alarm no.: 600808-600815)
Notes

type)
axis/spindle
axis 19 – 31 not realized
Notes

User areas in DB2 (Parameter "ExtendAlMsg"=False)

(Message type)
180 (EM) 700007 700006 700005 700004 700003 700002 700001 700000
User area 0 (alarm no.: 700000-700015)
181 (EM) 700015 700014 700013 700012 700011 700010 700009 700008
182 (EM) User area 0: byte 3 (alarm no.: 700016-700023)
184 (OM) User area 0: byte 5 (alarm no.: 700032-700039)
188 - 191 (EM) User area 1: bytes 1 - 4 (alarm no.: 700100-700131)
192 – 195 (OM) User area 1: bytes 5 - 8 (alarm no.: 700132-700163)
196 – 199 (EM) User area 2: bytes 1 - 4 (alarm no.: 700200-700231)
Notes


(Message type)
284– 287 (EM) User area 13: bytes 1 - 4 (alarm no.: 701300-701331)
Notes


(Message type)
Notes

FC10 alarms in DB2 (FB1-Parameter "ExtendAlMsg" = True)
Channel areas in DB2 (Parameter "ExtendAIMsg"=True)
DB2 Signals for PLC messsages (PLC  HMI)

type)
Channel 1
0
Feed disable (without alarm no.)
1
2 Feed and read-in disable byte 1 (without alarm no.)
6 Read-in disable byte 1 (without alarm no.)
10 NC Start disable byte 1 (without alarm no.)
11 NC Start disable byte 2 (without alarm no.)
12 Feed stop GEOaxis 1 byte 1 (without alarm no.)

18 - 119 Channel 2 - Channel 10 (without alarm no.)
Notes

type)
Channel 1
310 (EM) 510007 510006 510005 510004 510003 510002 510001 510000
311 (OM) 510015 510014 510013 510012 510011 510010 510009 510008
Notes

type)
Channel 2
328 (EM) 520007 520006 520005 520004 520003 520002 520001 520000
329 (OM) 520015 520014 520013 520012 520011 520010 520009 520008
Notes

type)
Channel 3
346 (EM) 530007 530006 530005 530004 530003 530002 530001 530000
347 (OM) 530015 530014 530013 530012 530011 530010 530009 530008
Notes

type)
Channel 4
364 (EM) 540007 540006 540005 540004 540003 540002 540001 540000
365 (OM) 540015 540014 540013 540012 540011 540010 540009 540008
Notes

type)
Channel 5
382 (EM) 550007 550006 550005 550004 550003 550002 550001 550000
383 (OM) 550015 550014 550013 550012 550011 550010 550009 550008
Notes

type)
Channel 6
400 (EM) 560007 560006 560005 560004 560003 560002 560001 560000
401 (OM) 560015 560014 560013 560012 560011 560010 560009 560008
407(EM) Read-in disable byte 2 (alarm no.: 560208-560215)
Notes

type)
Channel 7
418 (EM) 570007 570006 570005 570004 570003 570002 570001 570000
419 (OM) 570015 570014 570013 570012 570011 570010 570009 570008
Notes

type)
Channel 8
436 (EM) 580007 580006 580005 580004 580003 580002 580001 580000
437 (OM) 580015 580014 580013 580012 580011 580010 580009 580008
Notes

type)
Channel 9
454 (EM) 590007 590006 590005 590004 590003 590002 590001 590000
455 (OM) 590015 590014 590013 590012 590011 590010 590009 590008
Notes

type)
Channel 10
472 (EM) 500007 500006 500005 500004 500003 500002 500001 500000
473 (OM) 500015 500014 500013 500012 500011 500010 500009 500008
Axis areas in DB2 (Parameter "ExtendAIMsg" = True)

(Message
type)
axis/spindle
120
Feed stop/spindle stop for axis/spindle 1 (without alarm no.)
121
122 - 181 Feed stop/spindle stop for axis/spindle 2 -
Feed stop/spindle stop for axis/spindle 31 (without alarm no.)
Notes


(Message
type)
axis/spindle
490 (EM) 600107 600106 600105 600104 600103 600102 600101 600100
Feed stop/spindle stop for axis/spindle 1 (alarm no.: 600100-600015)
491 (OM) 600115 600114 600113 600112 600111 600110 600109 600108
492 (EM) Feed stop/spindle stop for axis/spindle 2 (alarm no.: 600200-600207)
503 (OM) Feed stop/spindle stop for axis/spindle 7(alarm no.: 600708-600715)
Notes


(Message
type)
Notes

User areas in DB2 (Parameter "ExtendAIMsg" = True)
type)
182
User area 0: byte 0 (without alarm no)
183
184 - 308 User area 0: byte 1 -
User area 0: byte 63 (without alarm no)
Notes


(Message type)
554 (EM) 700007 700006 700005 700004 700003 700002 700001 700000
User area 0 (alarm no.: 700000-700015)
555 (EM) 700015 700014 700013 700012 700011 700010 700009 700008
562 - 565 (EM) User area 1 bytes 1 - 4 (alarm no.: 700100-700131)
566 - 569 (OM) User area 1 bytes 5 - 8 (alarm no.: 700132-700163)
630 - 633 (OM) User area 9 bytes 5 - 8 (alarm no.: 700932 - 700963)
Notes


(Message type)
Notes


(Message type)
Notes

Signals from/ to NCK, PLC, HMI

On-board NCK input and outputs to NCK (DB10)
DB10 Signals to NC (PLC  NCK)

DBB0 Disabling of digital NCK inputs /Z1-A2/
Digital inputs without hardware On-board inputs

Input 8 Input 7 Input 6 Input 5 Input 4 Input 3 Input 2 Input 1
DBB1 Setting of digital NCK inputs from PLC
Digital inputs without hardware On-board inputs

DBB2 - Unassigned
DBB3
DBB4 Disabling of digital NCK outputs /Z2-A4/

Digital outputs without hardware On-board outputs
Output 8 Output 7 Output 6 Output 5 Output 4 Output 3 Output 2 Output 1
DBB5 Overwrite screenform of digital NCK outputs /Z2-A4/

DBB6 Setting value of digital NCK outputs from PLC /Z2-A4/

DBB7 Input screenform of digital NCK outputs /Z2-A4/

st
DBB8 - Machine axis number table for FC 19, FC 24, FC 25, FC 26 (1 MCP)
DBB29
DBB30 Upper limit of machine axis numbers for FC 19, FC 24 (1st MCP)
With 0, the max. number of machine axis numbers applies
DBB32 - Machine axis number table for FC 19, FC 24, FC 25, FC 26 (2nd MCP)
DBB53
DBB54 Upper limit of machine axis numbers for FC 19, FC 24 (2nd MCP)
With 0, the max. number of machine axis numbers applies
Notes

General signals to NCK (DB10)
DB10 Signals to NC (PLC  NC)

DBB56 Keyswitch /Z1-A2/ Acknowl. Emergency
Emergency Stop
Stop /Z1-A2/
/Z1-A2/
Position 3 Position 2 Position 1 Position 0
DBB57 PC INC inputs in
shutdown mode group
(Only 840Di) area active
DBB58 Collision
detection off
DBB59
On board NCK/HMI inputs and outputs (DB10)

DB10 Signals from (NCK -> PLC)
DBB60 For free disposal Actual value of the digital ON-BOARD inputs of the NCK
On-board inputs /Z2-A4/
Input 4 Input 3 Input 2 Input 1
DBB61 -
DBB63
DBB64 Setpoint for the digital outputs of the NCK without hardware Setpoint for the digital on-board outputs of the NCK /Z2-A4/
/Z2-A4/
DBB65 - unassigned
DBB67
DBB68 Handwheel 1 moved
DBB71 Modification counter inch/metric system of units
DBB72 Status of the actual value display indicated (1st MCP)
HT 8  HMI Travel keys MCS/ Valid display

displayed WCS
DBB73 Status of the actual value display indicated (2nd MCP)
HT 8  HMI Travel keys MCS/ Valid display

displayed WCS
Notes

DB10 Signals from (NCK -> PLC)

st
DBB74 - Machine axis numbers of the displayed axes (1 MCP)
DBB79 MCP1AxisFromHMI
HT 8  HMI
DBB80 - Machine axis numbers of the displayed axes (2nd MCP)

DBB85 MCP2AxisFromHMI
HT 8  HMI
DBB86 Reserved
DBB88 Reserved
Notes

Selection/status signals from HMI (DB10)
DB10 Signals from NC (NCK  PLC)
DBB90
ePS  PLC
DBB91
PLC  ePS
DBB92
GP  PLC DP1 MPI/DP
Bus Bus
Slaves OK Slaves OK
DBB93 unassigned
DBB94 unassigned
DBB95 unassigned
DBB96 unassigned
DBB97 Channel number for handwheel 1 /Z2-H1

