En 840D SL Complete Service v26

SINUMERIK 840D sl
Service Documentation
Sinumerik 840D sl
Edition 2011.3
Training Manual
This document was produced for training purposes.

Siemens assumes no responsibility for its contents.
SINUMERIK 840D sl
Service Manual for

Turning and Milling machines
Valid for:
Sinumerik 840D sl Software 2.6

Contents
Start
A060
System
Overview
A002
A041
Service & A061
Machine and
Commissioning Menu overview
Setting Data
Tools
A021
Access levels
A025
Time and Date
Settings
A044
A007 A035
Licence and
Electronic Program
Option
Logbook Handling
Commissioning
A017
Data
Management
A010
PCU and TCU
Connections
and Diagnostics
A036
A003 A051
NCU Connec-
Battery and Fan Line and Motor
tions and
Exchange Modules
Diagnostics
A008
MCP:
Connections
and Diagnostic
A026
Creating a PLC
Program
A037
A033 A034
Alarms
PLC Functions PLC Interface
Structure
A031
PLC Alarms
and Messages
A058
PLC Onboard
Diagnostics
A053 A084
A011
Axis and Drive Encoder
Easy Screen
Diagnostics Adjustments
A006
Electrical
Cabinet Design
A103
Service Used
Cases
A043
End Technology
Settings
A060 System Overview
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 component 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 Operate sys-
tem and the components which make up the system.
Content:
Sinumerik
System Overview: TCU
System Overview: PCU50.3
System Overview: PCU50.3 & TCU
840D sl Sinumerik Operate Page 1 This document was produced for training purposes.
A060
A060
A060 Page 2 840D sl Sinumerik Operate

A060
System overview: Description

System overview:
START
The 840D sl Sinumerik Operate system is made up of a vari-
ety of hardware components.
This module gives a graphical overview of those components System

and shows where each component is connected. Overview:
TCU
System
Overview:
PCU50.3
System
Overview:
PCU50.3 &
TCU
System overview:
END
Notes
840D sl Sinumerik Operate Page 3 A060

A060
System Overview: 840D sl Sinumerik Operate with TCU
USB
USB X500 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

A060
System Overview: 840D sl Sinumerik Operate with PCU50.3
DVI External monitor

X1
Factory network.
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

A060
System Overview: 840D sl Sinumerik Operate with PCU50.3 and TCU
DVI
Factory
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

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 required. 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 genera-
tor)
HMI Advanced for PC (Including WinSCP3) - From commissioning/service toolbox. (Configuration of drives and
running service commands)
RCS Commander - System card back-up, Remote control (Viewer)
Note: 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 HMI Advanced (Includes WinSCP3)
 Set the network settings of the host computer
 Connect to the controller using each of the software packages.
Content:
Sinumerik
Theory and Objective.
PLC Toolbox Installation.
HMI Advanced Installation
RCS Commander Installation.
Network Settings
Online Connection-RCS Commander
Online Connection-HMI Advanced
Online Connection-WinSCP3
Online Connection-Simatic Manager
840D sl SINUMERIK Operate Page 1 This document was produced for training purposes.
A002
A002
A002 Page 2 840D sl SINUMERIK Operate

A002
Service and Commissioning Tools: Description Service and
Commissioning
Step 7 PLC Simatic Manager Tools:
START
The Simatic Manager is required for service and commission- Online
ing functions. It should be ensured that this is already installed Connection:
on the computer that is to be used for commissioning. WinSCP3
PLC Toolbox Installation: PLC Toolbox

Installation
The toolbox DVD contains four individual software items that
supplement/update the S7 PLC Programming Tool. Online
Connection:
 PLC Basic Program for 840D sl - Basic program, Simatic Manager
containing Siemens standards blocks.
HMI
Advanced
 Sinumerik Add-on for STEP7 - Files for Sinamics
Installation
Starter.
Service and
Commissioning
 NCVar Selector - Program for the reading of NC vari- Tools:
able in the PLC. END
RCS
 PLC Symbols Generator - Generation of PLC Commander
Symbols Installation
Additional Software Items:
 HMI Advanced - Configuration of drives during the

commissioning stage.
Network Settings
 WinSCP - Used for viewing the content of the Linux
partition and running Service Commands. (Installed as
part of HMI Advanced installation.
 RCS Commander - Service, commissioning and re-

mote control (Viewer). These functions are explained in Online
detail in the relevant modules. Installed from a sepa- Connection:
rately supplied CD. RCS Commander
Online
Connection:
HMI Advanced
Notes
840D sl SINUMERIK Operate Page 3 A002

A002
PLC Toolbox Installation A different destination path can be entered if required.
Toolbox content:
PLC Basic Program for 840D sl

Sinumerik Add-on for STEP7
NCVar Selector
PLC Symbols Generator
Installation Process
The toolbox is a compressed file and requires extracting to a

suitable destination folder.
Select “Extract all”
Allow the extraction process to complete.
Notes

A002
Locate and run the “Set-up.exe” file found in the folder that Further acknowledgements to dialogue boxes etc will be
the files were extracted to. required.
A series of dialogue boxes relating to language selection,

licensing etc will need to be acknowledged.
Continue until the following dialogue box appears. It is neces-

sary to select all four available items
The following dialogue box indicates that the installation was

succesful
The toolbox components will now be installed in turn.
Notes

A002
HMI Advanced Installation (Includes WinSCP) Read the recommendations and warnings
The HMI Advanced software is used for drive configuration and

tool management set-up. The software is part of the Commis-
sioning/Service Tools supplied on DVD.
Installation DVD for Commissioning/Service Tools:
Installation is started by selecting the “Setup.exe” file in the The software licence agreement must be acknowledged.
“IBN-TOOL” folder of the DVD.
Notes

A002
There are three connection options available. The option to be The 840D sl is part of the SolutionLine product range, therefore
selected is the first one: the “SolutionLine” option should be selected.
“Online: The PC is operated with an NC”
This means that we are going online to connect to an actual
NC.
The other possibilities allow local connections with or without a
simulated NC.
A summary of the selections made, the components to be

installed and the path of the installation is displayed
The HMI Advanced is used on several types of controllers

and not just 840D sl.
Some of these controllers connect via MPI (Multi Point Inter-
face) and not Ethernet.
The MPI drivers can be installed here, this is not necessary
for the 840D sl
Notes

A002
When the installation is complete the computer will need re- RCS Commander Installation
starting.
The RCS Commander software package is supplied
separately from the toolbox.
Installation DVD for RCS Commander:
RCS Commander allows a remote operation between the

840D sl controller and a computer.
WinSCP3 is automatically installed as part of the Startup Tool. Data such as part programs etc can be transferred between
This is used for viewing the content of the Linux partition of the the remote computer and the controller.
controller and running Service Commands.
A viewer function is available in the RCS Commander soft-
The path for the installation is: ware. The viewer is used to remotely connect to the controller
(Remote diagnostics).
The software can also be used to write images to compact

flash cards for service and commissioning tasks.
Installation:
Double click the Setup.exe” file

to start the installation.
The installation should be allowed to finish. The connection

of RCS Commander will be tested later in this module.
Notes

A002
General Network Settings: Setting the computer to automatically obtain an IP address
In order to communicate via the X127 ethernet port it is neces- The computer has to be set to obtain an IP address automati-
sary to know the network adapter type of the computer. cally.
Open the properties of the network adapter.
X127 is a DHCP server with a fixed IP address of 192.168.215.1
Addresses 192.168.215.2 to 192.168.215.31 are automatically
issued.
The computer to be connected has to be set to automatically
obtain an IP address.
Checking the network adapter type:
Click “Internet
Protocol (TCP/IP)”
from the list and
then select
“Properties”.
Ensure that
“Obtain an IP
address
automatically” is
In the following example the network adapter is a:- selected.
“Marvell Yukon 88E8055 PCI-E Gigabit Ethernet Controller” Confirm the
changes with the
Note: The adapter type will vary between computer types. OK key.
Notes

A002
Online Connection-RCS Commander The access level determines which data can be accessed via
Double click the “RCS Commander” icon which is found on the RCS Commander. The “Manufacturer” login grants the most
PG/PC desktop. access, the “User” login is the most restrictive.
Passwords:-
Manufacturer-SUNRISE
Service-EVENING
User-CUSTOMER
Select the login and enter the password.

When the program is opened for the first time after the
installation it is necessary to assign a password for encryption If the “Save authentication” option is selected the password will
purposes. not be requested when further connections are made.
A dialogue box appears where the choice of connection is

made.
A default connection is available, this is specifically for con-
After a short delay the data folders of the controller will
necting to X127 of the controller . (IP address 192.168.215.1).
appear in the bottom half of the RCS Commander screen, this
indicates a successful connection was made.
It is necessary to login with a password.
The various functions of the RCS Commander tool are de-

scribed in elsewhere in the course.
Notes

A002
Online Connection: HMI Advanced Select the “Engineering Tools (Recommended)” option. This is
for connecting via interface X127
During installation a folder is created on the desktop of the
computer. Within this folder are shortcuts for starting the “NC
Connect Wizard” and “HMI Advanced.
NC Connect Wizard Connection/cabling information is provided. (A crossover cable

is preferred)
Start the wizard and select the option “840D solutionline” .
Notes

A002
X127 has a fixed address of 192.168.215.1. 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.
The network adapter is the one identified earlier in the
module on Page 9. Avoid using the “Auto” option.
Setting the PG/PC Interface
It is also necessary to check the PG/PC interface setting to

ensure that the software is able to communicate.
The “Access
The correct access point needs to be selected, failure to do
Point of the Appli-
this will prevent the connection of the software to the con-
cation” needs to
troller.
be selected from
the list.
These settings are checked in the “Control Panel” area of
the PG/PC.
Select the
network adapter
which is in use.
Notes

A002
Connect an ethernet cable between the computer and port Online Connection: WinSCP3
X127 of the controller. Run the HMI Advanced via the “HMI
Advanced” shortcut. Run the program from the desktop item.
The software will boot to the following screen: Information has to be entered:
Host name: IP address of controller - 192.168.215.1
User name: Default - “manufact”
Password: SUNRISE
Protocol: SCP
To exit the software select the F10 key on the PG/PC The settings can be saved for future use.
keyboard followed by the “EXIT” soft-key.
A warning about the dangers of saving password details is

issued.
Notes

A002
A name for the session can be changed from the default. After a short delay the program will open. The left hand col-
umn shows the folder structure of the host computer.
The file system of the controller and the CF card can be

viewed. it is also possible to view files such a compensation
tables
The new session can now be seen on the WinSCP login

screen. To make the connection, select the “Login” button.
Host computer Controller (CF card)
Notes

A002
Online Connection: Simatic Manager The Ethernet adapter of the computer needs to be selected
from the list. In this example the adapter is of the type:
Start the Simatic Manager via the desktop icon. TCP/IP-> Intel® PRO/100 VE
The program will open, locate the “File” menu and select
“open”.
The setting for the connection can now be changed. Open the
“Options” menu and select “Set PG/PC Interface. Any changes are indicated via an information box.
Notes

A002 END
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 al-
lows these to be accessed via X127
Seeing these shows that the connection to the controller has
been established.
The accessible nodes in this case are:
Numerical Control Unit (NCU)

Thin Client Unit (TCU)
Machine Control Panel (MCP)
A002: END
Notes

A061 Menu Overview
Module Description:
The 840D sl SINUMERIK Operate system is split into 6 menu areas. Each menu area is sub-divided to allow
the user easy access to the necessary areas of the system.
Menu Areas:
 Machine
 Parameter
 Program
 Program Manager
 Diagnostics
 Start-up
Module Objective:
Upon completion of this module you will know the menu areas of the 840D sl SINUMERIK Operate system.
Content:
Sinumerik
Menu Select Button

Mode Selection
Menu Selection
Menu Area: Machine (JOG Mode)
Menu Area: Machine (MDA Mode)
Menu Area: Machine (AUTO Mode)
Menu Area: Parameter
Menu Area: Program
Menu Area: Program Manager
Menu Area: Diagnostics
Menu Area: Start-up
A061
A061

A061
Menu Overview: Description Menu

Overview:
START
Menu Area:
The 840D sl SINUMERIK Operate system is split into 6 menu Program
areas.
Manager
Each menu area is sub-divided to allow the user easy access
to the necessary areas of the system.
Menu Select
Menu Areas: Button
Menu Area:
 Machine Diagnostics
 Parameter
 Program
Mode
 Program Manager Selection
 Diagnostics
 Start-up Menu Area:
Start-up
Menu
Selection
Menu
Overview:
END
Menu Area:
Machine (JOG
Mode)
Menu Area:
Machine (MDA
Mode)
Menu Area:
Machine
(AUTO Mode)
Menu Area:
Parameter
Menu Area:
Program
Notes

A061
Menu Select Button
The menu system of the 840D sl SINUMERIK Operate is accessed via the “Menu Select” button.
The location of the “Menu Select” button is always to the lower right of the screen of the operator panel.
Examples:
Notes

A061
Mode Selection
Pressing the Menu Select button reveals 6 horizontal menu soft-keys and 5 vertical soft-keys.
The 5 vertical soft-keys can be used to change between the machine modes: This can also be
achieved via the Machine Control Panel.
Vertical Soft-key Functionality:
Automatic mode (AUTO) is selected.
Manual Data Automatic mode (MDA) is selected.
Jog mode (JOG) is selected.
Reposition mode (REPOS) is selected.
Reference Point (REF POINT) mode is selected.
Notes

A061
Menu Selection
The 6 horizontal soft-keys are used to select the different menus.