HMI  PLC
D C B A
DBB98 Channel number for handwheel 2 /Z2-H1

HMI  PLC
D C B A
DBB99 Channel number for handwheel 3 /Z2-H1/

HMI  PLC
D C B A
DBB100 Axis number for handwheel 1 /Z2-H1/

HMI  PLC
Machine axis Handwheel Contour E D C B A
/Z2-H1/ selected handwheel
/Z2-H1/
HMI  PLC
/Z2-H1/
HMI  PLC
/Z2-H1/
DBB103 HMI battery HMI tempera AT box ready HMI HMI Remote
HMI  PLC alarm -ture limit /Z1-A2/ fan monitor- HD monitor- diagnosis
/Z1-A2/ active
/Z1-A2/ ing ing /FBFE/
/Z1-A2/
Notes

General signals from NCK (DB10)

DBB104 NCK CPU 1. OB1 cycle Op2Key Op1Key HHU MCP 2 MCP 1
GP  PLC ready ready ready ready ready ready
/Z1-A2/
DBB105 Toolmanage-
GP  PLC ment command
cancellation
DBB106 EMER- Collision detec-
GENCY Stop tion off
active /Z2-M5/
/Z1-N2/
DBB107 Inch system NCU-link Probe actuated

/Z1-G2/ active /Z2-M5/
/Z2-B3/
Probe 2 Probe 1
DBB108 NC ready Drive ready Drives in HMI CPU HMI 2 CPU HMI2 CPU
/Z1-A2/ /Z1-A2/ Ready Ready
cyclic opera- ready
(HMI to (HMI to MPI)
tion OPI) /Z1-A2/ E_HMI2
/Z1-A2/ ready
/Z1-A2/
DBB109 NCK battery Air temp. Heat sink PC operat- NCK
alarm alarm temp. alarm ing system alarm present
/Z1-A2/ /Z1-A2/ NCU 573 /Z1-A2/
/Z1-A2/ fault
/HBI/
DBB110 Software cams minus /Z2-N3/
7 6 5 4 3 2 1 0

15 14 13 12 11 10 9 8

23 22 21 20 19 18 17 16

31 30 29 28 27 26 25 24
DBB114 Software cams plus /Z2-N3/

7 6 5 4 3 2 1 0

15 14 13 12 11 10 9 8

23 22 21 20 19 18 17 16

31 30 29 28 27 26 25 24
Notes


31 30 29 28 27 26 25 24
DBB118 ePS-Daten
ePS 
PLC
DBB119 ePS-Daten
ePS 
PLC
DBB120 ePS-Daten
ePS 
PLC
DBB121 ePS-Daten
ePS 
PLC
Notes

External digital inputs of the NCK (DB10)

DBB122 Disable the external digital NCK inputs
DBB123 Values from the PLC for the external digital NCK inputs



Notes

External digital outputs of the NCK (DB10)

DBB130 Disable the external digital NCK outputs /Z2-A4/
DBB131 Overwrite screenform for the external digital NCK outputs /Z2-A4/
DBB132 Value from the PLC for the external digital NCK outputs /Z2-A4/
DBB133 Default screenform for the external digital NCK outputs /Z2-A4/


Notes

Analog inputs of the NCK (external) (DB10)
DB10 Signals to NCK (PLC  NCK)

DBB146 Disable the analog NCK inputs /Z2-A4/
DBB147 Specified analog value for NCK from PLC /Z2-A4/

DBW148 Setpoint from PLC for analog input 1 of NCK /Z2-A4/
DBB164 unassigned
DBB165
Notes

Analog outputs of the NCK (external) (DB10)
DB10 Signals to NCK (PLC  NCK)

DBB166 Overwrite screenform for the analog NCK outputs /Z2-A4/
DBB167 Default screenform for the analog NCK outputs /Z2-A4/
DBB168 Disable the analog NCK outputs /Z2-A4/
DBB169 Reserved
DBW170 Setpoint from PLC for analog output 1 of NCK /Z2-A4/


External digital input and output signals of the NCK (DB10)
DB10 Signals from NCK (NCK  PLC)

DBB186 Actual value of external digital NCK inputs /Z2-A4/
DBB190 NCK setpoint for external digital NCK outputs /Z2-A4/
Notes

Analog input and output signals of the NCK (DB10)

DBW194 Actual value for analog input 1 of the NCK /Z2-A4/
DBW210 Setpoint for analog output 1 of the NCK /Z2-A4/
DBW226- Collision detection 8 bytes = 64 bits

DBW233
NCK  PLC
DBW234 - Collision detection 8 bytes = 64 bits
DBW241
PLC  NCK
Expansion handwheel signals from NCK (DB10)

Ethernet-Handrad stands still

DBB245
Handwheel 6 Handwheel 5 Handwheel 4 Handwheel 3 Handwheel 2 Handwheel 1
DBB246 Reserved
Notes

Mode group-specific signals to mode group 1 (DB11)
DB11 Signals to mode group 1 (PLC  NCK)

DBB0 Mode group BAG-Stopp Mode group Mode change Operating mode
reset Mode group stop disable /Z1-K1/
/Z1-K1/ stop Axes /Z1-K1/ /Z1-K1/ JOG MDA AUTO
plus spindle
/Z1-K1/
DBB1 Single block Machine function
/Z1-K1/ /Z1-K1/
Type A Type B REF REPOS TEACH IN
DBB2 Machine function

Var. INC 10000 INC 1000 INC 100 INC 10 INC 1 INC
DBB3 unassigned
DB11 Signals from mode group 1 (NCK  PLC)

DBB4 Strobe mode
HMI  PLC /Z1-K1/
JOG MDA AUTO
DBB5 Strobe machine function

HMI  PLC /Z1-K1/
REF REPOS TEACH IN
DBB6 All channels NCK internal Mode Group Mode group Active operating mode
in reset state JOG active reseted ready /Z1-K1/
/Z1-K1/ /Z1-K1/ /Z1-K1/
JOG MDA AUTO
DBB7 Active machine function

/Z1-K1/
REF REPOS TEACH IN

Notes

DB11 Signals to mode group 2 (PLCNCK)

DBB20 Mode group Mode group Mode group Mode change Operating mode
reset stop stop disable /Z1-K1/
/Z1-K1/ Axes plus /Z1-K1/ /Z1-K1/
spindle
/Z1-K1/
JOG MDA AUTO
DBB21 Single block Machine function
/Z1-K1/
Type A Type B REF REPOS TEACH IN
DBB23 unassigned
DB11 Signals from mode group 2 (NCK  PLC)

DBB24 Strobe mode
HMI  PLC /Z1-K1/
JOG MDA AUTO
DBB25 Strobe machine function
HMI à PLC /Z1-K1/
REF REPOS TEACH IN
DBB26 All channels NCK internal Mode group Mode group Active operating mode
in reset state JOG active reseted ready /Z1-K1/
/Z1-K1/ /Z1-K1/ /Z1-K1/
/Z1-K1/
JOG MDA AUTO
DBB27 Active machine function
REF REPOS TEACH IN

DBB28 Machine functions
Notes

Signals for Safety SPL (safe programmable logic) (DB18)
DB18 Signals for Safety SPL (PLC  PLC)

DBB0- unassigned
DBW34
DBB36 Stop E SPL READY

DBB37
Data area / error
DB18 Signals for Safety SPL (PLC  NCK)

Data area for SPL inputs/outputs
SPL_DATA.INSEP [1..32]
DBD38
SPL_DATA.INSEP [33..64]
DBD42
SPL_DATA.OUTSEP [1..32]
DBD46
SPL_DATA.OUTSEP [33..64]
DBD50
Data area for user SPL
DBD54 SPL_DATA.INSIP [1..32]
SPL_DATA.INSIP [33..64]
DBD58
SPL_DATA.OUTSIP [1..32]
DBD62
SPL_DATA.OUTSIP [33..64]
DBD66
SPL_DATA.MARKERSIP [1..32]
DBD70
SPL_DATA.MARKERSIP [33..64]
DBD74
Notes


SPL_DELTA.INSEP [1..32]
DBD78
SPL_DELTA.INSEP [33..64]
DBD82
SPL_DELTA.OUTSEP [1..32]
DBD86
SPL_DELTA.OUTSEP [33..64]
DBD90
SPL_DELTA.INSIP [1..32]
DBD94
SPL_DELTA.INSIP [33..64]
DBD98
SPL_DELTA.OUTSIP [1..32]
DBD102
SPL_DELTA.OUTSIP [33..64]
DBD106
SPL_DELTA.MARKERSIP [1..32]
DBD110
SPL_DELTA.MARKERSIP [33..64]
DBD114
CMDSI
DBD118
Systemfehler
DBD119 cross-checking
Error number
DBD120
0 = no error
1 - 320 = Signal number starting from SPL_DATA.INSEP [1]
Level indicator of cross-checking
DBD124
(diagnostics option: how many SPL signals currently differ in level)
Notes

Supplementary data areas

Data area for single-channel inputs/outputs
DBB128 PLCSIOUT [1 .. 8]
NCK  PLC
NCK  PLC

NCK  PLC
NCK  PLC
DBB132 PLCSIIN [1.. 8]

PLC  NCK
DBB133 PLCSIIN [9 .. 16]
PLC  NCK
PLC  NCK

PLC  NCK
SPL status
DBB136
PROFIsafe module(s) for

DBB138
th th th th
8 input byte 7 input byte 6 input byte 5 input byte 4th input byte 3rd input byte 2nd input byte 1st input byte
DBB139
PROFIsafe module(s) for

DBB140
th th th
8 output 7 output 6 output 5th output 4th output 3rd output 2nd output 1st output
byte byte byte byte byte byte byte byte
DBB141
DBB142 -
DBB 149
DBB150 -
DBB157
DBB158 -
DBB188
Notes

F_SENDDP (transmitter)

1. F_SENDDP interface: FSDP[1].
DBW190
ERR_REAC
DBB192 SUBS_ON ERROR
DBB193
DBW194 DIAG
DBW196 RETVAL14
DBW198 RETVAL15

DBW200
ERR_REAC
DBB203
DBW204 DIAG
DBW206 RETVAL14
DBW208 RETVAL15

DBW210
ERR_REAC
DBB213
DBW214 DIAG
DBW216 RETVAL14
DBW218 RETVAL15
Notes

F_RECVDP (receiver)
DB18 SPL-Signals (PLC  NCK)

1. F_RECVDP interface: FRDP[1].
DBB220
SUBS[7] SUBS[6] SUBS[5] SUBS[4] SUBS[3] SUBS[2] SUBS[1] SUBS[0]
DBB221 SUBS[15] SUBS[14] SUBS[13] SUBS[12] SUBS[11] SUBS[10] SUBS[9] SUBS[8]
DBB222 REAC
DBB224 ACK_REI
DBB225 SEND-
ACK_REQ SUBS_ON ERROR
MODE
DBW226 DIAG
DBW228 RETVAL14
DBW230 RETVAL15

DBB232
DBW234 REAC
DBB236 ACK_REI
DBB237 SEND-
ACK_REQ SUBS_ON ERROR
MODE
DBW238 DIAG
DBW240 RETVAL14
DBW242 RETVAL15

DBB244
DBW246 REAC
DBB248 ACK_REI
DBB249 SEND MODE ACK_REQ SUBS_ON ERROR
DBW250 DIAG
DBW252 RETVAL14
DBW254 RETVAL15
Notes

SPL user data
DB18 SPL-Signals (PLC  NCK)

DBD256 SPL_USER_DATA[0]
Notes

Signals from/to operator panel (DB19)

DB19 Signals to operator panel (PLC  HMI)
DBB0 Actual value Back up HMI-Adv Clear Clear cancel Key disable Screen dark- Screen bright
in WCS travel re- shutdown recall alarms alarms /Z1-A2/ ening /Z1-A2/
0=MCS corder HMI-Adv HMI-Adv /Z1-A2/
/Z1-A2/
Rights for the External
DBB1 external Viewer
viewer
DBB2
DBB4
DBB6 Analog spindle 1, capacity in percent
DBB7 Analog spindle 2, capacity in percent
DBB8 Channel number of machine control panel to HMI
DBB9 Reserved for selection Automato OEM2 OEM1

tool measure-
ment
DBB10 PLC Hardkeys (Values 1 ... 255, Default: 0 )
Reserved for hardkey function expansions
DBB11
DBB12
DBB13 part program Reserved Disable
Teach trans-
/Z1-A2/
fer
Select Load Unload IHsl/IM9
DBB14 0=act. FS RS-232 act. FS: Index of file to be transferred in the standard list.
1=pas. FS RS-232 pass. FS: Number of the control file for user file names.
DBB15 RS-232 act. FS: Index that specifies the axis, channel or tool no.
RS-232 pass. FS: Index of the file to be transferred in the user list
DBB16 1=pas FS Part program handling: Number of the control file for user file names.
/IHsl/IM9
DBB17 Part program handling: Index of the file to be transferred in the user list
/IHsl/IM9
DBB18
DBB19 Reserved (signal counter)
Notes

DB19 Signals from operator panel (HMI  PLC)

DBB20 MCS/WCS Simulation Language 2 Recall alarm Cancel alarm Cancel key Screen is dark
Change- active switched cleared cleared actuated /Z1-A2/
over /Z1-A2/ HMI-Emb. HMI-Adv HMI-Adv /Z1-A2/
/Z1-A2/ /Z1-A2/ /Z1-A2/
DBB21 Active HMI operating area
DBB22 Displayed channel number from the HMI /Z1-A2/
DBB23
DBB24 actual mask number from JobShop
DBB26 Part program handling status /Z1-A2/
Select Load Unload Active Error OK Reserved
DBB27 Error program handling /Z1-A2/
DBW28 Mask number for "Extend user interface" IHsl/BE2
DBB30 Control bits PLC --> HMI
Exit mask Request mask
DBB31 Control bits PLC --> HMI
Inactive bit Error, Not Mask exited Mask active Mask re- Mask request
possible to quested accepted
request
mask
DBB32 FunctionSelectionNo. from PLC
PLC  HMI Busy func- Strobe func-

tion tion
DBB33 Parameter 1 for FunctionSelectionNo. (function selection from DBB32)
PLC  HMI
PLC  HMI
PLC  HMI
DBB36 Error code for FunctionSelectionNo. (function selection from DBB32)
HMI  PLC
HMI  PLC
HMI  PLC
Notes


HMI  PLC
DBB40 - Reserved
DBB47
DBB48 PLC busy HMI strobe FunctionSelectionNo. from HMI

function function
HMI  PLC
DBB49 Error code for FunctionSelectionNo. (function selection from DBB48)
PLC  HMI
DBB50 - Interface 2nd HMI

DBB99 Assignment as for DBB0 to DBB49
DBB100 Switchover interface to HMI

Knocking interface (HMI announces itself to NCU)
ONL_REQUEST /Z2-B3/
Online request from HMI
HMI writes its client identification as online request
(bit 8-15: bus type, bit 0-7: HMI bus address)
DBB102 ONL_CONFIRM /Z2-B3/
Acknowledgment from PLC to online request
PLC writes HMI client identification as acknowledgment (bus type, HMI bus address;
as with DBB100).
DBB104 PAR_CLIENT_IDENT /Z2-B3/
HMI writes its client identification (bus type, HMI bus address; as with DBB100).
DBB106 PAR_HMI_TYP /Z2-B3/
Type of HMI as per NETNAMES.INI: Main / subordinate operator panel / server /...
DBB107 PAR_MSTT_ADR /Z2-B3/
HMI writes address of MCP to be activated; 255, when no MCP activated
DBB108 PAR_STATUS /Z2-B3/

PLC writes online enable for HMI
DBB109 PAR_Z_INFO /Z2-B3/

PLC writes additional info about status
DBB110 M_TO_N_ALIVE
Sign of life from PLC to HMI through M to N block
DBB112 Reserved bus type MCP
Notes


DBB113 ParOpKeyAdr
Direct key index knocking interface
DBB114 ParTcuIndex
TCU index knocking interface
DBB115 ParHt2Index
Ht2 index login interface
DBB116 Direct key address

1st online interface
DBB117 Direct key address

2nd nline interface
DBB118 TCU index

1st online interface
DBB119 TCU index

nd
2 online interface
Online interface HMI 1 (user)

DBB120 MMC1_CLIENT_IDENT /Z2-B3/
PLC writes PAR_CLIENT_IDENT to MMCx_CLIENT_IDENT when HMI goes online.
DBB122 MMC1_TYP /Z2-B3/
DBB123 MMC1_MSTT_ADR /Z2-B3/
DBB124 MMC1_STATUS /Z2-B3/

Connection status, HMI and PLC alternately write their requests/acknowledgments
DBB125 MMC1_Z_INFO /Z2-B3/

Additional info connection status (pos./neg. acknowledgment, error messages...)
DBB126 Reserved TCU1_ MMC1_ MMC1_ MMC1_ MMC1_ MMC1_ MMC1
SHIFT_ CHANGE_
LOCK ACTIVE_ ACTIVE_ ACTIVE_ MSTT_ SHIFT
DENIED CHANGED PERM REQ SHIFT_ LOCK
/Z2-B3/ /Z2-B3/ /Z2-B3/ /Z2-B3/ LOCK /Z2-B3/
/Z2-B3/
Notes


DBB127 Reserved Bus type MCP
DBB128 - Reserved Transline (Transline DB number)

DBB129
Online interface HMI 2 (user)
DBB130 MMC2_CLIENT_IDENT /Z2-B3/

PLC writes PAR_CLIENT_IDENT to MMCx_CLIENT_IDENT when HMI goes online
DBB132 MMC2_TYP /Z2-B3/

PLC writes PAR_MMC_TYP to MMCx_TYP when HMI goes online
DBB133 MMC2_MSTT_ADR /Z2-B3/