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

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

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

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

Include password entry, machine data modifications, creating archives, creating
alarm files, PLC diagnostics, time/date settings, network set-up, licensing/option
selection, system data management, servo optimisation etc.
Reboot HMI
A further soft-key is available which is used for rebooting the HMI only. This is found via the
Menu extension key.
The Reboot HMI soft-key is used when only the HMI requires re-booting.
The NC/PLC/Drives are not normally affected during the reboot process, however
it is possible to monitor the HMI status in the user PLC so that conditions can be
applied.
Notes

A061
Menu Area: Machine (JOG Mode)
Notes

Menu Area: Machine (MDA Mode) A061
Notes

A061
Menu Area: Machine (AUTO Mode)
Notes

Menu Area: Parameter A061
Notes

A061
Menu Area: Program
Notes

Menu Area: Program Manager A061
Notes

A061
Menu Area: Diagnostics
Notes

A061
A061: END
Menu Area: Start-up
Notes

A041 Machine and Setting Data
Sinumerik
Operate
Module Description:
Machine and Setting data's are used in many ways to influence the operation of a machine.
During commissioning some of the machine data is automatically set while other machine data has to be
manually set.
Over time, as the machine mechanically wears it may be necessary to edit certain machine data such as
compensation data's.
This module shows the different machine data areas and how to activate the machine data.
Module Objective:
Upon completion of this module you will be able to locate the different Machine/Setting data areas and be
able to carry out adjustments if required.
You will also be able to create a customised user list containing machine and setting data which are specific
to a particular function/area of a the machine.
Content:
Sinumerik
Machine & Setting Data Overview
Editing Machine & Setting Data
User Views
A041
A041

A041
Machine and Setting Data: Description Machine and

Setting Data:
START
Machine and Setting data's are used in many ways to influ-
ence the operation of a machine.
During commissioning some of the machine data is automati-
cally set while other machine data has to be manually set.
Over time, as the machine mechanically wears it may be nec- Machine &
essary to edit certain machine data such as compensation Setting Data
data's. Overview
This module shows the different machine data areas and
other criteria such as how to activate the machine data.
Editing
Machine &
Setting Data
User Views
Machine and
Setting Data:
END
Notes

A041
Machine & Setting Data Overview MD/SD name Activation
Number (System language) Value method
General assignment
Units
The Machine/Setting data are divided into the following ranges:
Range Description
9000 - 9999 Display machine data
10000 - 19999 General machine data
20000 - 29999 Channel-specific machine data
30000 - 39999 Axis-specific machine data
41000 - 41999 General setting data
42000 - 42999 Channel-specific setting data
43000 - 43999 Axis-specific setting data
51000 - 51999 General cycle machine data
52000 - 52999 Channel-specific cycle machine data
53000 - 53999 Axis-specific cycle machine data
54000 - 54999 General cycle setting data
Plain text description
55000 - 55999 Channel-specific cycle setting data the selected MD/SD.
56000 - 56999 Axis-specific cycle setting data
MD/SD identification:
Each range contains the individual machine/setting data. The MD/SD name contains identifiers so that the system can
Machine data is often referred to as MD, while setting data is identify that particular data.
referred to as SD.
1st character
$ = System variable (Present on all MD & SD)
Machine/Setting Data Location:
2nd character (Defines between MD or SD)
The following soft-key selection is used to locate the MD/SD
M = Machine data
area.
S = Setting data
3rd character (Defines type of MD/SD)

M = Display Machine Data
N = General Machine Data / Setting data
C = Channel Machine Data / Setting data
The data is listed in numerical order with the MD/SD number A = Axis Machine Data / Setting Data
in the left column. The following columns show the descrip-
tion/name, value, units and activation requirement.
4th character
S = Cycle Data (Defines MD/SD as cycle data)
Examples:
9900 $MM_MD_TEXT_SWITCH Display MD
54600 $SNS_MEA_WP_BALL_DIAM General Cycle SD
55623 $SCS_MEA_EMPERIC_VALUE Channel Cycle SD
30200 $MA_NUM_ENCS Axis MD
Notes

A041
The following data ranges are used for the machine data: Help Function:
$MM_ Display machine data The function of each MD/SD is described in detail via the
$MN_ General machine data “Help” key.
The MD/SD first needs to be selected and then the “Help” key
$MC_ Channel-specific machine data pressed. The key is found on the NC keyboard
$MA_ Axis-specific machine data
$MNS_ General cycle machine data
$MCS_ Channel-specific cycle machine data
$MAS_ Axis-specific cycle machine data
The following data ranges are used for the setting data:
$SN_ General setting data A detailed description will be displayed. This will include units,
limits etc as well as the functionality.
$SC_ Channel-specific setting data
$SA_ Axis-specific setting data
$SNS_ General cycle setting data
$SCS_ Channel-specific cycle setting data
$SAS_ Axis-specific cycle setting data
Indexes:
Certain MD/SD have indexes. The function and number of

indexes depends on the data in question.
Example:
General MD 10000 $MN_AXCONF_MACHAX_NAME_TAB
Activation of the MD/SD:
This MD is used for defining the names of the axes in the
system. Each axis name is assigned to an index the MD.
There are four methods available for activating the MD/SD.
The method depends on the MD/SD in question.
The right hand column of the screen displays the required
method.
Active via “Reset (po)” soft-key or controller

power off/on.
Active on selection of “Set MD active (cf)” soft

key.
Further examples:
30240[0] $MA_ENC_TYPE = The type of encoder connected Active on selection of the appropriate PLC
to the 1st measuring system input. interface signal, usually via MCP “Reset” key.
30240[1] $MA_ENC_TYPE = The type of encoder connected
to the 2nd measuring system input.
Active immediately the “Input” key is selected
to confirm the value.
Notes

A041
Units for MD/SD Editing Machine & Setting Data
The function of the MD/SD determines the units in use. To locate the machine data screens first ensure that the rele-
The following table shows the abbreviations and descriptions of vant access level is active (Module B021 Protection Levels)
the units. then use the following key sequence:-
Unit Description
mm/sec Millimetres/second: Linear velocity/speed
rpm Revolutions/minute: rotational velocity/speed

The default is for the General Machine screen to be displayed
m/s² Meters/second-squared: Linear acceleration
rev/s² revolutions/second-squared: rotary acceleration
kgm² Kilogram/meter-squared: Moment of inertia

s seconds: measurement of time.
Hz Cycles/second: Frequency.
deg Degrees: Angular measurement.
mm/rev millimetres/revolution: linear feed-rate determined

by a rotary axis.
m/s³ Meters/second-cubed: linear jerk
rev/s³ revolutions/second-cubed: rotary jerk
Kg Kilogram: Measurement of mass
mm millimetre: Linear measurement.
Nm Newton-Metre
The machine data which are available for viewing can be re-
mH milli-Henry: Measurement of inductivity stricted via the “Display options” soft-key
A Amperes (Amps): Electrical current
V Volts: Electrical potential
Some MD/SD have no units associated with them. In this case

use the “Help” function to determine the data type required.
Notes

A041
The Machine & Setting Data is separated into different groups.
The correct machine data should first be located. This is
General MD and general Cycle MD. done by either using the page/cursor keys or the search
function.
The search function is activated with the “Search” soft key. If
Channel-specific MD and channel-specific Cycle MD.
the Machine Data number is known this can be typed into the
dialogue box. It is also possible to enter part or all of the MD
Axis-specific MD and axis-specific Cycle MD. name in text format.
User Views- Allows the user to create list of specific

machine data.
Control Unit MD.
Supply MD (ALM/SLM-only DriveCLiQ types).

When the correct MD has been found, a value can be en-
Drive MD (Motor Modules) tered. In this example we are going to change Display MD
9900 from 0 to 1. This will change the MD/SD description
from system language to plain text.
For further data the “Menu Extension” key must be selected.

This allows access to the Setting Data and also the Display
Machine Data.
The correct machine data has to be highlighted. The number

1 is entered and confirmed with the “Input” key.
On pressing the “Input” key the text of the machine data

changes immediately (see below). This will apply to all MD/
SD.
General SD and general Cycle SD.
Channel-specific SD and channel-specific Cycle SD.
Axis-specific SD and axis-specific Cycle SD.
Display MD.
Notes

A041
Some MD/SD have no units associated with them. In this case User Views
use the “Help” function to determine the data type required.
The “User views” function allows a customised list of machine
data to be made. MD/SD can be listed that are of importance
MD/SD with “Bit patterns. to a specific task/function of the machine.
If the letter “H” appear as the last digit in the “Value” column the
MD/SD requires a value in Hexadecimal format. A bit pattern
can be viewed.
To view the bit pattern, highlight the MD/SD and then use the
“Select” key found on the NC keyboard.
Example: Channel MD 20310
A descriptive list of each individual bit is displayed. Use the

cursor keys to highlight the required bit, use the select key to
activate/deactivate the bit.
Edit existing machine data list or create new machine data list.
Enter a name for the list e.g. SPINDLE_PARAMETERS.

The “User views” soft-key will also be displayed in the
“Parameter/Setting data” area if the option is selected.
REMEMBER:- Create a data backup.

Any changed MD/SD should be saved in an archive.
See Module A017
Notes

A041
The new entry will be displayed in the View menu. Select the data to be added to the list.
It is now possible to add the required MD/SD.
Or
The selected MD will appear on the screen.
The General machine data will be displayed by default.

A list of all types of data can be viewed on the “Select” list
Repeat the procedure to add further data to the list.
Text for information purposes can be added:
The text entered in the “Text” area will be displayed on the list.
The text entered in the “Description” area is displayed at the
In the following example Axis MD for the spindle will be added. bottom of the screen.
The required MD/SD type is selected from the list and con-
firmed with the “Input” key. Text to be displayed on the list.
(Maximum 30 displayable characters)
Detailed text to be displayed at the bottom of

the screen. (Maximum 80 characters)
Notes

A041 END
The position of the text line can be selected when editing is
complete.
Or
The changes that can be made will depend on the MD/SD in

question.
In this example, a different axis for the MD has been selected.
Example of a list of spindle specific MD complete with descrip-
tive texts:
Short text description.
To change the order that the items appear on the list, first se-
lect the item to be moved and then move it up/down the list via
the “Up” or “Down” soft-keys.
Each press will move the item one position.
Detailed text description.

Or
Modifying a MD/SD entry: Any unwanted items are removed via the “Delete” Soft-key.
The entries on the list can be modified by selecting the

“Properties” soft-key.
Select the entry to be modified and press the “Properties” soft-

key.
A041: END
Notes

A021 Access Levels
Sinumerik
Operate
Module Description:
The data of 840D sl controller is protected by using one of seven access levels, four of which are set via a
key-switch and three by password.
This module explains the different access levels, how to set these levels and how to protect
individual files.
Module Objective:
Upon completion of this module you will be able to set the different access levels using a password or key
switch.
You will also be able to change the access levels of individual NC programmes.
Content:
Sinumerik
Password and key-switch information.
Setting and Deleting the Password.
Protection of files.
A021
A021
A021 Page 2 SINUMERIK 840D sl Operate

A021
Access Levels: Description Access

Levels:
START
The data of 840D sl controller is protected by using one of
seven access levels. Four of which are set via a key-switch
and three by password.
This module explains the different access levels, how to set
Password
these levels and how to protect individual files.
and
key-switch
information
Setting and
Deleting the
Password
Protection of
files
Access
Levels:
END
Notes

A021
Password and key-switch information Setting and Deleting the Password
The following table shows the password/key-switch positions

and associated access levels/users. Setting the password:
The screen for entering the password is reached via the fol-
Access
Intended user Protected via lowing key presses:
level
1 Manufacturer Password: SUNRISE
2 Installation Engineer, Password: EVENING
3 End User Password: CUSTOMER
4 Programmer, Setter Key-switch position 3
5 Qualified operator Key-switch position 2
6 Trained operator Key-switch position 1
7 Untrained operator Key-switch position 0
The key switch is located on the MCP and has four positions.
Three colour coded keys are available, each of which allow a
different access level. This is from a standard Siemens ma-
chine control panel. It is possible that a
manufacturer may use a different method to set the interface
signal.
Key switch Colour coded keys
Access levels of the three keys: Continue with the “Set password” soft-key.
Key colour Switch position Access level
No key required 0 7
A dialogue box is opened, this box shows the current access
Black 0&1 6-7 level and allows a password to be entered using the key-
Green 0, 1 & 2 5-7 board.
Orange 0, 1, 2 & 3 4-7
It is the responsibility of the OEM to ensure that the key-switch

signals are transferred to the PLC interface.
DB10.DBB56 is used for the transfer of the key-switch signals.
DB10 Key-switch signals to NC (PLC  NC)
Bit7 Bit6 Bit5 Bit4 Bit3 Bit2 Bit1 Bit0 After typing the password it is confirmed by pressing the “OK”
DBB56 soft key.
Key- Key- Key- Key-
switch switch switch switch
Pos.3 Pos.2 Pos.1 Pos.0
Notes

A021
The dialogue box disappears and the current access level is In this example the “Manufacturer” password is active, this
displayed above the left hand horizontal soft-keys. allows the Manufacturer, Service & User passwords to be
changed.
Manufacturer
password
Active.
Service Field where the

option is new password is
selected for to be entered.
changing.
Note: The password remains active after power off/on.

Deleting the password:
Module B033 explains how password deletion can be auto-
mated. Deleting the active password will result in the access level be-
ing determined by the key switch.
Changing the password:
It may be necessary to change the password from the default.

To change a password the same level of access or higher
should be set. E.G to change the “Service” password, levels 2
or 1 must be active.
It should be noted that the highest level password (Level 0) is

not available for general use.
This means that if the “Manufacturer” password is changed
and then forgotten, the only way to gain access to level 1 is to
re-commission the controller and return the passwords to de-
fault.
Select the “Change password” soft key.
The following dialogue box will be displayed. Here a new

password can be entered and confirmed.
In this example the “Manufacturer” password is active, this
allows the Manufacturer, Service & User passwords to be
changed.
Navigation of the dialogue box is achieved via the cursor and
select keys, confirmation is via the “OK” soft key.
Notes

A021 END
Protection of files A dialogue box allows four properties to be changed. In the
Certain files such as important cycles, programmes etc can be following example, the program:-
individually protected against accidental editing, deletion or
execution. They can also be hidden from view.
 Can only be executed if the “Service” password or
higher is active
The file to be protected has to be located before the properties
can be edited. In this example, the part programme  Can only be written to (Edited) if the “Manufacturer”
“Example.MPF” is to have it’s properties changed. password or higher is active
The “Part program” directory is located by selecting the  Will only be listed if the key switch position 0 or higher
“Program manager” key. is active
 Can only be read if the key switch position 1 or higher
is active
By highlighting the “Part programs” directory and opening it

with the “Input” key we can see the program “Example.MPF”.
Ensure this is highlighted.
When the correct settings have been entered the “OK” soft
key has to be selected.
The properties of the file are found by paging right and select-
ing the properties Soft-key.
A021: END
Notes

A025 Time and Date Settings
Sinumerik
Operate
Module Description:
It is important that the system date and time are correct.
This is necessary for checking when an alarm occurred or when a file (Part program, archive etc) was
created or edited.
If at the time of installation, the time and date is not set correctly, the Guarantee period of the controller could
be effected.
Before the date and time displays can be edited, the password for the “User” or higher must be entered.
Module Objective:
Upon completion of this module you will be able to set the time and date for the system.
Content:
Sinumerik
Setting the Date and Time
A025
A025

A025
Time and Date

Time and Date Setting: Description
Setting:
START
It is important that the system date and time are correct.
This is necessary for checking when an alarm occurred or

when a file (Part program, archive etc) was created or edited.
If at the time of installation the time and date is not set cor- Setting the
rectly, the Guarantee period of the controller could be af- Date and Time
fected.
Before the date and time displays can be edited, the pass-
word for the “User” or higher must be entered.
Time and Date

Setting:
END
Notes

A025 END
Setting the Date and Time (TCU) Setting the Date and Time (PCU50)
The date/Time screen is reached with the following soft key On systems with a PCU there are two date/time areas, one for
sequence: the NCU and one for the PCU. When the date and time is set
it is automatically transferred to both areas.
The time and date can now be checked and corrected if

necessary.
The time and date can now be checked and corrected if
necessary.
Use the cursor keys to move between the data fields.

The format can be changed by highlighting the required input
field and using the “Select” key.
If the date or time is changed, each element has to

be confirmed using the “Input” key.
If the date or time is changed, each element has to
be confirmed using the “Input” key.
Once all elements of the time & date are correct Once all elements of the time & date are correct
press the “OK” soft key. The current date/time will press the “OK” soft key. The current date/time will
then be updated with the new values. then be updated with the new values.
A025: END
Notes

A035 Program Handling
Sinumerik
Operate
Module Description:
It is often a requirement to store machining programs off-line on an external computer.
RCS Commander is a multi-functional software tool which connects via Ethernet (X127 & X130), one of the
functions offers the possibility to connect remotely to controllers in order to transfer machining programs to
and from an external computer.
An External Viewer is included in the software which is used to remotely view and if necessary make
changes to the data of the controller.
It is also possible to configure and assign controller soft-keys to networked computers as another method of
program handling.
Module Objective:
Upon completion of this module you will be able to:
 Connect remotely via network to the controller using RCS Commander and use copy and paste functions
to transfer machining programs.
 Use the External Viewer to monitor and/or change the data of the controller.
 Configure soft-keys in the Program manager and assign these to networked computers.
Content:
Sinumerik
RCS Commander connected via X127
RCS Commander connected via X130
Program Handling
External Viewer
Configuring a Network Drive
System Network Center
A035
A035

A035
Program Handling: Description

Program
Handling:
It is often a requirement to store machining programs off-line START
on an external computer.
RCS Commander is a multi-functional software tool. One of

the functions offers the possibility to connect remotely to con- RCS
trollers in order to transfer machining programs to and from Commander:
an external computer. via X127
It is also possible to configure and map controller soft-keys to

networked computers as another method of program han-
dling. RCS
Commander:
via X130
RCS Com-
mander-
Configuration
of Bookmarks
External
Viewer
Configuring a
Network Drive
System
Network
Center
Program
Handling:
END
Notes

A035
RCS Commander connected via X127 Double click the “RCS Commander” icon which is found on
the PC desktop
Connection using X127 (DHCP Server)
A DHCP server is an Ethernet port which issues IP addresses.
In order for a successful connection to be made it is necessary
set the external computer to receive an IP address automati-
cally. This is selected in the properties area of the TCP/IP
internet protocol.
When the program is opened for the first time after the
installation it is necessary to assign a password for encryp-
tion purposes.
A dialogue box appears where the choice of connection is

made.
A default connection is available, this is specifically for con-
necting to X127 of the controller (IP address 192.168.215.1).
Select the option “Obtain IP address automatically”
Notes

A035
Select the “User” login and enter the password. RCS Commander connected via X130
Password:-CUSTOMER Configuring Interface X130
Ethernet interfaceX130 is configurable, the port can be as-

signed a fixed IP address or be set to automatically acquire
an IP address.
Interface X130 is primarily for connecting to the factory net-
work. When configuring for connection to a factory network,
certain information from the factory network administrator is
required.
Firewall: X130 has a firewall which can inhibit the online con-
nection of certain software tools. It is possible to open ports to
allow connections to be made.
Make an online connection with RCS Commander via X127.
Locate the “basesys.ini” file.

Path = System CF-Card\user\system\etc
The connection process will now start:
When the information box has cleared, the folder structure of

the host PC will be seen in the top half of the RCS Com-
mander program.
The lower half shows the folder structure of the controller.
Double click the “basesys.ini” file, this will open in a text editor.
Locate/search for the “Firewall” entry.
The semicolon at the beginning of the following line

“FirewallOpenPorts="TCP/5900 TCP/102" has to be removed.
This will open the ports and allow communication.
Programs and files can now be copied and pasted between

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

A035
X130 Controller Set-up
The controller settings for X130 can now be entered.
Any existing X130 settings should be recorded before any

changes are made.
IP address restrictions- IP addresses 192.168.215.xxx &

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

Computer Network Settings address to X130.
When using X130 in a manual set-up, the IP address and Locate the “TCP/IP diagnostics” screen with the following key
subnet mask of the external computer will also have to be selection:
manually entered. If the controller is part of an existing
network this address must be unique.
The following example shows how to manually assign an IP

address of 192.168.100.2 and subnet mask of 255.255.255.0.
The subnet mask must match the one entered on the
controller.
Select the „Use the following IP address” option and enter a An overview of the X120 and X130 interfaces is displayed.
unique IP address, example 192.168.100.2 with a subnet X120 is the system network to which is connected hardware
mask of 255.255.255.0 such as Machine Control Panels (MCP‟s), Operator Panels
(OP‟s) etc. This interface cannot be configured.
X130 is the company network and is configurable.
Notes

A035
A more detailed view of the interfaces can be seen. To The following example shows X130 being manually configured
configure X130 select “Change”. with an IP address of 192.168.100.1 and a subnet mask of
255.255.255.0
When the settings have been entered select the “OK” soft-key”
and perform power off/on of the controller.
Allow the configuration process to complete
The settings can now be changed. Use the cursor and select
keys to navigate the screen. Note the message displayed above the horizontal soft-keys:
Address Type: DHCP-To obtain IP address automatically.
Manual-To enter a defined IP address.
To activate the settings carry out a reset procedure:
Notes

A035
Allow the boot process to complete. RCS Commander Connection
Check that the settings for X130 are correct A default connection is available in RCS Commander for con-
necting to X127. If ethernet port X130 is to be used a new
connection will have to be created.
Enter the IP address of X130 (192.168.100.1) also enter a

connection name and choose a login level (Manufacturer,
Service, User) and the correct password for the selected
login.
The “Availability” of the network connection is shown. In the

example below X120 has a green/white tick symbol with an
availability of 100%, this indicates that the connection has
hardware attached and is healthy.
X130: Connection not

in use
Controller IP address
X120: Connection in see page 6
use
Login:User
Password:CUSTOMER
Set the Transmission

mode to LAN
Notes

A035
A few moments later the connection will be made and the
folder structure of the controller will be displayed in the lower
half of the RCS Commander program
The new connection is now listed in the Available connections

list:
A connection can also be made from the toolbar:
Programs and files can now be copied and pasted between

the host PC and the controller.
It is also possible to create files/directories on the controller.
From the drop down menu select the connection to be used

then press the “Connect” button.
Notes

A035
RCS Commander-Configuration of Bookmarks A name for the bookmark needs to entered and then saved.
Operator specific files are located in three directories:

MPF - Main Program Files
SPF - Sub Program Files
WKS - Work-piece Directory
These directories are found in the NC data folder of the con-

troller.
Bookmarks
Standard Bookmarks are preset by default and are used to

take the user directly to certain areas of the controller. It is
also possible for the user to add further bookmarks.
The Bookmark will now appear in the Bookmark list.
To transfer files between the controller and PC use the right-

click and copy/paste functions
NC data folder containing Standard Bookmarks- selected

MPF, SPF & WKS folders from the drop-down list
Adding Bookmarks
Bookmarks are added by right-clicking on a folder that is to be

bookmarked and selecting “Add to bookmarks”.
Example: Right click on the WKS folder
Notes

A035
External Viewer Behaviour for remote access:
The external viewer duplicates the controller display on the

external computer including menu and soft-key functionality.
When the viewer connects, access can be restricted on the When a connection attempt is made a dialogue box will ap-
HMI or by the PLC interface. pear which requires acknowledgement, this determined how
long the dialogue box stays on the screen.
To configure the HMI use the following soft-key sequence:
When set to “allowed”, then the controller will allow the con-
nection, even when the dialogue box has not been acknowl-
edged.
If set to “Denied” the connection will be blocked if the dialogue
box is not acknowledged.
The settings are saved by selecting the “OK” soft-key.
Connecting the Remote Viewer
To start this function select the following icon from the RCS
Commander tool bar.
Alternatively select “Start” from the “Remote control” drop
down menu.
When the viewer attempts to connect, providing that the re-

mote viewer has not been blocked, the screen of the control-
Viewing Rights-HMI ler will be displayed.
Rights for remote access - Selected in HMI If an acknowledgement is required, a dialogue box will ap-
Do not allow remote access-Prevents remote connections. pear. The person at the controller should acknowledge with
Allow remote monitoring-The remote computer can monitor the “Yes” soft-key.
the controller. This should be done within the time limit specified on the
Allow remote operation-The remote computer can access the RCS set-up screen.
various screens of the controller and changes can be per-
formed.
Viewing Rights-PLC
Rights for remote access, Specified by PLC (Not settable on
screen)
The access can be restricted/blocked via the user PLC with
interface signals. These signals have priority over the
“Selected in HMI” settings. It may be necessary to Contact
the machine manufacturer if the PLC is restricting the viewer
access.
Notes
840D sl SINUMERIK Operate Page 11

A035
When the connection is successful the viewer will display the A shared folder is required on the PC for the storage of files.
same screen as the controller.
For reasons of security it is possible to restrict network access
to the shared folder. By setting “Permissions”
The following example will show how to create a folder on the

D drive and how to set up sharing and permissions.
The option “Simple file sharing” should be deselected via the

“Tools” menu in Windows® Explorer:
The following keys are used to navigate the controller from the
remote PG/PC:
F1 to F8 - Horizontal soft-keys
Shift & F1 to F8 - Vertical soft-keys
F9 - Page Back/Up
F10 - Menu Select
Shift & F9 - Page right
F12 - Help function
Escape - Alarm Cancel
Select - Space Bar
Programs, machine data etc can be directly changed from the

remote computer, archives can also be created.
Configuring a Network Drive
The Network drive function is dependant on a licensed option

being available and set. (Network drive management part
number: 6FC5800-0AP01-0YB0) Module A044
The transfer of programs can be achieved by mapping a soft-

Deselect “Simple file sharing”
key to a networked Computer. The soft-key will appear in the
Program Manager area of the controller.
The computer connected to the network must have been

logged in with a username and password. This information will
be required for inputting on the controller.
The computer log-in used in this example is:
Username: AUDUSER
Password: SUNRISE
Notes

A035
Select the D drive, right click with the mouse pointer in the
right hand Window and create a new folder.
Enter a suitable name for the new folder.
Right click on the folder and select “Properties”.
Select the
“Sharing” tab
Select “Share
this folder”.
The “Share
name” will auto-
matically take
the folder name
Select
“Permissions”
The share permissions for the new folder can be set. The
folder access over the network can be restricted to certain
users. The following example sets the permissions for
“AUDUSER” (Log-in name of the computer).
Notes

A035
A list of user is revealed when the “Find Now” button is The following settings allow the user “AUDUSER” to have full
selected control of the shared folder including editing/creating items.
The list of users authorised to use the computer is displayed.

It is possible to set up permissions for any user on the list.
Locate and select “AUDUSER” from the list.
Logical Drive Set-up
Mapping the Shared Folder
The folder previously set up for sharing now needs to be

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

The user named “AUDUSER” is now authorised to access the manager area which, when selected will display the content of
shared folder. The type of access is determined next. the shared folder and allow file transfer using copy and paste
functions.
Use the following key selection to reach the Logical Drives con-
figuration screen:
Notes

A035
The new soft-key will now be available in the Program area:
The USB port is configured as default, this should be left

untouched. The next available free area is position 2. Use
the cursor and select keys to navigate the screen.
Files can be copied to/from the controller using the Copy/

Paste soft-keys.
The new folder is also available in the “System data” area.

This provides a convenient method of saving files such as
archives to a safe storage location.
In the following example, details of the external PC have
been entered.
Information such as IP address, share name, log on details
etc. are required.
Ensure that a suitable network cable is connected and select
the “Activate drive” soft-key.
A message will be displayed briefly above the horizontal soft-

keys to show a connection was made. To continue press the
“OK” soft-key.
Notes

A035
System Network Centre (SNC)
The "System Network centre" is available on the NCU as well

as on the PCU.
All TCU configuration and connection settings can be carried
out via the "SNC"!
SNC start via PCU:
The Windows environment of the PCU has a

shortcut for running the SNC program.
SNC start via NCU:

To start the SNC on a TCU it is necessary to press the follo-
wing keys simultaneously:
Configuration of port X130 via SNC
Ethernet port X130 is configurable and can be assigned a fixed

IP address or be set to automatically obtain an IP address.
Port X130 is primarily for connecting to the factory network.
When configuring for connection to a factory network, certain
information is required from the factory network administrator.
Per default, the port has an activated firewall, which can cause
connection problems. The firewall should therefore be
deactivated.
The firewall for port X130 can be deactivated via System

basics.
Selcet service session select and select with the next dialogue
show Commanschell
Login with manufact and SUNRISE as a passport Word.
Execute “System Network Center" with "sc start snc" com-

mand.
Notes

A035
Setting VNC Connection of the OP/TCU
The server IP address is set via the Properties of the TCU,

e.g. 192.168.214.1 (HMI of the NCU) or 192.168.214.241
(HMI of the PCU with distributed configuration).
For example, for a loading point with OP8/TCU and a
distributed PCU50 with OP15 and TCU in the operator panel.
One VNC points to the HMI NCU (OP8), the other to the HMI
PCU.
Configuration of one NCU with TCUs and MCPs

In principle, no special settings (basesys.ini) are required for this
configuration. DHCP server and internal HMI sl remain switched
on.
Configuration of one NCU with one PCU 50.3, MCPs and, if
required, TCUs
The following settings (basesys.ini) of the NCU are required for
this configuration:
Host name: ........
The settings must be taken over with “Apply”!
SyncMode: master priority
As a rule, the internal HMI sl should be switched off, because the
All settings with regard to networking and TCU configuration
operation of two HMIs (HMI Advanced and Operate) on one NCU
can be made via “SNC“!
is only permitted in special cases.
PCU-Basesoftware as of V8.6 SP1 is recommended for use on
The Config.ini files
the PCU 50.3.
card/user/common/tcu/<TCU-Name>/common/tcu/
config.ini and the basesys.ini are edited via the SNC. If the system contains a TCU (HT8) that is to be connected to the
PCU 50.3 per default, the IP address of the PCU must be ente-
Important: red at VNC connection (config.ini)!
All operator stations in the system network (TCUs, HT8, PCU
50) are administered on the NCU with "ON_MASTER", Removal of TCUs
i.e. this contains the config.ini files relevant for the runtime TCUs that are not active can be removed on the “OPs” tab.
and also the .leases file with all the IP addresses assigned in
the system. The distribution of the config.ini files to all the
other NCUs/PCUs is performed by the master NCU with the
"Distribute tcudata" softkey.
With the "Clear dhcp" softkey and subsequent Power Off/On
of the entire system, the NCUs/PCUs are assigned their spe-
cified IP addresses and new IP addresses assigned for TCUs
and MCPs and then the .leases file distributed to all NCUs/
PCUs.
The config.ini files of all operator stations can be edited
directly on the master NCU with the System Network Center,
OPs tab, on each PCU 50.3. The distribution of the data to all
NCUs/PCUs is performed automatically with each change.
A035 : END
Notes