PLC writes PAR_MSTT_ADR to MMCx_MSTT_ADR when HMI goes online
DBB134 MMC2_STATUS /Z2-B3/

Connection status, MMC and PLC alternately write their requests/acknowledgments
DBB135 MMC2_Z_INFO /Z2-B3/

Additional info connection status (pos./neg. acknowledgment, error messages...)
Reserved TCU2_ MMC2_ MMC2_ MMC2_ MMC2_ MMC2_ MMC2_

DBB136
SHIFT_
LOCK CHANGE_ ACTIVE_ ACTIVE_ ACTIVE_ MSTT_ SHIFT_
DENIED CHANGED PERM REQ SHIFT_ LOCK
/Z2-B3/ /Z2-B3/ /Z2-B3/ /Z2-B3/ LOCK /Z2-B3/
/Z2-B3/
DBB137 Reserved Bus type MCP
DBB138 – Reserved Transline (Transline DB number)

DBB139
DBB140 - Code carrier input parameters
DBB197 Optional package SINTDC on HMI-Advanced required
DBB198 - Code carrier return parameters

DBB250 - Commands
DBB256 - Commands for Paramtm.exe

DBB268 Traffic light status

Optional package TPM on HMI-Advanced required
DBD270 - Counter[1 ... 32]

DBD394 Optional package TPM on HMI-Advanced required
Notes

PLC machine data (DB20)
DB20 PLC machine data (PLC  operator)

DBW0 INT values
DBW
DBW INT values
DBB Bit arrays
DBB
DBB Bit arrays
DBD REAL values
DBD
DBD REAL values
Notes

Channel signals (DB21 - DB30)

Signals to/from NCK channel (DB21 – DB30)
DB21 - Signals to NCK channel (PLCNCK)

DB30
DBB0 Activate dry Activate M01 Activate sin- Activate DRF
run feedrate / /Z1-K1/ gle block /Z1- /Z2-H1/
Z1-V1/ K1/
DBB1 Activate pro- PLC action CLC over- CLC stop /Z3 Time moni- Synchron- Enable pro- Activate
gram test complete /Z1- ride /Z3-TE1/ -TE1/ toring act. ized action tection zones referencing /
/Z1-K1/ K1/ (tool manage OFF /Z1-A3/ Z1-R1/
-ment)
/FBSY/
DBB2 Skip block activate /Z1-K1/
/7 /6 /5 /4 /3 /2 /1 /0
DBB3 Nibbling and punching /K2-N4/
Manual re- Stroke not Stroke de- Stroke sup- Manual Stroke en-
lease of operating /K2 layed /K2-N4/ pres-sion stroke enable able
stroke 2 -N4/ /K2-N4/ /K2-N4/ /K2-N4/
DBB4 Feedrate override /Z1-V1/
H G F E D C B A
DBB5 Rapid traverse override /Z1-V1/
H G F E D C B A
DBB6 Feedrate Rapid trav- Program Delete Delete dis- Read-in dis- Feed disable
override erse override level abort / subroutine tance-to-go able override /Z1-
active active Z1-K1/ no. of passes /Z1-A2/ /Z1-K1/ V1/
override /Z1- override /Z1-
V1/ V1/
DBB7 Reset Suppress NC Stop NC Stop /Z1- NC Stop to NC Start /Z1- NC Start
/Z1-K1// Start Lock axes plus K1/ block limit /Z1 K1/ disable /Z1-
spindle -K1/ K1/
/Z1-K1/
DBB8 Activate machine-related protection area /Z1-A3/
Area 8 Area 7 Area 6 Area 5 Area 4 Area 3 Area 2 Area 1
DBB9 Activate machine-related protection area /Z1-A3/
Area 10 Area 9
DBB10 Activate channel-specific protection area /Z1-A3/
DBB11 Activate channel-specific protection area /Z1-A3/
Area 10 Area 9
Notes

Control signals to geometry axes
DB21 - Signals to NCK channel (PLC  NCK)

DB30
Geometry axis 1
DBB12 Traversing keys Rapid trav- Traversing Feed stop /Z1 Activate handwheel
/Z2-H1/ erse over- key disable / -V1/ /Z2-H1/
ride /Z2-H1/ Z2-H1/
pus mnus 3 2 1
DBB13 Geometry axis 1

machine function /Z2-H1/
DBB14 OEM signals geometry axis 1

Traversing keys Rapid trav- Traversing Feed stop /Z1 Activate handwheel
ride /Z2-H1/ Z2-H1/
plus minus 3 2 1


Traversing keys Rapid trav- Traversing Feed stop /Z1 Activate handwheel
ride /Z2-H1/ Z2-H1/
plus minus 3 2 1

Notes

Operating signals from HMI/status signals from NC channel

DB21 – Signals from NCK channel (NCK  PLC,
DB30 HMI  PLC, PLC  NCK)

DBB24 Dry run M01 se- Select NCK- DRF se- ePS loading pro-
HMI  feedrate lected /Z1- related M01 lected /Z2- gram
selected / K1/ H1/
PLC Z1-V1/
DBB25 Program REPOS Feedrate REPOSPATHMODE
HMI  test se- MODE override for
lected /Z1- EDGE rapid traverse
PLC K1/ selected /Z1-
V1/ 2 1 0
DBB26 Skip block selected /Z1-K1/

HMI  7 6 5 4 3 2 1 0
PLC
DBB27 Skip block selected
HMI  /Z1-K1/
PLC /9 /8
DBB28 OEM channel signals

PLC 
NCK
DBB29 Do not Switch off Switch off Activate Activate fixed feed
PLC  disable wear workpiece PTP /FBMA/, /Z1-V1/
tool monitoring counter motion
NCK
4 3 2 1
DBB30 No tool Activate NCK Neg. direc- Simulation Activate contour handwheel
PLC  change -related M01 tion simula-
contour Handwheel 3 Handwheel 2 Handwheel 1
NCK commands tion contour
/Z1-H2/ handwheel
handwheel
DBB31 Skip block active REPOS MO- REPOSPATHMODE
PLC  DE EDGE
NCK /9 /8 2 1 0
DBB32 Last action M00/M01 Approach Action Execution from
NCK  block ac- active block active / block ac- external source
PLC tive /Z1- /Z1-K1/ Z1-K1/ tive /Z1- active
K1/ K1/
DBB33 Program Transfor- M02/M30 Block search Handwheel Revolutio-nal Orientable Referencing active
NCK  test active / mation active active override feedrate active toolholder ac- /Z1-R1/
PLC Z1-K1/ active /Z1- /Z1-K1/ /Z1-K1/ active /Z1-V1/ tive
K1/ /Z2-H1/
/K2-M1/
DBB34 OEM channel signals feedback
NCK 
PLC
DBB35 Channel status /Z1-K1/ Program status /Z1-K1/

NCK 
PLC
Reset Interrupted Active Aborted Interrupted Stopped Waiting Running
DBB36 NCK alarm Channel- Channel Interrupt All axes station- All axes requiring
NCK  with proc- specific NCK ready processing ary /Z1-B1/ reference points
PLC essing stop alarm present for opera- active are referenced
present /Z1 /Z1-A2/ tion /Z1-K1/ /Z1-R1/
-A2/
Notes

DB21 – Signals from NCK channel (NCK  PLC,

DB30 HMI  PLC, PLC  NCK)

DBB37 Stop at Read-in en- CLC CLC CLC Contour handwheel active /Z2-H1/
NCK  block end able is ig- stopped stopped active
PLC with SBL is nored upper lower limit / /Z3-TE1/ Handwheel 3 Handwheel 2 Hand-
sup- /Z1-K1/ limit /Z3- Z3-TE1/ wheel 1
pressed TE1/
/Z1-K1/
DBB38 Nibbling and punching /Z2-N4/
NCK 
PLC Acknowl. manual Stroke
stroke enable enable
/Z2-N4/ active
/Z2-N4/
DBB39 Protection
NCK  zones not
PLC guaran-
teed
Notes

Status signals of geometry axes
DB21 – Signals from NCK channel (NCK  PLC)
DB30
Traverse command Travel requests Handwheel active /Z2-H1/
/Z2-H1/
plus minus plus minus 3 2 1

active machine function
/Z2-H1/
DBB44
HMI  PLC

Traverse command Travel requests Handwheel active
/Z2-H1/ /Z2-H1/

/Z2-H1/
DBB50
HMI  PLC

Traverse command Travel requests Handwheel active
/Z2-H1/ /Z2-H1/

/Z2-H1/
DBB56
HMI  PLC
Notes

Change signals on auxiliary function transfer from NC channel
DB21 – Signals from NCK channel (NCKPLC)

DB30
DBB58 M fct. 5 M fct. 4 M fct. 3 M fct. 2 M fct. 1
change /Z1- change /Z1- change /Z1- change /Z1- change /Z1-
H2/ H2/ H2/ H2/ H2/
DBB59 M fct. 5 M fct. 4 M fct. 3 M fct. 2 M fct. 1
not decoded not decoded not decoded not decoded not decoded
DBB60 S fct. 3 quick S fct. 2 quick S fct. 1 quick S fct. 3 S fct. 2 S fct. 1
change /Z1- change /Z1- change /Z1-
H2/ H2/ H2/
DBB61 T fct 3 quick T fct. 2 quick T fct. 1 quick T fct. 3 chan- T fct. 2 chan- T fct. 1 chan-
ge/Z1-H2/ ge/Z1-H2/ ge /Z1-H2/
DBB62 D fct. 3 quick D fct. 2 quick D fct. 1 quick D fct. 3 chan- D fct. 2 chan- D fct. 1 chan-
ge ge/ ge /Z1-H2/
/Z1-H2/ Z1-H2/
DBB63 DL fct. quick DL fct. chan-
ge
DBB64 H fct. 3 quick H fct. 2 quick H fct. 1 quick H fct. 3 H fct. 2 H fct. 1
change /Z1- change /Z1- change /Z1-
H2/ H2/ H2/
DBB65 F fct. 6 F fct. 5 F fct. 4 F fct. 3 F fct. 2 F fct. 1
change /Z1- change /Z1- change /Z1- change /Z1- change /Z1- change /Z1-
H2/ H2/ H2/ H2/ H2/ H2/
DBB66 M fct. 5 quick M fct. 4 quick M fct. 3 quick M fct. 2 quick M fct. 1 quick
DBB67 F fct. 6 quick F fct. 5 quick F fct. 4 quick F fct. 3 quick F fct. 2 quick F fct. 1 quick
Notes

Transferred M/S functions

DB30
DBW68 Extended address M function 1 (binary)
/Z1-H2/
DBD70 M function 1 (binary)
/Z1-H2/
/Z1-H2/
/Z1-H2/
/Z1-H2/
/Z1-H2/
/Z1-H2/
/Z1-H2/
/Z1-H2/
DBD94 M function 5 (binary) /Z1-H2/
DBW98 Extended address S function 1 (binary)

/Z1-H2/
DBD100 S function 1 (REAL format)
/Z1-H2/
/Z1-H2/
/Z1-H2/
/Z1-H2/
/Z1-H2/
Notes

Transferred T/D/DL functions
DB21 - Signals from NCK channel (NCKPLC)

DB30
DBW116 Extended address T function 1 (16 bit INT)
DBW118 T function 1 (binary) /Z1-H2/

DBD118 For 8-decade T nos., T function 1 (32 bit DINT) is used in DBD 118 (see note)
DBW122 T function 2 (Int)
DBW126 T function 3 (Int)

DBB128 Extended address D function 1 (8 bit INT)
DBB129 D function 1 (binary) /Z1-H2/

DBW130 For 5-decade D nos., D function 1 (16 bit DINT) is used in DBD 130 (see note)
DBB131 D function 2 (8 bit Int)
DBB133 D function 3 (8 bit Int)

DBW134 Extended address DL function (16 bit INT)
DBD136 DL function (REAL)
Notes

Transferred H/F functions

DB30
DBW140 Extended address H function 1 (binary)
/Z1-H2/
DBD142 H function 1 (REAL or Dint)
/Z1-H2/
/Z1-H2/
DBD148 H function 2 (REAL or Dint) /Z1-H2/
/Z1-H2/
DBD154 H function 3 (REAL or Dint)
/Z1-H2/
DBW158 Extended address F function 1 (binary)
/Z1-H2/
DBD160 F function 1 (REAL format)
/Z1-H2/
/Z1-H2/
/Z1-H2/
/Z1-H2/
/Z1-H2/
/Z1-H2/
/Z1-H2/
DBW182 Extended address F function 5 (binary) /
Z1-H2/
/Z1-H2/
/Z1-H2/
/Z1-H2/
Notes

Decoded M signals (M0–M99)

DB30
DBB194 Dynamic M functions
M07 M06 M05 * M04 * M03 * M02 M01 M00

/Z1-H2/
M15 M14 M13 M12 M11 M10 M09 M08

/Z1-H2/
M23 M22 M21 M20 M19 M18 M17 M16

/Z1-H2/
M31 M30 M29 M28 M27 M26 M25 M24

/Z1-H2/
M39 M38 M37 M36 M35 M34 M33 M32

/Z1-H2/
M47 M46 M45 M44 M43 M42 M41 M40

/Z1-H2/
M55 M54 M53 M52 M51 M50 M49 M48

/Z1-H2/
M63 M62 M61 M60 M59 M58 M57 M56
DBB202 Dynamic M functions /

Z1-H2/
M71 M70 * M69 M68 M67 M66 M65 M64

/Z1-H2/
M79 M78 M77 M76 M75 M74 M73 M72

/Z1-H2/
M87 M86 M85 M84 M83 M82 M81 M80

/Z1-H2/
M95 M94 M93 M92 M91 M90 M89 M88

/Z1-H2/
M99 M98 M97 M96
DBB207
Notes

Active G functions

DB30
DBB208 Number of active G function of G function group 1 (binary) /Z1-K1/
... ...
DBB270 Number of active G function of G function group n-1 (binary) /Z1-K1/
DBB271 Number of active G function of G function group n (binary) /Z1-K1/
Signals for protection areas from NC channel

DB30
DBB272 Machine-related protection area preactivated /Z1-A3/
DBB273 Machine-related protection area preactivated /Z1-A3/
Area 10 Area 9
DBB274 Channel-specific protection area preactivated /Z1-A3/
DBB275 Channel-specific protection area preactivated /Z1-A3/
Area 10 Area 9
DBB276 Machine-related protection area violated /Z1-A3/
DBB277 Machine-related protection area violated /Z1-A3/
Area 10 Area 9
DBB278 Channel-related protection area violated /Z1-A3/
DBB279 Channel-related protection area violated /Z1-A3/
Area 10 Area 9
Notes

Instruction controlled signals to NC channel

DB21 – Signals to NCK channel (NCKPLC)
DB30
DBB280 Synch. action Reserved
disable re-
quest
DBB281 Synch. action
disabled
DBW282 - Reserved
DBW298
DBB300 Disable synchronized actions /FBSY/
No. 8 No. 7 No. 6 No. 5 No. 4 No. 3 No. 2 No. 1




Notes

DB21 -
Signals from NCK channel (NCKPLC)
DB30
DBB308 Synchronized actions can be disabled /FBSY/
Nr. 8 Nr. 7 Nr. 6 Nr. 5 Nr. 4 Nr. 3 Nr. 2 Nr.1

Nr. 16 Nr. 15 Nr. 14 Nr. 13 Nr. 12 Nr. 11 Nr.10 Nr.9

Nr. 24 Nr. 23 Nr. 22 Nr. 21 Nr. 20 Nr. 19 Nr.18 Nr.17


Nr. 40 Nr. 39 Nr. 38 Nr. 37 Nr. 36 Nr. 35 Nr. 34 Nr. 33



Cyclic Signals
DBB316 Active G functions

G00 geo.
DBB317
Tool missing PTP motion Travel re- Workpiece External
active quest drive setpoint language
/FB3/F2/ test reached mode active
DBB318
Overstore Dry-run Associat- Stop delayed TOFF move- TOFF active Search active ASUP
active feedrate edM01 ment active /FB1/F2 stopped
/F1/A2 active active /FB3/F2/ /FB1/K1/
DBB319
No tool Stop-delay- Repos DE- Delay FTS Repos Path Repos Path Repos Path REPOS
change com- range not FERRA L Mode Ackn 2 Mode Ackn 1 Mode Ackn 0 MODE ED-
mand active activated Chan /FB1/K1/ /FB1/K1/ /FB1/K1/ GE ACKN
FB1/K1 /FB1/K1/
Notes

Signals to/from orientation axes
DB21 - Signals to NCK channel (PLCNCK)

DB30
Orientation axis 1 /Z2-H1/
DBB320 Traversing keys
plus minus Rapid trav- Traversing Feed stop Activate handwheel

erse override key disable
(bit value coding)
DBB321 Orientation axis 1
DBB322 OEM signals orientation axis 1
plus minus Rapid trav- Traversing Feed Activate handwheel

erse override key stop (bit value coding)
disable
plus minus Rapid Traversing Feed Activate handwheel

traverse key stop (bit value coding)
override disable
Notes


DB30
DBB332 Travel command Travel request Handwheel active
plus minus plus minus (bit value coding)

Active machine function

DBB336
Travel command Travel request Handwheel active
(bit value coding)
plus minus plus minus

DBB340 Travel command Travel request Handwheel active
plus minus plus minus (bit value coding)