A035 END

A044 Licence and Option Management
Sinumerik
Operate
Module Description:
When a CF card with options is purchased a software licence key is issued. The licence key is linked to the
CF card via the card serial number.
This module explains the licensing procedure and how to activate options.
Module Objective:
Upon completion of this module you will be able to check the control for the correct licence and
activate options.
Content:
Sinumerik
Entering and Checking Licences
Assigning Licences
A044
A044

A044
Licence and Option Management Licence and

Option
Management:
START
When a CF card with options is purchased a software
licence key is issued. The licence key is linked to the
CF card via the card serial number.
This module explains the licensing procedure and how Entering and
to activate options. Checking
Licences &
Options
Assigning
Licences
Licence and
Option
Management:
END
Notes

A044
Entering and Checking Licences & Options
To check the licence number, use the following key

combination:
Information regarding the licence and the CF card serial num-

ber is displayed.
The licence number is specific to the internal compact flash
card serial number.
For this reason a copied CF card cannot be used without gen-
erating an error message.
The licence key can be entered on this page. This is activated
by an NCK reset using the “Reset (po)” soft-key.
For retrieving a lost key, use the “Show Licence Key” option,
found in the left hand column.
From the “Please select” menu, choose “Hardware serial
number”.
This is the serial number of the internal CF card taken from
the licence screen shown on the controller.
The control should arrive with documentation regarding the

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

prior to attempting any work where the NC data might be lost/
reloaded. This is described on page 6.
If the licence key is lost it is possible to retrieve it via the inter-

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

www.siemens.com/automation/license
Notes

A044
The license key can be saved as a text file by right clicking on
the “Save license as a key file” link.
Example: Saving as a text file
The license key will now be displayed. A license report can

be requested and emailed to an email address.
Notes

A044
Saving the licence number: Restoring the licence number:
It is possible to save the licence number to a file so that it can Select the “Read in licence key” soft-key.
easily be restored.
Highlight the licence key file and press the “OK” soft-key.
Choose the destination for the licence key.
Create a new directory if required.
The licence key will now appear in the licence key box.
The new folder now appears. Select “OK” to save the licence
key file to this folder.
A message is displayed momentarily above horizontal soft-

keys.
Notes

A044
Assigning Licences
Handling of Options:
If a licence key is insufficient for a required option, it is possible
The “All options” soft-key can be selected to view all set and
to assign a new licence key that includes the missing option.
licensed options.
The assignment of a new licence key is done via the internet.
Each option is issued a Licence Certificate. The certificates are

delivered with the CF card and contains the licence and dis-
patch note numbers.
Example: A licence certificate
To select an option use the cursor keys to highlight the de-

sired option and the press the “Select” key to activate or enter
a number depending on the type of option being activated.
An NC reset (Reset (po) ) is required to complete the proce-
dure.
Sequence:
The licensing is achieved by a series of steps on the Siemens

licensing website.
Before commencing note the hardware serial number and the

hardware type from the licence manager screen.
Non-licensed options:
If a non-licensed option is activated, the controller will issue a
licence alarm.
To see all non-licensed options, select the “Missing licences”

soft-key.
Notes

A044
Access the “Web Licence Manager“ on a PC with Internet ac- Step 2 of 5 - Identify Product:
cess: http://www.siemens.com/automation/license Enter the hardware serial number and select the product. Con-
tinue to step 3 with the “Next“ button.
Step 1 of 5 - Login:
To login, select “Direct Access“ on the “Web Licence Manager“
screen.
Step 3 of 5 - Selecting the option:

Any options not yet assigned are displayed. You can now as-
sign additional options to the hardware. Continue to step 4
Enter the license number and the dispatch note number. Con- with the “Next“ button.
tinue to step 2 with the “Next“ button.
Notes

A044
Step 4 of 5 - Assigning the Licence: Saving the licence as an ALM file:
The selected option is now ready for assigning.
Download the Licence Key by double clicking the following link.
Save the file to a suitable place in order that it can be loaded to

the controller.
You assign the licences to the hardware specified by clicking
the “Assign“ button.
Change to the licensing screen and enter the Licence Key by
pressing the “Read in licence key“ softkey.
Select the file to be loaded and continue with the “OK” soft-key.
Step 5 of 5 - Generate Licence Key:

The Licence Key includes all options assigned for the specified
hardware.
There are three methods for saving the file. Two of these are in
PDF or TXT format.
The remaining option is as an ALM file, this can be read directly
into the controller as described earlier in the module.
Notes

A044 END
It can be checked whether the Licence Key has been entered
successfully by pressing the “All options“ softkey and checking
that the missing option is licenced.
Setting the Options according to the Licence Key:

It is possible to set all the options that are assigned to the cur-
rent licence key by selecting the “Set option acc. Lic” soft-key
All options should now be set according to the licence key:
A044: END
Notes

A007 Electronic Logbook
Sinumerik
Operate
Module Description:
The electronic logbook function of the 840D sl controller is used to enter data such as manufacturer (OEM),
dealer and user information, 1st and 2nd commissioning dates as well as records of service
visits.
This data is then saved to a log file. The log file has to be uploaded into the EUNA database via the upload
website.
The function is not only necessary for warranty issues but also for service personnel (Records of new and pre-
vious service visits) and also for quality control measures.
Module Objective:
Upon completion of this module the course participant will be able to do the following:
 Import/Enter Logbook data

 Make logbook entries
 Save and load the log file using the Online Registration website.
Content:
Sinumerik
Logbook information
Importing/Entering Logbook data.
1st Commissioning-Start-up Complete.
2nd Commissioning-Machine Installed.
Recording a Service Visit.
Saving the Logbook Data-identSNAPSHOT.
Uploading to the Online Registration Website.
Siemens assumes no responsibility for its contents. A007
A007

A007
Electronic Logbook: Description
Electronic Logbook
The electronic logbook function of the 840D sl controller is START
used to enter data such as manufacturer (OEM), dealer and
user information; 1st and 2nd commissioning dates, and
records of service visits.
This data is then saved to a log file. The log file has to be Logbook
uploaded into the EUNA database via the online registration information
website.
The function is not only necessary for warranty issues, but also
for service personnel (Records of new and previous service Importing/
visits) and for quality control measures. Entering
Logbook
data
1st Commis-
sioning-
Start-up
Complete
2nd Commis-
sioning-
Machine
Installed
Recording a
Service Visit
Saving the
Logbook Data-
identSNAP-
SHOT
Uploading to
the Online
Registration
Website
Electronic Logbook
END
Notes

A007
Logbook Information Importing/Entering the Logbook Data
In the past, the validity of warranty claims was difficult to man- The OEM and Dealer information can be imported to the con-
age and was the cause of delayed service response times. troller in three ways:
System/hardware faults were logged in paper logbooks which
were then usually left on the machine and often became dam-  Import the XML file via the “Import” soft-key.
aged or lost. (Preferred method)
By using EUNA and the Electronic Logbook system, the war-
ranty will automatically start, a record of the machine details  Copy/paste the XML file in the “System data” area.
and breakdowns will also be available on the controller. (If the “Import” soft-key is not available)
The time and date of each entry is recorded; it is impor-  Type the information directly on the controller.
tant that the time and date settings of the controller are (When the files are not available)
correct. Incorrect time and date settings can lead to early
expiry of the warranty.
The preferred method is to obtain the correct xml files from
It is necessary to make entries at certain stages during the life your Siemens contact partner. These are pre-populated files
of the machine: containing the relevant OEM/machine information etc. Using
this method guarantees the consistency between the data
- Manufacturer information at OEM stored in EUNA and the data stored on the machine.
- Dealer information at delivery and installation of machine
- End user information at delivery and installation of machine The following files can be imported:
- 1st Commissioning - End of start-up at Manufacturer
- 2nd Commissioning Machine installed - End of start-up at
end user File Function
- All service visits
oem.xml Manufacturer information
oemsubs.xml Manufacturer subsidiary information
identSNAPSHOT
dealer.xml Dealer information
When the information has been entered it needs to be saved,
this is via a soft-key on the Logbook screen. This procedure user.xml End user information
will create a log file.
ma_types.xml List of available machine types
This is known as the “identSNAPSHOT” function and is a
snapshot of the system including version data, cycle data, The files are imported using the “Import” soft-key, failing this,
hardware components etc the copy and paste option can be used.
If the files are not available they can be created directly on the
Each time a logbook entry is made, the log file should saved controller or offline on a computer.
and uploaded to the EUNA database via the Online Registra-
tion Website.
The name of the file is made from a combination of the ma- Machine Identity File (identity.xml)
chine name and system CF card serial number.
When the information has been imported the “identity.xml” file
is automatically created which contains all the information
from the imported xml files.
If data is already present in the logbook area and needs to be

overwritten, then the identity.xml should first be deleted from
the system.
The machine name/number is also stored in General Machine

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

A007
Concept for Electronic Logbook Data Import and Upload:
Offline preparation identSNAPSHOT-Controller

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

Load via “Import” soft-key.
Or *Country*
OEM.xml:
No “Import” soft-key? *Manufacturers name*
Load via “Copy/paste” function.
Or *Town*
OEM.xml:
File not available?
Input data via controller keyboard.
Dealer Data Dealer Data (identity.xml)
dealer.xml: *Customer number* Export & upload

Load via “Import” soft-key.
Or *Country* Online
OEM.xml: Registration
No “Import” soft-key? *Dealers name*
Load via “Copy/paste” function.
Or *Town* Configuration data:
OEM.xml: components, machine identity,
File not available? licences, version information,
Input data via controller keyboard. logbook entries etc.
User Data User Data (identity.xml)
No XML file available? Not usually available

Input data via controller keyboard. until point of sale.
Logbook entries
1st Commissioning
2nd Commissioning
Service visits
If the controller has existing machine identity data or a mistake is made when entering data manually, it is necessary to de-
lete the “identity.xml” file.
The location of the file varies between systems operating with a PCU50 or NCU.
The location of the “identity.xml” file:
PCU50: System hard disk\F:\HMI\hmisl\user\sinumerik\hmi\data\version\identity.xml
Embedded (TCU): System CF card\user\sinumerik\hmi\data\version\identity.xml
Notes

A007
Data Import function (Preferred method)
The Electronic Logbook is located in the Diagnostics area of the

controller:
The information will now appear on the screen. In this example
the Manufacturer file (oem.xml) was loaded.
To see data for Dealer or End User select the relevant soft-key.
Default Manufacturer screen with no data entered:
Ensure that the files to be imported are available on the control-

ler, network PC or USB memory device. A machine name/number is compulsory.
Select the location of the file to be imported, e.g. USB
Select the file to be imported, e.g. oem.xml Enter the machine name and/or number, e.g. VMC123.
The value entered here is transferred to General MD 17400.
Notes

A007
Machine type Copy and Paste Option
The machine type can be manually typed at the same time as If the “Import” soft-key is not available it is possible to copy the
the name/number is entered. Alternatively a list of machine files from USB/networked PC via the “system data” area using
types can be viewed if the “ma_types.xml” has been imported. the copy and paste functions.
Example of an “ma_types.xml” file that has been edited to in-

clude three machine types.
Cursor to the source containing the file e.g. USB device.
When the file is imported, the machine types will appear in the
drop down list.
Locate the destination folder (Machine identity).
Once the choice of machine type is made it cannot be undone

unless the “identity.xml” file is deleted.
The controller now needs to be powered off/on.
Notes

A007
Subsidiary files Select the branch/subsidiary name; in this case “ABC SUB”
Subsidiary files are used to define the details of manufacturer

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

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

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

manufact.” soft-key.
This the original manufacturer soft-key with different text. The
The default screen displays the manufacturer data.
text of the soft-key changes depending on the current selected
screen.
Templates for xml Files
Templates for the various xml files are available in the

“HMI data\Templates\Examples\Machine identity” folder.
Select the “Manufacturer” soft-key to view the “oem subsidi-

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

been made. This is the name of the branch, i.e. the subsidiary.
Notes

A007
The templates can be used if the files cannot be obtained from Or Or
the Siemens partner. They should be copied and edited to
leave the original templates intact.
Example template for dealer.xml. Example: Manually entered “End user” data.
The file contains various

xml commands but no
dealer data.
Example: A “dealer.xml” file with dealer information. The file

can be imported using the method described earlier.
A summary of the information can be seen.
Manually Entering Machine Identity Data
If the data has to be manually entered due to lack of an xml

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

user.
Notes

A007
1st Commissioning-Start-up Complete
When the machine has been commissioned at the manufac-

To confirm that 2nd Commissioning is complete.
turer the “Start-up Complete” soft-key is selected. This auto-
matically logs the current time and date.
The information is now added to the main logbook page .
The file must be saved then uploaded to the EUNA data-

base!!
To confirm that 1st Commissioning is complete.
The information will appear on the main logbook page. Recording a Service Visit
Whenever an engineer visits the machine to carry out mainte-

nance etc, a record of the visit and information about the
work carried out should be entered into the Logbook.
To do this select the “New Entry” soft key.
The name and company/department of the engineer should

be entered followed by a detailed description of the fault and
work carried out.
2nd Commissioning-Machine Installed
When the machine has been installed at the end-user (2nd

commissioning) the “Machine Installed” soft-key is pressed
This automatically logs the current time and date.
Notes

A007
The details of the service visit are now shown on the Logbook The file is given a default name using details from the machine
page. information page. This can be changed. A comment can also
be added.
Two files are created by default, Version data and Configura-
tion data.
The “Version data (.TXT)” file is a text file and contains details
regarding the versions of the controller, drives etc.
The “Configuration data (XML)” file is an xml file and contains
more information about the whole system including the log-
book entries. It is this file which needs to be uploaded to the
database via the internet.
Saving the Logbook data
The following procedure shows how to save the newly entered

data to a file.
The file contains all information about the system (Controller,
drives, software and hardware etc) as well as the information
entered on the logbook pages.
The information will now be saved.
The save procedure should be carried out after each data
entry in the logbook.
To save the data to a file first locate and select the “Save”
soft-key.
The file should be saved to the default “Version data” folder as

a standard procedure to ensure that a copy is locally available . In this example, the files are saved in the “version” folder.
The file is to be uploaded to the online registration website via PCU50: System hard disk\F:\HMI\hmisl\user\sinumerik\
an external PC, therefore it should also be saved to an external hmi\data\version
USB/CF device.
Embedded (TCU): System CF card\user\sinumerik\hmi\
data\version
Notes