Notes

Tool management functions from NC channel

DB30
Modification signals tool management functions
DBB344 Last replace- Transfer to Tool limit Tool pre-
ment tool of new replace- value warning limit
tool group ment tool reached reached
DBB345 -
DBB347
Transferred tool management functions
DBD348 T number for tool prewarning limit (DINT)
DBD352 T number for tool limit value (DINT)
DBD356 T number of new replacement tool (DINT)
DBD360 T number of last replacement tool (DINT)
Notes

Signals from/to NC channel

DB30
CH_CYCLES_SIG_IN (Bit 0 - 7)
DBB364
CH_CYCLES_SIG_IN (Bit 8 - 15)
DBB365
CH_CYCLES_SIG_OUT (Bit 0 - 7)
DBB366
CH_CYCLES_SIG_OUT (Bit 8 - 15)
DBB367
CH_OEM_TECHNO_SIG_IN (DBB368 - DBB371)
DBB368
DBB369
DBB370
DBB371
DBB372 CH_OEM_TECHNO_SIG_OUT (DBB372 - DBB375)
DBB373
DBB374
DBB375
DBB376 ProgEventDisplay
DBB377 Stop Stop follow-

condition ing collision
detection.
DBB378 Silence ASUP
ASUP aktive
aktive
DBB379
DBB380
DBB381
DBB382
DBB383
Notes

DB21 - Signals to NCK channel (PLC  NCK, NCK  PLC)

DB30
Control
DBB384
program
PLC NCK branch
DBB385
DBB386
DBB387
Active transformation number
DBB388
NCK  PLC
DBB389
NCK  PLC
DBB390
NCK  PLC
DBB391
NCK  PLC
Notes

Signals from/to axis/spindle (DB31 – DB61)

DB31 – Signals to axis/spindle (PLC  NCK)
DB61
DBB0 Feedrate override /Z1-V1/

Axis and
H G F E D C B A
spindle
Override Position Position Follow-up Axis/spindle Sensor fixed Acknowl. Acknowl.

DBB1 active measuring measuring mode disable stop /Z1-F1/ fixed stop fixed stop
Axis and /Z1-V1/ system 2 system 1 /Z1 /Z1-A2/ /Z1-A2/ reached /Z1- reached .
spindle /Z1-A2/ -A2/ F1/ /Z1-A2/
Clamping in Delete dis- Controller Cam activa-

DBB2 Reference point value /Z1-R1/ progress tance-to-go/ enable tion
Axis and /Z1-A3/ spindle reset /Z1-A2/ /Z2-N3/
4 3 2 1
spindle /A2, S1/
Program test Velocity/ Activate fixed feed /FBMA/, /Z1-V1/ Enable Accept exter-
axis/ spindle spindle travel to fixed nal ZO
DBB3 release speed limita- stop /Z1-K2/
Axis and tion /Z1-F1/
/Z1-A3/
spindle
4 3 2 1
Traversing keys Rapid trav- Traversing Feed stop/

DBB4 erse override key disable spindle stop Activate handwheel /Z2-H1/
/Z2-H1/
Axis and /Z2-H1/ /Z2-H1/ /Z1-V1/
plus minus 3 2 1
spindle
DBB5 Machine function /Z2-H1/

Axis and
spindle
OEM axis signals

DBB6
OEM axis signals
DBB7
Request PLC Activation Allocate NC axis to channel

axis/spindle signal with /Z2-K5/
/Z2-K5/ change of
D C B A
this byte
DBB8 /Z2-K5/
Note: DBX8.4: is automatically reset after assignment.
Lock parame- Control parameter block

ter set defini- /Z1-A2/
DBB9 tion from NC
C B A
/Z1-A2/
REPOS
DBB10 DELAY
Notes


DB61
Start brake
test
DBB11
Delay refer- Modulo Limit 2nd software limit switch Hardware limit switch
DBB12 ence point Enabled /Z1-A3/ /Z1-A3/
Axis approach /Z1 plus minus plus minus
-R1/
Jogging to JOG fixed- JOG fixed- JOG fixed-
DBB13 position point point point
Axis approach 2 approach 1 approach 0
Activate Suppress
DBB14 program test program test
Axis
DBB15
Axis
Delete No n- Resynchronize spindle Gear has Actual gear stage /Z1-S1/
S value monitoring /Z1-S1/ changed over
DBB16
/Z1-S1/ when chang- 2 1 /Z1-S1/ C B A
Spindle ing gear
/Z1-S1/
Invert M3/M4 Resynchronize spindle at Feedrate
/Z1-S1/ pos. override f.
DBB17 /Z1-S1/ spindle valid
2 1 /Z1-S1/
Spindle
Setpoint rot. direct. Pendel- Oscillating

DBB18 /Z1-S1/ freigabe via PLC
/Z1-S1/ /Z1-S1/
Spindle links rechts
Spindle override
DBB19 /Z1-V1/
Spindle H G F E D C B A
Release
brake
DBB20
Antrieb
Pulse enable n controller Motor Selec- Motor selection /Z1-A2/ Drive parameter set selection
DBB21 /Z1-A2/ integrator tion done /Z1-A2/
Antrieb disable /Z1-A2/
B A C B A
/Z1-A2/
Acknow- Deselect safe Deselect

DBB22 Selection of Safe speed ledgement- standstill safe velocity
Safety communi- and standstill
Integr. bit value 1 bit value 0 cation failure
Notes


DB61
Activate test SINAMICS Activate end

DBB23 stop brake close position pair Transmission of
Safety 2
Integr. bit value 2 bit value 1 bit value 0
Master/ slave Bitwert für Momenten- CC_Slave Achse Schrittmot.

on CTRLOUT_changed: ausgleichs- Achse steuern
Drehüber-
Regler
1 0 Kopplung wachung
DBB24 Sollwertausgabezuord. Ein unter-
ändern drücken
(für Compile-Zyklen)
DBB25
Enable ESR Enable Compen-

DBB26 response slave axis sation control
Grinding overlay ON
Stop Resume
DBB27
Grinding HIAxMove Corr DEPBCS DEPMCS HIAxMove Corr DEPBCS DEPMCS
PLC checks AxStop, stop Stop at next Change re- Set reversal AX-RESUME AX- OscillAxExtR
DBB28 axis /Z2-P5/ reversal point versal point point /Z2-P2/ Reset eversal
Grinding /Z2-P5/ /Z2-P5/ /Z2-P5/ /Z2-P5/ /Z2-P2/
Pendeln
Disable auto- Start gantry

matic syn- synchroni-
DBB29
zation Gantry
Coupling chroni-zation
Reserved
DBB30
Technology
Notes


DB61
DBB31 Clear syn- Clear syn- Disable syn- Resynchro-

Technology chro-nism chro-nism chroni-zation nize
Deselect Deselect Deselect Deselect

DBB32
external stop external stop external stop external stop
Safety Integr. E D C A
Select override
DBB33
Safety Integr. Bit value 3 Bit value 2 Bit value 1 Bit value 0
DBB34-
DBB55
Spindle Spindle Seperate

DBB56 inside speed feed drive as
PLC  HMI clamping display C axis en-
gaged
DBB57
Reserved
DBB58
DBB59
Notes

DB31 – Signals from axis/spindle (NCK  PLC)

DB61
Position reached with exact References synchronizes /Z1 Encoder limit frequency ex- NCU_Link Spindle
DBB60 stop -R1/ ceeded /Z1-A3/ Axis active /no axis
Axis and /Z1-B1/ /Z2-B3/ /Z1-S1/
Spindle fine coarse 2 1 1 2
DBB61 Current con- Speed con- Position con- Axis/spindle Follow-up Axis ready Axial alarm Travel re-
troller active troller active troller active stationary mode active quest
Axis and /Z1-A2/ /Z1-A2/ /Z1-A2/ (n < nmin) /Z1-A2/ /Z2-B3/ /Z1-F1/
Spindle /Z1-A2/
Axis con- Force fixed Fixed stop Activate Measure- Revolutio-nal Handwheel Software
tainer rota- stop limited / reached travel to fixed ment active feedrate overlay ac- cams active /
DBB62 tion active Z1-F1/ /Z1-F1/ stop /Z1-F1/ active tive Z1-N3/
/Z2-M5/
/Z2-B3/ /Z1-V1/ /Z2-H1/
Axis/ spindle Axis stop PLC- AXRESET
Stop
disable active active controlled DONE
DBB63 /Z2-P2/ axis /Z2-P2/
HIAxMove Corr DEPBCS DEPMCS
active active active active /Z2-P2/
Traverse command Travel request Handwheel active /Z2-H1/

DBB64
/Z2-H1/
Axis and
Spindle plus minus plus minus 3 2 1
Active machine function /Z2-H1/

DBB65
Axis and
Spindle
OEM axis signals (Reserved)

DBB66
Axis and Activate
Spindle monitoring /
Z3-TE6/
DBB67
PLC axis/ Neutral axis/ Axis replace- New type NC axis/spindle in channel /Z2-K5/
spindle spindle ment possi- requested by
DBB68 /Z2-K5/ /Z2-K5/ ble PLC
/Z2-K5/ /Z2-K5/ D C B A
NCU number in NCU link network Control parameter block
DBB69 E D C B A C B A
Repos delay Repos shift Repos shift
DBB70 quit valid
PLC axis POS_RESTORED Brake test