A007
The file can be opened for viewing in the “System data” area: Uploading to the Online Registration Website
Use the copy/paste function to transfer the xml file to a USB

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

A new log file needs to be created when anything new is added
to the logbook.
The file must then be uploaded to the EUNA database.
The Online Registration website address is:

www.siemens.com/sinumerik/register
A language selection is available and an email address is

required. Notification emails will be sent to this address if the
“Enable email status notification“ option is selected.. To
continue use the “Next” key.
The information that was entered via the Logbook screen is

now stored in the xml file.
Service visits are found at the end of the file:
Language selection.
The file is closed with the following soft-key selection.
Notes

A007
Entering the email address and enabling the “enable email

status notification” selection.
Continue with the “Next” button.
To upload the XML file select the “XML Upload” key.
The selected file is now ready to upload, select the “Upload”

key.
Use the “Browse” key to locate the file.
Notes

A007 END
After a short delay an information box will indicate a successful Problems with uploading the XML files
upload operation.
In the event of an error during the upload process will be

necessary to email the xml file to:
service.euna.industry@siemens.com
The uploaded file will be seen in the “Assigned files list”
The “Action Bar” of the assigned files list is used for various
functions.
Refresh the page
Upload an XML file
View the file
Delete the file
A007: END
Notes

A017 Data Management
Sinumerik
Operate
Module Description:
It is necessary to have procedures in place for saving and restoring the customers data stored in the CNC.
The following cases have to be taken into consideration:

 Series machine production
 Exchange of the TCU
 Exchange of the PCU/Hard disk drive
 Exchange of the NCU/PLC
 Exchange of the system CF card
The back-up method used can differ between machines, depending upon the hardware configuration in use.
This module describes the methods for saving data so that it can be restored in the event of any of the above
eventualities.
Module Objective:
Upon completion of this module the course participant will know how to:
 Create and restore archives.

 Create and restore a system image.
 Create and restore a Ghost image
Content:
Sinumerik
Archives: TCU & PCU50.3
System CF Card: Backup & Restore
PCU50.3 Ghost Images
TGZ Backup Files
A017
A017 Page 840D sl SINUMERIK Operate

A017
Data Management: Description
Data Management:
It is necessary to have procedures in place for saving and re- START
storing the data stored in the CNC.
This data is made up of the operating system, machine data,
machine builder add-ons and end-user data.
There are several different methods available for saving the
data.
The method used is dependant upon the hardware installed as
Archives:
this determines the storage locations of the data and types of
TCU & PCU50
data.
Data backups are used for a variety of reasons.
The following cases have to be taken into consideration:

 Exchange of the TCU System CF
Card:
 Exchange of the PCU/Hard disk drive
Backup/
 Exchange of the NCU/PLC Restore
Data Types:
PCU50.3:
The controller data is split into four components. Ghost Images
 NC data
 PLC data
 Drive data
 HMI data
TGZ Backup Files
Data Management:
END
Notes

Machine Configuration Examples:
A017
TCU Main PCU50 Main TCU Main PCU50 Main PCU50 Main TCU PCU50 Main TCU
Embedded Cabinet Auxiliary Auxiliary
on PCU Embedded
OP0xx OP0xx OP0xx OP0xx OP0xx
OP0xx OP0xx
MCP MCP MCP MCP MCP
NCU NCU NCU NCU NCU
Switch Switch Switch Switch Switch
X120 X120 X120 X120 X120
Page 4
HMI embed-
Embedded- Embedded- Embedded-
CF Card CF Card CF Card ded
HMI OFF CF Card HMI OFF CF Card HMI ON
OFF
Ghost No Yes Yes Yes Yes

TGZ* Yes* Yes* Yes* Yes* Yes*
CF Card
Yes Yes Yes Yes Yes
Image
Archives Yes Yes Yes Yes Yes
*Note: For use in special cases only.
Notes
840D sl SINUMERIK Operate

A017
Archives TCU & PCU50
Series Star-up archives can be used to save NC, PLC, Drive

and HMI data.
Archives are created for a variety of reasons:

 Exchange of the TCU
 Exchange of the PCU
 Exchange of the NCU/PLC
To create a Series Start-up Archive locate the relevant area by

using the following key sequence.
Control Components:
The screen displayed has five choices:
The controller data is split into four components
Create series start-up - Archives of the four control compo-
nents (NC, PLC, Drives, HMI) can be created with this option NC data:- The NC data consists of:
All machine and Setting data (except for drive machine data)
PLC hardware upgrade archive (SDB’s only) - Creates a Tool & magazine data
PLC archive for use when starting up series machines. Compensation data
(For testing the PLC periphery components) Cycles
Offsets
Read in series start-up - Archives are read-in with this option. R parameters
Part Programs
Create original status archive - Used to create an archive Workpieces
that will return the machine to its delivery state. Option data
Global and Local user data (GUD & LUD)
Read in original status archive - For reading in the original
status archive PLC data: This will create an archive suited to restoring the
PLC user program.
Drive data: This will create an archive containing data for the
Sinamics drives.
Creating a Series Start-up Archive: HMI data: This saves data that is stored on the HMI.
The list comprises of:-
The method for creating archives is the same for both PCU50.3 Cycle storage
& TCU. However, when the data is stored locally it is to differ- Texts
ent destinations. Templates
In the case of the TCU the archives are stored on the system Applications
CF card. Configurations
With the PCU50.3 the data is stored on the hard disk drive. Version data
Logs
Ensure that the option “Create series start-up” is selected and User views
select “OK”. Dictionaries
Notes

A017
The four control components are available for selection. They
can be selected in any combination to create archives contain-
ing different data.
The NC data can be selected with or without compensation

data. The destination of the archive has to be chosen, this can be
Compensation data is machine specific data such as lead locally on the system CF card/hard disk drive or externally to a
screw error compensation. This would not be included in an USB device or networked PC.
archive used for series machine production. It is suggested that an archive be kept locally on the controller.
Copies can be made externally for use in the event of a data
The Drive data can be saved in two formats: restore.
ACX format (Binary) - The data in the file cannot be read by a

text editor.
ASCII format - The data can be read by a text editor.
If the HMI component is chosen you can include “All” HMI data
or be selective of the data to include via the “Execute” option.
Creating an NC archive
A name must be entered for the archive.
The following example will create an NC archive including
compensation data.
Use the cursor and select keys to select the necessary check
boxes.
The comment area at the bottom of the screen offers the
chance to add information about the archive.
The archive will now be created and stored in the destination

specified earlier.
Notes

A017
An information box indicates that the archive was successfully Information about the selected archive is displayed. This in-
created. cludes any comments entered by the creator.
The software version of the system that the archive was cre-
ated on is also displayed.
Restoring a Series Start-up Archive:
To restore an archive the option ”Read in start-up archive”

needs to be selected
The archive will be read in and a series of status boxes are

displayed.
Select the source from which the archive is to read in from.
A final status box will be displayed which confirms that the

archive was read in successfully.
Notes

A017
Creating Original Status Archives
Original status archives are used to restore the machine to its

delivery state. (Part programs, tool data, work offsets etc will
not be present)
The individual components are selected using the cursor/

select keys
The default selections are shown below. It has to be decided

by the machine builder which components are needed to re-
turn the machine to its original delivery state.
Allow the archiving process to complete:
The HMI selection has two options:
The files of the HMI can be quite large. To prevent the inclu-
sion of any unnecessary files it is possible to select which HMI
files are to be included.
All: This option will include all the HMI data
Execute: With this option you can select which HMI files to
include in the archive.
When the “Execute” option is selected a list of components of

the HMI is displayed. The items that are greyed out are items
which have no data currently associated with them.
Notes

A017
Reading in Original Status Archives If any overwrite questions arise, carefully read the message
before continuing with one of the responses below.
To restore an original status archive, the option ”Read in origi-
nal status archive” needs to be selected.
All files will be overwritten, archive continues to read in .
No overwriting, archive continues to read in.
Skip overwriting the file in question, archive continues

As only one Original Archive is allowed there isn’t a list select to read in.
from. Information about the archive contents is displayed.
Cancel the archive read in procedure.
Overwrite the file in question, archive continues to read

in.
When the archive has been read in a status box is

displayed to confirm this.
Status boxes will be displayed informing of the progress of the

read-in procedure
Notes

A017
Creating Archives with Shortcut keys System CF Card: Backup/Restore
A quick method of making a complete archive to a USB device In the event of the internal system CF card becoming defective,
is by selecting 3 keys simultaneously. it is possible to write a previously saved system image to a new
The keys to be pressed are “CTRL” + “ALT” + “S” CF card.
It is necessary first to obtain a replacement blank CF card
Simultaneously select the following keys to produce the ar- from Siemens. Part number for replacement 1GB card:
chive. 6FC5313-5AG00-0AA0.
The card will need to be licensed, this can only be done via the
Siemens Hotline.
+ + The serial numbers of the faulty and replacement cards are
required by the Hotline before a new licence number can be
issued.
Several dialogue boxes be will be shown, these will clear when
the archive has been created.
Creating a copy of the system CF card
The CF card should be removed from the controller and in-

serted into a computer using a suitable adaptor.
An image of the CF card will be saved as a file with img exten-
sion, this contains all information including the licence.
This file should not be used for series machines as it will erase
the licence on the destination CF card..
Location of system CF card on the lower front face of the NCU
The boxes will clear when the archive has been saved
A file with the .arc extension will be created and given a de-
fault name which includes time and date information.
It should be checked that the file exists on the USB/CF device
before commencing work.
Example:
Notes

A017
Start the RCS Commander software. The installation and first Highlight the drive letter of the CF card. Example “F:\”
start up of the software is described is described in Module
A002
A connection to the controller is not necessary, cancel the

“Selecting a connection” box.
From the “View” menu select the “Expert view” option.
The destination for the file has to entered.
From the “NC commissioning” list, select the option “Creating

the CF card image”.
Notes

A017
Choose a suitable name and destination for the file. The opportunity to create another image is offered. This not
The file extension (.img) should be selected. required therefore select “No”
Check that the image exists in the destination folder. The file
should be kept safe so that it can be written to a replacement
CF card should the original fail.
Replacing the system CF card
In the event of a faulty system CF card it is necessary to write

the previously saved image to the replacement card.
This is done using the RCS Commander program in a similar
way to creating an image.
Check that the information is correct before continuing.
The location of the image file is required.
The card will now be copied to the path/filename entered

earlier.
Notes

A017
Check the selections prior to continuing.
The writing procedure will begin.
The opportunity to write another image is offered. This not re-

The CF card drive letter needs to be selected, in this case “F:\” quired therefore select “No”.
The new card can now be inserted into the NCU and the
system switched on.
Notes

A017
Licensing Creating Ghost Images
The licence key number is matched to the System CF card First insert the USB (At least 2GB) device into the front USB
serial number, using a new CF card means that the numbers interface.
do not now correspond. The Ghost image is created via the Service Menu of the
Alarm number 8081 is generated because of this. The number PCU50.3.
of options not licensed will differ between machines. Power on the controller and wait for the following screen to
appear. Promptly (Within 3 seconds), select the “Cursor down”
key
The new licence number obtained from the Siemens Hotline

will need entering, this is described in Module A044.
PCU 50.3 Ghost Images
The PCU50.3 operates with a hard disk drive which contains

the operating system (Windows®), Sinimerik basic software,
Sinumerik 840D sl Operate software, archives, user files etc.
The hard disk is divided into four partitions (C, D, E, F)
The method used to back-up the hard disk drive is Norton
Ghost®.
Norton Ghost is present on all replacement hard disk drives to
faciltate creating and restoring a Ghost image.
The procedure produces a “Ghost image”. The size of the
Ghost image will depend on the individual application but is in
excess of 1GB.
The image can be saved externally to a USB device, provided
that there is sufficient space or via network.
It is also possible to create local Ghost images of partitions C,
E & F to partition D.
The white band moves off the “SINUMERIK” menu item on to
Prior to creating a Ghost image it is recommended that the
a hidden menu item.
archiving procedure is followed and that the files are saved to
This is the “Service Centre” menu, select “Input” to continue.
the hard disk of the PCU.
Hard Disk Partitions:
In order to enable the separation of the software packages, the

hard disk of the PCU 50.3 is sub-divided into four NTFS parti-
tions, each with different functionality.
Description of Partitions:
Partition C Emergency: Active primary partition

(Service/tools menu)
Partition D TMP: Extended partition

(Local images, install, update)
Partition E System: Primary partition

(Windows® operating system)
Partition F USER: Primary partition

(HMI, Shopmill/turn, Step7, OEM)
Notes

A017
The Service Centre will now be started. This runs from Ram- A summary will be displaced showing details of the Ghost im-
disk and take a short while to load. age.
A password is required, this password is “SUNRISE”
The process will begin, this may take some time depending
The Ghost image now needs to be given a name. Be sure to upon the size of the Ghost image
select “Enter” to confirm the image name.
Notes

A017
Restoring Ghost Images A summary will be displaced showing details of the Ghost im-
age.
Images are also restored using the Service Menu.
The restore process will begin, details such as time elapsed

and time remaining are shown.
Select the Ghost image to be restored.
Notes

A017
The computer (PCU50) name can be changed if required. Locate the “linuxbase-resize.img” file and select “Open”
If the PCU is connected to a factory network a specific name
may have to be entered.
Select “OK” to reboot the system.
TGZ backup files

Select the drive letter of the USB stick (Ignore the reference to
Another method of creating a backup of the System CF card is
the memory card)
using the Emergency Boot System.
A USB service stick is required. This is a bootable stick which
contains Emergency Boot System software.
When plugged into interface X125 the system will boot from the
USB device into the Emergency Boot System menu.
From this menu it is possible to create/restore a backup file.
The backup file will be of the TGZ type.

TGZ files are ideal for creating a backup for use with series
machine production. This is because the licence details con-
tained on the destination CF card will be left intact.
Creating a USB service stick.

RCS Commander is used for creating a USB service stick.
The software is delivered in “zip” format and should be ex-
tracted to a suitable place on a computer.
When extracted, the file “linuxbase-resize.img” can be found in
the following path:
Emergency Boot System 840Dsl V02_70_17_00\eboot_system
Run the RCS Commander software and select “Writing image

to CF card” found on the “NC Commissioning” menu.
Notes

A017
The writing process will begin
A number of backup choices are available, select the menu

item “Backup Complete CF card to USB memory stick”
The process can be repeated of required.
Creating a CF card backup (TGZ file)

A suitable filename should be entered. This should contain
Starting the Emergency Boot System. information that helps identify the file to other users. The TGZ
extension is mandatory.
Switch off the controller and insert the bootable USB stick
into X125 of the NCU.
The following screen will be displayed:
Cursor to the “Backup NCU Software and Data” menu item

and select “Ok”
Notes

A017
The backup procedure will begin. Restoring a CF card backup (TGZ)
The restoring of the TGZ file is also achieved from the Emer-
gency Boot System menu.
The backup TGZ file needs to be present on the USB Service

stick.
On completion, press any soft-key.
Insert the USB service stick
Select “Restore NCU Software and Data”
The original screen will be displayed.
Check that the file exists on the USB stick, the file should be
stored in a safe place, and be accessible to service personnel.
Notes

A017 END
The status of the procedure is displayed, allow this to continue.
On completion, press any of the soft-keys.
Power the controller off/on.

Standard NC machine data will have been loaded, it will be
necessary to load an archive containing the most up to date
data.
A017: END
Notes

A010 PCU, TCU and OP: Diagnostics and Interfaces.
Sinumerik
Operate
Module Description:
The PCU50.3 is an industrial PC with a removable hard disk drive which contains the operating system
(Windows®), Sinimerik basic software, Sinumerik 840D sl Operate software, Shopmill/ShopTurn, archives,
user files etc.
The PCU is equipped with 2 x LEDs and 2 x 7-segment displays to aid diagnostic procedures and various
interfaces.
The TCU (Thin Client Unit) serves solely as a human/machine interface and has no data storage possibilities
or diagnostic LEDs/displays. Various interfaces are found on the TCU.
Operator Panels (Ops) are used for interfacing the PCU/TCU to the controller. The PCU/TCU is easily
mounted on the rear of the OP. The OP has 2 x LEDs for basic diagnostic functionality and a single USB
interface.
Module Objective:
Upon completion of this module you will be able to locate:
 Diagnostic LEDs and displays of the PCU and understand their meaning.
 Interfaces of the PCU
 Interfaces of the TCU
 Operator Panel
Content:
Sinumerik
PCU50.3: Interfaces
TCU: Interfaces
PCU50.3: Diagnostic LEDs and Displays
Operator Panel Diagnostics and Interfaces
A010
A010

A010
PCU/TCU/OP
PCU and TCU Diagnostics and Interfaces
Diagnostics and
Interfaces:
START
The PCU50.3 is an industrial PC with a removable hard
disk drive which contains the operating system
(Windows®), Sinimerik basic software, Sinumerik 840D
sl Operate software, Shopmill/ShopTurn, archives, user
PCU50.3:
files etc.
Interfaces
The PCU is equipped with 2 x LEDs and 2 x 7-segment
displays to aid diagnostic procedures and various inter-
faces.
The TCU (Thin Client Unit) serves solely as a human/

machine interface and has no data storage possibilities
TCU:
or diagnostic LEDs/displays. Various interfaces are Interfaces
found on the TCU.
Operator Panels (Ops) are used for interfacing the

PCU/TCU to the controller. The PCU/TCU is easily
mounted on the rear of the OP. The OP has 2 x LEDs
PCU50.3:
for basic diagnostic functionality and a single USB in- Diagnostic
terface. LEDS and
Displays
Operator
Panel
Diagnostics
and
Interfaces
PCU/TCU/OP
Diagnostics and
Interfaces:
END
Notes

A010
PCU50.3 interfaces
The interfaces of the PCU50.3 are located on two sides

2 x status LEDs.
2 x 7 segment displays.
Ethernet 2
Ethernet 1
ON/OFF
switch
4 x USB 2.0 +24V DC

supply
Ribbon cable interface.

Connects PCU to OP
MPI/DP
2 x PCI
slots
Digital video
Interface.
BIOS battery
(DVI)
location.
Note:
Ethernet 1 is designated as the “Factory Network”. This is

used for connecting the machine to an existing network. This
could be used for example to centrally store machining pro-
grams etc.
Ethernet 2 is designated as the “System Network”. This is

used to connect to the various components of the system such
as the NCU, MCP etc.
Notes

A010
The hard disk drive (HDD) of the PCU is available as a spare TCU interfaces
part separately from the PCU.
A locking device is used to secure the HDD during transporta-
tion.
This help protects the hard disk against severe vibration
If attempting to power up the PCU in this condition the
following message will be displayed on the screen of the op-
erator panel:
Operating system not found. X206
+24V DC
Removable hard disk drive location: supply
X201
CF card
(Not enabled)
X202
System
Ethernet
X203 & X204

2 x USB
For the the NC keyboard
and USB memory devices.
On the reverse of the TCU are two ribbon cable connectors for
connecting to the operator panel.
Ribbon cable connectors:
Notes

A010
PCU50.3: Diagnostic LEDs and 7 Segment Displays Status codes during system power up, continued.
The diagnostics displays of the PCU50.3 consist of 2 x LEDs LED LED H1 H2 Status
And 2 x 7 segment displays. H1 H2 Display Display
A 0 TCU Wait for

support VNC
test step 3 server to
H1 H2
start
LED and LED and
7 segment 7 segment B 0 HMI Wait for
display display manager HMI
manager
to start
E 0 PCU General
H1: Assigned to the PCU basic software. Displays status Base fault: see
codes for system booting and shutdown. software Windows
“Event
H2: Assigned to the application software. viewer”
Status codes during system power up.
Status codes during operation.
LED LED H1 H2 Status

H1 H2 Display Display
Orange Orange Output of BIOS After switch on H1 H2 Display Display
post codes
Flashing 0 0 OK
Orange Off After cycling the BIOS green
Orange Off After starting Windows Flashing Error: See below
red
1 0 Start Load
Windows device 1 0 Temperature Housing or
drivers alarm CPU over
needed temperature
for
Windows 2 0 Fan alarm Housing or
CPU fan, low
2 0 PCU PCU hard- speed or
hardware ware ser- failure
service vice has
een 3 0 Hard disk S.M.A.R.T*
started alarm hard disk
error
5 0 Network Wait for
network
interfaces * Self Monitoring Analysis, and Reporting Technology.
8 0 TCU Wait for

support FTP
test step 1 server to Status codes during shutdown.
start
9 0 TCU Wait for H1 H2 Display Display
support TCU
test step 2 network Flashing 5 0 Shutdown active
boot and red/
TCU green
hardware
service to
start
Notes

A010 END
Operator Panel Diagnostics
There are two LEDs located on the front of the OP (Operator

Panel) The LEDs indicate:
The presence of power to the PCU/TCU
Temperature of the PCU out of permitted range (5—55ºC)
In normal running conditions the Power LED is permanently lit.

The temperature LED illuminates when the PCU50 housing or
CPU over temperature threshold is reached.
1 x USB interface
The rear of the operator panels are designed so that the PCU/
TCU can be easily mounted.
There are two ribbon cable connectors for transferring signals
between the OP and the PCU/TCU
A010: END
Notes

A010 END

A036 NCU Diagnostic Displays and Switches
Sinumerik
Operate
Module Description:
All variants of NCU’s are equipped with status LED’s and a 7 segment display.
When alarms relating to the NCU occur it is recommended that the status LED’s etc be checked to help
achieve a speedy diagnosis.
The 7 segment display can also be used to output the IP address of the NCU.
Two rotary switches, one for NCK functions and one for PLC functions are also present. Certain tasks can be
performed by changing the position of the switches.
The location and description of the status LED’s, 7 segment display and rotary switches is described in this
module.
Module Objective:
Upon completion of this module you will be able to check the status LED’s and 7 segment display of the
NCU.
Content:
Sinumerik
LED Status & 7 Segment Display Status
NCK & PLC Rotary Switches
A036
A036

A036
NCU Diagnostic
NCU Diagnostic Displays and Switches: Displays and
Switches:
START
All types of NCU are equipped with status LED’s.
When alarms relating to the NCU occur it is recommended
that the status LED’s be checked to help achieve a speedy
diagnosis.
Further diagnosis using a computer and diagnostic tools may Status LED’s
be required. and 7 Segment
Display
The location and description of the status LED’s is described
in this module.
During the boot phase of the NCU all LED’s will be briefly lit
and will be orange in colour.
NCK & PLC
Rotary
Switches
NCU Diagnostic
Displays and
Switches:
END
Notes

A036
Status LED’s and 7 Segment Display.
LED Colour Explanation
The NCU diagnostic features are found on the lower front face There is at least one fault (e.g. RESET,
and consists of a 7-segment display unit and 8 status-LED’s. red Watchdog monitoring etc.), or the control unit
is in process of booting.
RDY red/ Error during Compact flash Card access-

orange flashing 0.5Hz.
orange Compact flash Card access-random flashing.
green NC operative
RUN green PLC operative (PLC run)
STOP orange PLC in the Stop status (PLC stop)
SU/PF red FORCE activated (PLC force)
SF red PLC collective fault (PLC SF1)
DP1 red PROFIBUS DP1 collective fault (BUS1 F)
DP2 red PROFIBUS DP2 collective fault (BUS2 F)
Off when no option board is present.
There is at least one fault on the plugged
red
option board, or it is not ready.
OPT
The meaning depends on the option
green
(see applicable description). Flashing 0.5Hz.
Area of LED’s and 7 segment green Option is operative.

display.
The 7 segment display is found
beneath the light blue clip-on
cover. 7-Segment display
The 7-Segment display is located behind the lower cover of

the control unit.
The display can output a single numeric value (0 to 9) or a

single letter (A, C, E, F, P). A decimal point is present to the
lower right of the numeric value.
It serves as a status display during commissioning and can

be used to display the following information:
LED Location
 IP address of the NCU
 Test and diagnosis information
 Status during booting
During normal operation a "6." is displayed with the point

flashing. The “RDY” LED will be green and constant.
During the boot phase the display changes to indicate the

different stages of the boot process.
Reset button
7 segment display Location
Notes

A036
7-segment display during power up. NCK and PLC rotary switches
7-segment Meaning Two rotary switches, one for NCK functions and one for PLC
display functions are also present. Certain tasks can be achieved
depending on the position of the switches.
1 Not applicable.
Some tasks require a restart for activation, the “RESET” but-
2 Not applicable. ton is conveniently located for this purpose.
3 Debugger was initialised.
4 NRK operating system was successfully activated.
5 NRK operating system has booted, init task is be-

ing processed (The application boots)
6 Initialisation was successfully performed; the con-
6. trol is in cyclic operation and the cycles are active.
F Internal error.
1 or 2 CF card and SRAM data do not match. To resolve
this problem a general rest is required (Boot with Rotary switch
S3 in pos 1 or 2) location.
System Errors
Reset button
System errors are indicated by a combination of the “RDY”
location.
LED and the 7-segment display.
“RDY” LED fault description:
“RDY” LED Meaning

NCK switch functionality
Flashing red Permanent error: System stopped
@ 2Hz (See below for 7-segment display) Switch
Function
Position
Flashing red/ Temporary error: System may continue with
orange @ restricted functions. 0 Normal NCK boot up
2Hz (See below for 7-segment display)
1 NCK boot up with default values (Memory reset)
7_segement display in relation to “RDY” LED (See above) 7 Debug mode, NCK is not started.
8 IP address is displayed on 7 segment display
7 segment Meaning
display All others Not relevant.
Permanent error
“Crash”: Operating system crash (similar to a “Blue
C screen” in Windows) Further details can be found in PLC switch functionality.
the system log-file.
P “Partition”: Error when repartitioning Switch
Function
Position
Temporary error
“Error”: A read or write error has occurred on the 0 Run
Compact Flash Card (An additional point is dis-
E 1 Run (Protected mode)
played to indicate a “write error). It is possible that
the CF card is defective. 2 STOP
“Full”: The Compact Flash Card is full, it is possible
that not all services will have started. 3 Memory reset on boot up (MRES)
F When booting, the error is displayed for 1 minute; All others Not relevant.
the system will then continue to boot, however, it
can be assumed that problems will occur.
A036: END
Notes

A036 END

A003 Battery and Fan Exchange
Sinumerik
Operate
Module Description:
Certain components are equipped with backup batteries which maintain data stored in the volatile ram area.
Some are fitted with fans for the cooling of the electronics.
During the lifespan of the equipment it is possible that the battery will become less efficient, resulting in a
drop in voltage or that the cooling fans show signs of wear and tear. In either case the batteries or fans must
be replaced.
A data backup should be made before exchanging the battery (this is described in Module A017).
Caution
The Lithium-batteries must be replaced only by identical replacements or by types recommended by the
manufacturer. Otherwise component damage may occur.
All Lithium batteries must be returned to the manufacturer/recycler for disposal and must be treated as spe-
cial waste items.
Module Objective:
Upon completion of this module you will be able to locate and change the PCU50 battery and the NCU bat-
tery and fans.
Content:
Sinumerik
Battery Health and Safety Warning
PCU 50.3: Replacing the Battery
840D sl NCU: Replacing the Fan/Battery-Module.

Replacing the Battery
SINUMERIK 840D sl Operate Page 1 This document was produced for training purposes.
A003
A003

A003
Battery and fan Exchange Battery and fan

Exchange:
START
Certain components are equipped with backup batteries
which maintain data stored in the volatile ram area. Some are
fitted with fans for the cooling of the electronics.
During the lifespan of the equipment it is possible that the Batteries:
battery will become less efficient, resulting in a drop in volt- Health and
age or that the cooling fans show signs of wear and tear. In Safety Warning
either case the batteries or fans must be replaced.
A data backup should be made before exchanging the battery
(this is described in Module A017).
PCU 50.3:
Replacing
the battery.
840D sl NCU:
Replacing
the battery/
fans
Battery and fan

Exchange:
END
Notes
SINUMERIK 840D sl Operate Page 3 A003

A003
Batteries: Health and Safety Warning PCU 50.3: Replacing the battery.
Lithium batteries pose a risk to health and safety, please Before disconnecting the battery all present BIOS Settings
read the following before commencing the exchange of must be recorded.
batteries. This is particularly important if the default values have been
changed and have not been saved in the user profile.
The Lithium-batteries must be replaced only by types
recommended by the manufacturer. Failure to do this can Note
lead to component damage. If the new battery is connected within 1 minute of disconnect-
ing the old battery, all settings (including date / time) will be
All Lithium batteries must be returned to the manufacturer/ maintained.
recycler for disposal and must be treated as special waste
items.
Procedure:
The PCU50.3 is commonly located behind the operating panel
(OP). In certain cases it may be located remotely from the OP.
! 1. Switch OFF the control unit and switch ON again.