DBB71 permanently active
assigned 2 1
REPOS
DBB72
DELAY
HMI  PLC
DBB73
HMI  PLC
Notes


DB61
Modulo limit
DBB74
enabled ac-
Axis tive
JOG- Position JOG fixed-point approach JOG fixed-point approach
DBB75 position JOG active reached active
Axis reached 2 1 0 2 1 0
Rounding Indexing axis Positioning Path axis Scratch
DBB76
axis in posi- in position axis pulse
Axis tion /Z2-P2/ /Z1-A2/
Reduced-
DBB77
speed coli-
Axis sion
F function (REAL format) for positioning axis
DBD78 /Z1-V1/
Axis
Gear change- Setpoint gear stage /Z1-S1/

DBB82 over
Spindle /Z1-S1/ C B A
Actual rotat. Speed moni- Spindle in Support area Geometry Set speed Speed limit
direction CW toring setpoint limits violated monitoring /Z1-S1/ exceeded /
DBB83
/Z1-S1/ /Z1-V1/ range /Z1-V1/ Z1-S1/
Spindle /Z1-S1/
increased limited
Active spindle operating mode /Z1-S1/ Tapping with- CLGON ac- SUG active Const. cut-
DBB84 out compen- tive (grinding ting speed
Control mode Oscillation Position-ing Synchronous
Spindle sating chuck / /Z1-S8/ wheel sur- active
mode mode mode
Z1-S1/ face speed)
Spindle in Tool with
DBB85
dynamic
Spindle position
limitation
M function (binary) for spindle (M3, M4, M5, M19, M70 and/or via MD specified)
DBW86 /Z1-S1/
Spindle
S function (floating-point) for spindle
DBD88 /Z1-S1/
Spindle
Motor brake RIL 3) Ramp-

DBB92 released function gen-
Drive erator Block
activ
Enable n controller Drive Active motor /Z1-A2/ Active drive parameter set 0 … 7
DBB93 pulses integrator ready
B A C B A
Drive /Z1-A2/ disabled /Z1- /Z1-A2/
A2/
DBB94 nist  nsoll nist nx nist nmin Md  Mdx Ramp-up Temperature prewarning /Z1
complete -A2/
Drive /Z1-A2/ /Z1-A2/ /Z1-A2/ /Z1-A2/
/Z1-A2/ Heat sink Motor
DBB95
Drive
Master/ Bitwert für Master/ Slave Axis control Error rotation
slave active CTRLOUT_changed: active monitoring
Compen- coarse fine
DBB96 /Z3-TE3/ 1 0 /Z3-TE6/
sation con-
Change setpoint output as- troller activ
signment (for compile cycles)
Notes


DB61
OEM-Anwendung
Offset after Activate mir- Coupling Axis is slave
DBB97 turn-on point / roring active axis
Z3-TE6/ /Z3-TE6/
/Z3-TE6/ /Z3-TE6/
DBB98 Emergency Accel. warn- Speed warn- Overlaid Actual value Synchronism /Z2-S3/
retraction ing threshold ing threshold motion coupling
Synchronous coarse fine
active reached reached /Z2-S3/ /Z2-S3/
spindle
DBB99 Emergency Max. acce- Max. speed Synchro- Axis acce- Synchronis- Slave spindle Master spin-
retraction leration reached nization lerating moverride active dle active
Synchronous
enabled reached running back out /Z2-S3/ /Z2-S3/
spindle
Oscillation Oscillation Spark-out Error in oscil- Oscillation OscillAxEx-
DBB100
active motion active active lation cannot start / tReversal
Oscillation /Z2-P5/ /Z2-P5/ /Z2-P5/ /Z2-P5/ Z2-P5/ active
Gantry axis / Gantry lead- Gantry group- Gantry syn- Gantry warn- Gantry cut-off
Z2-G1/ ing axis ing is synchroni-zation ing limit ex- limit ex-
DBB101
/Z2-G1/ chronous run ready to ceeded /Z2- ceeded /Z2-
Gantry
/Z2-G1/ start G1/ G1/
/Z2-G1/
DBB102
Gantry
Syn-
chronism
DBB103
being
considered
Active infeed axis
DBB104 /Z2-P5/
Grinding Axis 8 Axis 7 Axis 6 Axis 5 Axis 4 Axis 3 Axis 2 Axis 1
Active infeed axis
DBB105 /Z2-P5/
Grinding
Axis 16 Axis 15 Axis 14 Axis 13 Axis 12 Axis 11 Axis 10 Axis 9
Active infeed axis
DBB106 /Z2-P5/
Grinding
Axis 24 Axis 23 Axis 22 Axis 21 Axis 20 Axis 19 Axis 18 Axis 17
Active infeed axis
DBB107 /Z2-P5/
Grinding Axis 31 Axis 30 Axis 29 Axis 28 Axis 27 Axis 26 Axis 25
Axis safely Communi- CRCerror Status pulses CRC or sign Safe opera-
DBB108 referenced cation failure deleted of life error tional stop /
Safety Integr. not acknow- safe speed
ledged active
DBB109 Actual position > cam position
Safety Integr. SN 4- SN 4+ SN 3- SN 3+ SN 2- SN 2+ SN 1- SN 1+
DBB110 n < nx Safe velocity active SG Safe zero
Safety Integr. speed active
B A
DBB111 Stop E Stop D Stop C Stop A/B

Safety Integr. active active active active
DBB112 Cam range bit for cam track 1

Safety Integr.
Notes


DB61

Safety Integr.

Safety Integr.

Safety Integr.
DBB116 Reserved
Safety Integr.
DBB117 Reserved Cam track

Safety Integr. 4 3 2 1

Safety Integr Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0

Safety Integr Bit 14 Bit 13 Bit 12 Bit 11 Bit 10 Bit 9 Bit 8


DBB122 Nockenbereichsbit für Nockenspur 3

DBB123 Nockenbereichsbit für Nockenspur 3



DBB126
Safety Integr
DBB127
Safety Integr
Program test
DBB128
Safety Integr Activate Suppress
DBB129
Safety Integr
DBB130
Safety Integr
DBB131
Safety Integr
Notes

Tool management interface

Interface for loading/unloading magazine (DB71)
DB71 Interface for loading/unloading magazine (NCK  PLC)
DBB0 Interface (I) active
I8 I7 I6 I5 I4 I3 I2 I1
DBB1
I16 I15 I14 I13 I12 I11 I10 I9
DBB2 Standard end-of-acknowledgement
I8 I7 I6 I5 I4 I3 I2 I1
DBB3
I 16 I 15 I 14 I 13 I 12 I 11 I 10 I9
DBB n + 0 Reserved Reserved Position- Order from NC- Positioning Relocate Unload Load
ing Program Magazine
Multitool
DBB n + 1 File in ex- Reserved Reserved Reserved Reserved Reserved Reserved Acknowle
tended area dgement
(DB1071) Status =
3
DBB n + 2
Assigned channel (8 bit INT)
DBB n + 3
Tool management no. (8 bit INT)
DBD n + 4
Unassigned parameter 1 (Dword)
DBD n + 8
DBD n + 12
DBW n + 16
Identification for loading/unloading station (Int), (fixed value 9999)
DBW n + 18
No. of loading station (INT)
DBW n + 20
Magazine no. (source) for unloading/reloading/positioning (INT)
DBW n + 22
Location no. (source) for unloading/reloading/positioning (INT)
Notes

DB71 Interface for loading/unloading magazine (NCK  PLC)

DBW n + 24
Magazine no. (target) for loading/reloading/positioning (INT)
DBW n + 26
Location no. (target) for loading/reloading/positioning (INT)
Reserved Loading/
DBB n + 28
unloading
without
magazine
DBB n + 29
Reserved
Initial addresses of the loading/unloading stations:

Loading/unloading station 1: n= 4 Loading/unloading station 3: n= 64
Loading/unloading station 2: n= 34 Loading/unloading station 4: n= 94
Load interface 1 is responsible for spindle loading and reloading of tools, for relocating tools and for positioning at any location (e.g. buffer).
Notes

Interface for spindle as change position (DB72)

DB72 Signals from spindle (NCK  PLC)
I8 I7 I6 I5 I4 I3 I2 I1
DBB1
I16 I15 I14 I13 I12 I11 I10 I9
DBB2 Standard end-of-acknowledgement
I8 I7 I6 I5 I4 I3 I2 I1
DBB3
I 16 I 15 I 14 I 13 I 12 I 11 I 10 I9
DBB n Spindle Replace man- Replace manual OldT in T0 Prepare chan- Perform Compul-
ual tool tool buffer no (n- ge change sory
Tool 42) (initiate: change
remains M06)
in spin-
dle
DBB n + 1 File in Reserved Acknowle

extended dgement
Status = 3
area
(DB1072
)
DBB n + 2
Assigned channel (8 bit INT)
DBB n + 3
Tool management no. (8 bit INT)
DBD n + 4
Unassigned parameter 1 (D word)
DBD n + 8
DBD n + 12
DBW n + 16 Buffer identification (Int), (fixed value 9998)