2. When the text ”Press F2 to enter set-up” is displayed at
Danger of explosion and release of harmful substances! the bottom of the screen, press the 2nd softkey or the F2
key on an external keyboard.
Do NOT:
3. Record the BIOS settings.
Throw a lithium battery into a fire
Solder anything to the casing 4. Switch OFF the control unit once more and lock the main
Open the casing switch to prevent accidental switching on of the power.
Short circuit the terminals 5. Open the battery compartment on the left side of the
Expose to temperatures above 100°C PCU 50.3
(Image 1).
DO: 6. Remove the battery holder (Image 2).
Dispose of properly 7. Disconnect the cable (Image 3).
Protect from direct sunlight,
8. Re-connect the cable on the new battery.
Avoid excessive humidity and condensation.
Observe the correct polarity. 9. Remove the old battery from the holder.
10. Clip the new battery into the holder.
11. Close the battery compartment.
12. Power on and enter the BIOS page, check the BIOS-
Setup settings or restore user profile.
Image 1: Battery location with battery cover open.
Image 1
Notes

A003
Image 2: Battery being withdrawn from the PCU50.3. Fan Information:
 Fan warning: If one of the fans no longer rotates.
 Fan fault: If both fans are stopped.
Approximately one minute later the components will be
switched OFF automatically and the status will be indicated by
means of the red SF LED.
Fans of the NCU types 710.2/720.2/730.2 will run initially on

power up for test purposes before switching off.
The fans will then be switched on automatically when the air
intake temperature of the NCU reaches 55ºC. The fans will
Image 2 switch off when the temperature reaches 35ºC
For NCU types 720.2PN/730.2PN the fans run continually.

Image 3: Battery fully withdrawn, revealing the connector.
Some battery/fan housings contain two fans.
Replacement:
Connector which
allows easy The fan/battery module is replaced as follows.
exchange of the Removal:
battery. 1. Switch OFF the control and secure against unintended
switching ON.
2. Gently push the fan/battery module backward. This will
release the retaining clips.
3. The fan/battery module can now be lowered and the rear
locator slid from the NCU box.
Image 3
Note: Replacing:
Batteries are perishable items. They should be replaced 1. Hold the fan/battery module tilted slightly forward.
every 3 years as a safeguard against unexpected problems.
2. Insert the locator into the guide at the bottom of the NCU
box.
840D sl NCU: Replacing the Battery/Fans.
3. Lift the front of fan/battery module upward, until the
retaining clips lock into place.
The battery and fans of the 840D sl NCU are contained in the
same housing which fits to the underside of the NCU box.
The battery and fans can be replaced separately or the whole The fan/battery module and the control unit are interfaced via
unit. two small plug/sockets, these are automatically connected
when the fan/battery module is locked into place.
Battery Information:
Battery buffered data is stored in the SRAM located on the

NCU board.
If the battery voltage falls to a critical level (2.7 to 2.9 Volts)
alarm number “2100 NCK battery warning threshold reached”
will be triggered.
The battery must then be replaced within 6 weeks of the alarm
first appearing.
If the battery voltage drops to the next critical level (2.4 to 2.6
Volts) alarm “2101 NCK battery alarm” is triggered. In this
case if the power is removed the buffered data will likely be
lost/corrupted.
Notes
SINUMERIK 840D sl Operate Page 5 A003

A003 END
Location and components of Battery/fan housing:
Fan Rear
Battery locator
Push to
release Battery/fan housing
Replacement of Battery:
If only the battery is to be replaced, the previous procedure for

removing the battery/fan module should be followed.
The battery is then disconnected via the plug/socket and then

withdrawn from the battery/fan module.
The new battery is fitted in the reverse order.
Connection for
battery lead
Battery lead
connector
A003: END
Notes

A051 Line and Motor Modules
Sinumerik
Operate
Module Description:
The 840D sl Sinumerik Operate is designed to work with the Sinamics S120 drive family using the DriveCLiQ
bus system.
The S120 Booksize version of drive components are the most common in use with the 840D sl controller.
S120 Blocksize/Chassis versions are also available.
This module describes the S120 Booksize line and motor components, including connection and power
off/on requirements.
Module Objective:
Upon completion of this module you will know how the drive components of the 840D sl system are inte-
grated and how the power to these components should be applied and removed.
Content:
Sinumerik
Topology
General Information
Drive Module power Supply
Smart Line Module (SLM)
Active Line Module (ALM)
Motor Module (MM)
Supply and Enabling Examples
A051
A051

A051
Line and Motor

Line and Motor modules: Description
Modules:
START
The 840D sl Sinumerik Operate is designed to work

with the Sinamics S120 drive family using the Drive-
CLiQ bus system.
The S120 Booksize version of drive components are Topology

the most common in use with the 840D sl controller.
S120 Blocksize/Chassis versions are also available.
This module describes the S120 Booksize line and mo-

tor components, including connection and power
off/on requirements. General In-
formation
Drive Module
power
Supply
Smart Line Module

(SLM)
Active Line
Module (ALM)
Motor Module
(MM)
Supply and
Enabling
Examples
Line and Motor

Modules:
END
Notes

A051
Topology
Example– 5 axis system (Spindle, X, Y, Z, A) “fast commissioning“
The system assigns the object/component numbers on the Drive-CLiQ Bus in the order they are connected
The order is with the compounds X100, X200 and X201 fixed and goes until the last X201.
From the last DO (MoMo 5 / 6), the components are then assigned in reverse order from X203.
Drive objects are ControlUnits, MotorModule and LineModule with DriveCLiQ.

A drive object consists of the components “MotorModul, Motor, encoder interface and encoder “.
Motors, encoders etc are classed as drive components.
.
CU is always object number 1.
Objects are numbered in red text.

Components are numbered in purple text.
NCU 1 MoMo 2 MoMo 3 4 MoMo 5 6
X105
1 2 3 4 5 6
X104
X103 X203 X203
X102 X202 X202 X202
X101 X201 X201 X201
X100 X200 X200 X200
Sp X Y Z A X500
SMI- 21 SMI- 18 SMI- 15 SMI- 12 SMI- 9 SMC
ENC- 22 ENC- 19 ENC- 16 ENC- 13 ENC- 10 ENC- 7
MOT- 23 MOT- 20 MOT- 17 MOT- 14 MOT- 11 MOT- 8
2 3 4 5 6 6
Notes

A051
Topology
Example- 7 axis system with NX ...“fast commissioning“
Equipment connected to X101 is assigned to the CU, the numbering is continued completely.
For those involved in NX... (CU) the connected drives/motors uses the same numbering rules as the CU.
Drive system
NCU 1 ALM 2 MoMo 3 MoMo 4 5 MoMo 6 7

Drive device 1: NCU
X105
1 2 3 4 5 6 7
X104
X103 X203 X203
X102 X202 X202 X202 X202 DMC 23
X101 X201 X201 X201 X201

X505
X100 X200 X200 X200 X200
X504
X503
M1 M2 M3 M4 M5 X500 X500
SMI- 20 SMI- 17 SMI- 14 SMI- 11 SMI- 8 X502 SMC SMC
ENC- 21 ENC- 18 ENC- 15 ENC- 12 ENC- 9 SMC- 24 SMC- 26
MOT- 22 MOT- 29 MOT- 16 MOT- 13 MOT- 10 X501 ENC- 25 ENC- 27
3 4 5 6 7 X500
Drive device 2: CU
NX 1 MoMo 2 3
X105
1 2 3
X104
X103 X203
X102 X202
X101 X201
M6 M7 X500
SMI- 7 SMI- 4
X100 X200 ENC- 8 ENC- 5 SMC
MOT– 9 MOT– 6 SMI- 10
ENC- 11
2 3
Notes

A051
General Information Drive Module power Supply
Line and Motor Modules Power Requirements
Line and motor modules are responsible for supplying power to The drive modules require two power supplies in order to op-
the motors. erate.
The Sinumerik 840D sl works with the Sinamics S120 range of
drive products. A 3 phase AC supply (380V to 480V +10% (-15% < 1 min) to
All Motor Modules have to be connected to the DriveCLiQ bus the bottom of the line module is used to produce the 600V DC
system. link. The DC link is distributed to the motor modules via a bus
All Line Modules with the exception of 5 & 10Kw SLM modules bar system on the front of the drive modules beneath a flip
have to be connected to the DriveCLiQ bus system. down cover
Line modules require a 3 phase AC supply, this is rectified into An electronics supply (+24V DC) is required and must be sup-
a DC supply which is then supplied to the motor modules via plied to the Line Module via connector X24. This is then dis-
the DC link bus bars. tributed by a bus bar system to the remaining drive modules.
The electronic supply is used internally by the drive modules
Motor modules convert the DC link back into a controllable AC for powering of the electronic circuitry etc. Externally it is used
supply which is used to drive the servo motors. for supplying the Drive-CLiQ encoders and fault, ready and
By regulating the frequency and voltage of the AC supply to the enable signals.
servo motors it is possible to precisely control the movement of
motors.
Line and motor modules are available in different variants de- Location of the electronics supply and DC link bus bars:
pending on the machine requirements.
Bridging device for
Each module requires a +24V DC control voltage, this is sup- 24V DC Electronics supply (X24) continuity of the
plied by the user to the line module and then distributed to the +24V DC bus
motor modules via a bus system. between drive
modules.
Example, S120 Line module with two motor modules:
+24V DC Bus-bar
0V DC Bus-bar
+ DC Link Bus-bar
- DC Link Bus-bar
LM MM1 MM2
X24– Electronic Supply 24V DC
“M” Terminal: Electronics ground
X24
Line Module Motor Modules

“+” Terminal: +24V DC (20.4V to 28.8V)
(LM) (MM)
Notes

A051
Smart Line Modules (SLM) Connector locations X21, X22 & X24
The SLM is responsible for rectifying the AC mains supply into

the DC link voltage which is then utilised by the Motor Mod-
ules.
This DC link voltage is non-stabilised on all SLM types
The SLM is also responsible for handling the regenerative cur-
rent caused by the braking of motors. The regenerative current
is fed back into the mains network. This eliminates the need for
X21: X22: (SLM 5 & 10Kw
braking resistors and complex measures for heat dissipation. Enable, ready only)
The SLM is available in 5, 10, 16 & 36Kw variants with internal and fault sig- Regeneration and
or external cooling capability. nals fault
reset signals
Smart Line Modules- 5 & 10Kw
The 5 & 10Kw SLM’s are not used on the Drive-CLiQ network,
because of this there are slight differences with terminal func-
tionality compared to Drive-CLiQ type modules.
Example:-An internally cooled 10Kw SLM module showing

terminal locations etc. X24:
24V DC Elec-
tronics supply
SLM
X22 Terminal description and functionality

X21: X22:
Various signals Various signals
X24:Electronics
supply
Electronics/DC link Terminal Function Description
bus bars (below flip
down cover) +24 V DC Supply for use with the
+24V DC
1 functions of X22.2 & 3 described be-
(Output)
low.
Applying +24V DC will cause the re-
generation function to be disabled.
In some cases it may be necessary to
stop the regeneration of current
LED status Disable
caused by braking motors. Example:-
Indicators 2 Regeneration
A poor quality mains Network not able
(Input)
to handle regeneration.
Note: The fitting of resistor modules to
dissipate excess energy will be re-
quired when this function is used.
Applying +24V DC will cause the re-
setting of any drive faults.
Fault Reset A fault occurring on the drives system
3
(Input) will be latched, this can be reset with
this function providing the cause of
X1: Mains supply the original fault is no longer present.
Protective earth (3-Phase AC)
connections 0V DC Must be connected to the same 0V of
4
(Ground) the electronics supply (X24).
Notes

A051
LED Status Display
X21 Terminal description and functionality LED Colour Status Explanation
Green On Module is healthy and operational.
Terminal Function Description Pre charging of DC link active; By-
Yellow On
Switches high (+24V DC) when the follow- pass relay dropped out.
ing conditions are true: READY Over temperature/current fault or
 Electronics supply present (X24). (Top) Red On electronics power supply outside
 DC Link is pre-charged. permitted range.
Ready  Pulses enabled (X21.3) Off

Electronics power supply outside
permitted range.
1 Signal  No over-temperature DC LINK
Yellow On DC link voltage within tolerance.
(Output)  No over-current (Bottom)
Red On DC link voltage outside tolerance.
It is recommended that the signal is con-
nected directly to the 840D sl controller via
connector X122 pin 1. This is the OFF1 Smart Line Modules- 16Kw and above
enable signal.
Switches low when any of the following These models are always required to be connected to the
conditions arise: Drive-CLiQ drive bus network.
The functionality of certain terminals is therefore different from
 Over-temperature threshold
the non-Drive-CLiQ SLM modules.
reached.
Regeneration can be deactivated by parameter P3533-Inhibit
 I²t threshold reached. regenerative operation.
Pre-  Mains fault making regenerative
2 warning feedback impossible. If feedback is Terminal locations of an internally cooled 36Kw SLM:
(Output) intentionally deactivated (X22.2 is
high) this warning is disabled.
This signal is for use by the manufacturer

X200/X201/X202:
to set a user alarm and alert the operator X21:Pulse en- Drive-CLiQ
to a problem. able connectors
Applying +24V DC will cause the pulses to
be enabled. (Current consumption:10mA)
X24:Electronics
supply
This signal must be removed at least 10ms
prior to the 3-phase mains supply being Electronics/DC
link bus bars
removed.
(below flip down
Failure to do this can lead to damaged cover)
drive modules. This is especially important
when the axes/spindles are decelerating
and causing regenerative currents. if the
mains circuit is opened these regenerative
Enable currents remain within the drive system
3 Pulses causing damage to the modules. LED status
(Input) It is recommended that this terminal is con- Indicators
nected via an early break contact on the
machine isolator switch and the line con-
tactor (If used).
If the terminal is used by the manufacturer
it must be ensured that it is controlled in
the suggested manner.
When used in this way the transistors will
be switched off and mains regeneration
halted, the motors will then coast to a halt.
This is not suitable for an emergency stop
situation.
Protective earth X1: Mains supply
Enable (3-Phase AC)
Must be connected to the 0V of the enable terminals
4 Pulses
pulses supply.
(Ground)
Notes

A051
Connector locations X21, X24, X200, X201 & X202 LED Status Display
LED Colour Status Explanation

Off
permitted range.
X21: Module configured and ready, Drive-
Pulse enable (PE) Green On
CLiQ communication is active.
Drive-CLiQ communication is being
Orange On
established/module not configured.
X202: READY
Drive-CLiQ (Top) Red On At least one fault is present.
Green/ Flashing Firmware download procedure is
Red 2Hz running.
X201:
Green/
Drive-CLiQ
Orange Flashing Component recognition is active
or Red/ 2 Hz (p0124 = 1)
X200: Orange
Drive-CLiQ Electronics power supply outside
Off
permitted range.
X24: DC LINK DC link voltage within tolerance-Only
Orange On
24V DC Electronics (Bottom) if unit is configured and ready.
Supply DC link voltage outside tolerance-
Red On
Only if unit is configured and ready.
X21 Terminal description and functionality
Terminal Function Description