(corresponds to ”Target position for new tool”)
DBW n + 18 Relative location (target) in the buffer (INT)
DBW n + 20 Magazine no. (source) for new tool (INT)
DBW n + 22 Location no. (source) for new tool (INT)
DBW n + 24 Magazine no. (target) for old tool (INT)
Notes

DB72 Signals from spindle (NCK  PLC)

DBW n + 26 Location no. (target) for old tool (INT)
DBW n + 28 Tool new: location type (INT)
DBW n + 30 Tool new: size left (INT)
DBW n + 32 Tool new: size right (INT)
DBW n + 34 Tool new: size top (INT)
DBW n + 36 Tool new: size bottom (INT)
DBB n + 38 Tool status for tool new

Manual 1:1 Master tool to be loaded to be unloaded ignore dis- ID for tools
tool Change abled in buffer
Tool status for tool new
DBB n + 39
Tool was Tool fixed Tool being Prewarning Tool meas- Tool Tool enabled Active tool
in use location changed limit reached ured disabled
coded
DBW n + 40 Tool new: T no. (INT)
DBW n + 42 If DBX (n+0.4) = 1, then buffer location of old tool is entered here.
DBW n + 44 Original magazine of new tool
DBW n + 46 Original location of new tool
Initial addresses of the buffers:

Spindle 1: n= 4
Spindle 2: n = 52
Notes

Interface for circular magazine (DB73)

DB73 Signals from circular magazine (NCK  PLC)
I8 I7 I6 I5 I4 I3 I2 I1
DBB1
I16 I15 I14 I13 I12 I11 I10 I9
Standard end-of-acknowledgement
DBB2
I8 I7 I6 I5 I4 I3 I2 I1
DBB3
I 16 I 15 I 14 I 13 I 12 I 11 I 10 I9
DBB n
Reserved Replace Reserved Reserved T0 Reserved Perform change Obligatory
manual (initiation: change
tool T no.)
DBB n + 1 File in Reserved Reserved Reserved Reserved Reserved Reserved Acknowl-
extended area edgement
(DB1073) Status = 3
DBB n + 2 Assigned channel (8 bit INT)
DBB n + 3 Tool management no. (8 bit INT)
DBD n + 4 Unassigned parameter 1 (D word)
DBW n + 16 Reserved
DBW n + 18 Reserved
DBW n + 20 Circular magazine no. (INT)
DBW n + 22 Location no. for new tool (INT)
DBW n + 24 Magazine no. of the old tool
DBW n + 26 Location no. for old tool (INT)
DBW n + 28 Tool new: location type (INT)
DBW n + 30 Tool new: size left (INT)
DBW n + 32 Tool new: size right (INT)
DBW n + 34 Tool new: size top (INT)
DBW n + 36 Tool new: size bottom (INT)
Notes

DB73 Signals from circular magazine (NCK  PLC)

Tool status for tool new
DBB n + 38 Manual tool 1:1 Master tool to be loaded to be unloaded ignore dis- ID for tools
Change abled in buffer
DBW n + 39 Tool status for tool new
Tool was in use Tool fixed Tool being Prewarning Prewarning Tool measured Tool Tool enabled
location changed limit limit reached disabled
coded reached
DBW n + 40 Tool new: T no. (INT)
DBW n + 42 Original location of new tool in this circular magazine
Initial addresses of the circular magazines: circular magazine 1: n = 4

2: n = 48
Interface for loading / unloading (Multitool) (DB1071)
DB1071 Loading / unloading points (NCK PLC)

Distance code
DBW n+0
Number of Multitool locations

DBW n+2
Multitool distance
DBW n+4
Multitool number
DBW n+8
Multitool location number

DBW n+10
Toolholder
DBW n+12
Reserved
DBW n+14
Reserved
DBW n+16
Reserved
DBW n+18
Notes

Interface for spindle (Multitool) (DB1072)

DB1072 Spindle (NCK  PLC)
Distance code
DBW n+0

DBW n+2
Multitool distance
DBW n+4
Multitool number (tool new)

DBW n+8
DBW n+10 Multitool location number (tool new)

Multitool number (tool old)
DBW n+12
Multitool location number (tool old)

DBW n+14
Location type
DBW n+16
Tool size left

DBW n+18
Tool size right

DBW n+20
Tool size above

DBW n+22
Tool size below

DBW n+24
Tool status
DBW n+26
T number of the tool

DBW n+28
Tool holder
DBW n+30
Original magazine of the new tool

DBW n+32
Original location of new tool

DBW n+34
Reserved
DBW n+36
Notes

Interface for Revolver (Multitool) (DB 1073)

DB1073 Revolver (NCK  PLC)
Distance code
DBW n+0

DBW n+2
Multitool distance
DBW n+4
Multitool number (tool new)

DBW n+8
Multitool location numberr (tool new)

DBW n+10
Multitool number (tool old)

DBW n+12
Multitool location numberr (tool old)

DBW n+14
Location type
DBW n+16
Tool size left

DBW n+18
Tool size right

DBW n+20
Tool size above

DBW n+22
Tool size below

DBW n+24
Tool status
DBW n+26
T number of the tool

DBW n+28
Tool holder
DBW n+30
Original magazine of the new tool

DBW n+32
Original location of new tool

DBW n+34
Reserved
DBW n+36
Notes

Signals to/from the machine control panel and HHU (GD communication)
DB77 Signals to and from the machine control panel and HHU
DBB0- Input signals from MCP1 to PLC, MPI Bus (GD communication)
DBB7
DBB8 - Output signals from MCP1 to PLC, MPI Bus (GD communication)
DBB15
DBD16 Status send MCP1, MPI bus (GD communication)
DBD20 Status receive MCP1, MPI bus (GD communication)
DBB24 - Input signals from MCP2 to PLC, MPI bus (GD communication)
DBB31
DBB32 - Output signals from MCP2 to PLC, MPI bus (GD communication)
DBB39
DBD40 Status send MCP2, MPI bus (GD communication)
DBD44 Status receive MCP2, MPI bus (GD communication)
DBB48 - Input signals from HHU to PLC, MPI bus (GD communication)
DBB53
DBB60 - Output signals from PLC to HHU, MPI bus (GD communication)
DBB79
DBD80 Status Send HHU, MPI bus (GD communication)
DBD84 Status Receive HHU, MPI bus (GD communication)
Appendix C: END
Notes

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SINUMERIK 840D sl

STEP 7 Basic course

This document was produced for training purposes.

STEP 7 Basic course

Sinumerik 840D sl Software 4.5

The 840D sl Sinumerik Operate system is made up of a variety of hardware components.

A detailed description of the components is given in the NC61 catalogue.

840D sl with TCU

A060 Page 2 840D sl Sinumerik Operate

840D sl: NCU

840D sl Sinumerik Operate Page 3 A060

840D sl with TCU

X120 system network

A060 Page 4 840D sl Sinumerik Operate

DVI External monitor

OP0xx & PCU50.x

X120 system network

840D sl Sinumerik Operate Page 5 A060

840D sl with PCU50.x and TCU

X120 system network

A060 Page 6 840D sl Sinumerik Operate

SINUMERIK and SINAMICS automation system components

840D sl Sinumerik Operate Page 7 A060

840D sl: NCU and NX

840D sl: NCU and NX

Property NCU 710.3 PN NCU 720.3 PN NCU 730.3 PN

A060 Page 8 840D sl Sinumerik Operate

Key Data for NCU and NX

840D sl Sinumerik Operate Page 9 A060

Schematic representation of the NCU 7x0

Internal structure of the NCU

A060 Page 10 840D sl Sinumerik Operate

Representation of NCU 730.3

position of the measuring sockets

T1 Measuring socket 2 Load current: max. 3 mA

M Ground The reference potential is terminal M

840D sl Sinumerik Operate Page 11 A060

Name Function Status Meaning

Flashing red/orange Error accessing CompactFlash Card

A060 Page 12 840D sl Sinumerik Operate

840D sl Sinumerik Operate Page 13 A060

Description of LEDs on the NX10.3 / 15.3

LED Color Status Description

Green Continuous light NX is ready for operation

A060 Page 14 840D sl Sinumerik Operate

NX10 / NX15: connection DRIVE CLiQ

The following table illustrates this relation:

840D sl Sinumerik Operate Page 15 A060

S120 Komponenten booksize

840D sl as central control unit

Line Modules for power supply :

One or several motor modules to control the motors

•Single Motor Modules to 200 A

Active/ Smart Line Module

Single/ Double Motor Module

A060 Page 16 840D sl Sinumerik Operate

SINAMICS: Connection to the Components