1 Not used Not used
2 Not used Not used
Applying +24V DC enables the pulses.
(Current consumption:10mA)
This signal must be removed at least
10ms prior to the 3-phase mains supply
being removed.
Failure to do this can lead to damaged
drive modules. This is especially impor-
tant when the axes/spindles are regener-
ating. If the mains circuit is opened in this
state, regenerative currents remain within
Enable
the drive system causing damage to the
Pulses
modules.
3 Input
It is recommended that this terminal is
(EP)
connected via an early break contact on
the machine isolator switch and the line
contactor (If used).
If the terminal is used by the manufac-
turer it must be ensured that it is con-
trolled in the suggested manner.
halted, the motors will then coast to a
halt. This is not suitable for an emergency
stop situation.
EP Must be connected to the 0V of the en-
4
(Ground) able pulses supply.
Notes

A051
Active Line Modules (ALM) Location of ALM connectors X21, X24, X200, X201 & X202
The ALM is responsible for the rectification of the AC mains

supply into the DC link voltage which is then utilised by the X21:
Motor Modules. Enable and
Temperature sensor.
This DC link voltage is also stabilised unlike the SLM mod-
ules
The ALM is also responsible for handling regenerative current
caused by the braking of motors.
X203: Drive-CLiQ.
The regenerative current is fed back into the mains network.
This eliminates the need for braking resistors and complex
measures for heat dissipation.
X202: Drive-CLiQ.
Regeneration can be deactivated by parameter P3533-Inhibit
regenerative operation.
The modules are available in 16, 36, 55, 80 & 120Kw variants
with internal or external cooling capability. X201: Drive-CLiQ.
The ALM is always connected to the Drive-CLiQ bus and has
four Drive-CLiQ connections.
The stabilised DC link makes the ALM suitable for high dy- X200: Drive-CLiQ.
namic machinery where the acceleration and positioning of
axes/spindles is critical. X24: 24V DC
Electronics supply
Terminal locations of ALM modules:-
X21: X200/X201/
Pulse enable, X202: X21 Terminal description and functionality
temperature Drive-CLiQ
sensor
X24: Electronics/DC + Temp Temperature sensor input from Active
Electronics link bus bars 1
supply.
(Input) Interface Module (Observe the polarity)
(below flip
down cover) - Temp Temperature sensor input from Active
2
(Input) Interface Module (Observe the polarity)
LED status
Indicators Applying +24V DC enables the pulses.
This signal must be removed at least
10ms prior to the 3-phase mains supply
being removed.
Failure to do this can lead to damaged
drive modules. This is especially important
when the axes/spindles are regenerating.
X1:
3-Phase AC If the mains circuit is opened in this state,
Protective Mains supply regenerative currents remain within the
earth Enable drive system causing damage to the mod-
connections. 3 Pulses ules.
(Input) It is recommended that this terminal is
connected via an early break contact on
the machine isolator switch/line contactor.
If the terminal is used by the manufacturer
it must be ensured that it is controlled in
the suggested manner.
halted, the motors will then coast to a halt.
This is not suitable for an emergency stop
situation.
EP Must be connected to the 0V of the enable
4
(Ground) pulses supply.
Notes

A051
ALM LED Status Display. Motor Modules (MM)
LED Colour Status Explanation Motor Modules are responsible for converting the DC link volt-
Electronics power supply age into a variable AC voltage in order to drive the motors.
Off The modules have to be connected to the Drive-CLiQ bus.
outside permitted range.
Single/double axis and internally/externally cooled versions
Module configured and ready,
are available.
Green On Drive-CLiQ communication is
Double axis modules are equipped with four Drive-CLiQ con-
active.
nectors, one more than the single axis modules.
Drive-CLiQ communication is
Orange On being established/module Single Axis MM
not configured. Available in the following rated current output sizes:
Red On At least one fault is present. 3, 5, 9, 18, 30, 45, 60, 85, 132 & 200A.
READY Green/ Flashing Firmware download procedure
Red 2Hz is running. Example: A single axis MM showing connector locations etc.
(Top)
Green/
Orange Flashing Component recognition is active
or Red/ 2 Hz (p0124 = 1)
Orange
Off
permitted range.
X200/X201/X202:
DC link voltage within tolerance- X21: Drive-CLiQ
DC LINK Orange On Only if unit is configured and Enables etc.
(Bottom) ready.
DC link voltage outside tolerance-
Red On Only if unit is configured and
ready.
Electronics/DC
link bus bars
(below flip down
cover)
LED Status
Indicators
X11: Brake output
for MM of 45A and
above
Protective
X1: Output to
earth
Motor, including
terminals
the brake output
for MM less than
45A
Notes

A051
Double Axis MM Terminal descriptions
Available in the following rated current output sizes:
3, 5, 9 & 18A
Example: A double axis MM showing connector locations. X21: Pulse

These units will have two identical Motor/Brake connectors
(X1 & X2) and two identical enable connectors (X21 & X22).
X21: Pulse X22: Pulse
X22:Motor 2 X203:
X21:Motor 1
Enables etc.
Enables etc. X202:
X202:
X201:
X200/X201/X202/ Electronics/DC
link bus bars X201:
X203:
Drive-CLiQ (below flip down X200:
connectors cover)
X200:
LED Status
Indicators
Single axis Double
X1 & X2 Output
to Motor,
including the Connector X21 & X22 (X22 only for double axis
brake output for modules)
Protective MM less than
earth 45A
connections
Positive temperature sensor input from
+ Temp
X11: Brake out- 1 non-Drive-CLiQ temperature sensor.
put for MM of
(Input)
Type:- KTY84-1C130/PTC
45A and above
Negative temperature sensor input from
- Temp
2 non Drive-CLiQ temperature sensor.
(Input)
Type:- KTY84-1C130/PTC
Applying +24V DC will cause the pulses
of the individual axis to be enabled.
When the signal is low, “Safe pulse
suppression” is activated.
Note:-No electrical isolation occurs
Enable
between the Motor module and the motor.
Pulses
3 This enable signal is only operational if the
(EP)
Safety Integrated function “Safe Standstill
Input
(SH)” is enabled.
This is a dual channel monitoring system of
the Control Unit and Motor Module. The
status of the Enable Pulses input is cross
checked against the corresponding CU input,
an error is reported if they do not match.
EP Must be connected to the 0V of the enable
4
(Ground) pulses supply.
Notes

A051
LED Status Display Supply and Enabling Examples
LED Colour Status Explanation
For trouble free operation it is essential that the drives are
Electronics power supply outside powered on/off and enabled correctly.
Off
permitted range. If the mains supply switch/contactor is opened while the drive
Module configured and ready, pulses are enabled and the drive is in regeneration mode, the
Green On Drive-CLiQ communication is regenerative current which is normally fed back into the mains
active. will have no where to go, except that is into the motor and line
Drive-CLiQ communication is modules, this can result in damage to these modules.
Orange On being established/module not con- The solution is to use an auxiliary contact fitted to the mains
READY figured. switch and drive line contactor.
(Top) This auxiliary contact must open at least 10ms before the
Red On At least one fault is present. main contacts open.
Green/ Flashing Firmware download procedure The contact is wired to the Pulse Enable terminal of the SLM/
Red 2Hz is running. ALM module.
Green/ If the Main switch or contactor is operated while the drive is in
Orange Flashing Component recognition is active operation the pulses will be disabled and the motors will free
or Red/ 2 Hz (p0124 = 1) wheel to a standstill. (Except when the Safety Integrated func-
Orange tion “Safe Stop” is enabled)
Electronics power supply Any potentially harmful current will be unable to enter the drive
Off modules as the transistors are now switched off.
outside permitted range.
DC link voltage within tolerance-
Below is the timing diagram for the enabling of drives via the
DC LINK Orange On (Only if unit is configured and
controller using a line Contactor.
(Bottom) Ready)
DC link voltage outside tolerance
Red On (Only if unit is configured and
ready)
Motor connector (MM less than 45A) Minimum 10ms-

if supply disconnected
Screw terminals. Not while drive is operational
Fixing screw on Crimped cable Metal connector

types housing, also used
for cable shield Mains supply
E Stop active
DB56.DBX0.1
Brake: Negative Brake: Posi-
Connection tive Connec- Input to ALM/SLM via line switch
Enable Pulses
tion ALM/SLM
X21.3
Output/Input from/to 840D
Locating key- Locating key- In-feed ready.
Changeable From/to 840D sl
Link X132.8 to
X122.1 (OFF1)
Energise line Output from 840D

contactor–
Motor: Phase Motor: Phase Motor: Phase 840D sl X132.10
U V W Output
Input from N/O contact
Line contactor
energised-
840D sl X132.4
Input
For MM modules of 45A and above, the brake is supplied by a Input to ALM/SLM
separate connector (X11). OFF3 Enable
from user to
840D sl
The brake control circuit is isolated therefore it is not permissi-
X122.2
ble to connect the –ve brake connector to the 0 volt common of
the machine.
Notes

SLM 5 & 10Kw, (Not DriveCLiQ) no line contactor,
user controlled enable. X122 & X132 Digital I/O
I2t alarm Drive enable
From SLM to from SLM X21.1 to
user 840D X122.1
Mains (OFF1)
A051
supply

Main Early break OFF3 enable
Switch contact (E stop) from user
to 840D X122.2
Supply to other
equipment
X21
Line module X122 X132
Optional: Pulse
enable via user
PLC or 840D X122/ DriveCLiQ
X132
Page 14
+24V 24V DC 0V
PSU
Filter Reactor
Notes
A051
SLM 5 & 10Kw (Not DriveCLiQ) User controlled line
contactor and 840D sl controlled enables. X122 & X132 Digital I/O
Drive enable
A051
I2t alarm
From SLM to from SLM X21.1 to
user 840D X122.1
Mains
(OFF1)
supply

to 840D X122.2
Supply to other
equipment
X21
Optional: Pulse
enable via user
X132
0V +24V
Page 15
Line contactor Energise line
Line Early break energised- contactor-
Contactor contact to user PLC from user PLC
+24V 24V DC 0V
PSU
Filter Reactor
Notes
A051

ALM and SLM 16 & 36Kw.
No line contactor with 840D sl controlled enables.
X122 & X132 Digital I/O
Drive enable
from 840D X132.8
Mains to 840D X122.1
supply (OFF1)
A051

to 840D X122.2
Supply to other
equipment
X21
Optional: Pulse
enable via user
X132
Page 16
+24V 24V DC 0V
PSU
Filter Reactor
Notes
A051
ALM and SLM 16 & 36Kw. User controlled
line contactor and 840D sl controlled enables. X122 & X132 Digital I/O
A051
Drive enable
from 840D X132.8
Mains to 840D X122.1
supply (OFF1)

to 840D X122.2
Supply to other
equipment
X21
Optional: Pulse
enable via user
X132
0V 24V
Line contactor
Page 17
Energise line
Line Early break energised- contactor-
Contactor contact to user PLC from user PLC
+24V 24V DC 0V
PSU
Filter Reactor
Notes
A051

ALM and SLM 16 & 36Kw.
840D sl controlled enables and line contactor X122 & X132 Digital I/O
Drive enable
Mains from 840D X132.8
supply to 840D X122.1
Line contactor
(OFF1)
energised to
840D X132.4
A051 END

to 840D X122.2
Supply to other
equipment
X21
Line module X122 Energise line X132
contactor-
Optional: Pulse
from 840D
enable via user
DriveCLiQ X132.10
PLC or 840D
X122/X132
0V 24V
Page 18
Line Early break
Contactor contact
+24V 24V DC 0V
PSU
Filter Reactor
A051: END
Notes
A051
A008 Machine Control Panel Testing
Sinumerik
Operate
Module Description:
The Machine Control Panels (MCP) are connected to the system network X120 (Industrial Ethernet) of the
840D sl Sinumerik controller .
Each MCP, maximum of two, needs to be uniquely addressed via its addressing switch.
It is also necessary to understand the parameterisation of PLC function block FB1 to determine start address of
MCP I/O.
This module shows how the MCPs are addressed and how the parameterisation of the function block is made.
Module Objective:
Upon completion of this module the course participant will know how to:
 Set the address of an MCP.

 Cary out a signal test on an MCP
Content:
Sinumerik
Machine Control Panel Types
MCP483 PN Front and rear Layout
MCP310 PN Front and rear Layout
PLC Configuration
Machine Control Panel Addressing
Machine Control Panel Interface Signals
Machine Control Panel Signal Test
A008
A008

A008
Machine Control Panels: Description

Machine Control
Panels:
The Machine Control Panels (MCP) are connected to START
the system network X120 (Industrial Ethernet) of the
840D sl Sinumerik controller .
Each MCP, maximum of two, needs to be uniquely ad-

dressed via its addressing switch. Machine
It is also necessary to understand the parameterisation Control
of PLC function block FB1 to determine start address of Panel Types
MCP I/O.
This module shows how the MCPs are addressed and

how the parameterisation of the function block is made.
MCP483 Front
and Rear layout
MCP310 Front
and Rear layout
MCP
Configuration and
Addressing
Machine Control
Panel Interface
Signals
MCP Signal Test
Machine Control
Panels:
END
Notes

A008
Machine Control Panel Types:
Mechanical and membrane types of MCP are available in two formats (MCP483 and MCP310). The MCP483 is
483mm in width; the MCP310 is 310mm in width.
The major differences between the two formats are, the number of keys, layout of keys etc The input/output assign-
ment also differs.
The functionality and purpose of the two variants is, however, identical (Controlling of axes, mode selection etc)
There are no separate MCPs for turning or milling technologies.
MCP483:
6FC5303-0AF22-0AA1 MCP483C PN (Mechanical type keys)

6FC5303-0AF22-1AA1 MCP483 PN (Membrane type keys)
S1
MCP310:
6FC5303-0AF23-0AA1 MCP310C PN (Mechanical type keys)

6FC5303-0AF23-1AA1 MCP310 PN (Membrane type keys)
Notes

MCP483 Front Layout
JOG REP REF T1 T2 T3 X Y Z

Teach 4th 5th 6th
VAR 1 T4 T5 T6
Emergency in Axis Axis axis Spindle Feed
Stop Override Override
7 th 8th
MDA 10 100 T7 T8 T9
Axis Axis
MCS
Auto 1000 10000 T10 T11 T12
WCS
Page 5
Blank for Blank for Single Cycle Cycle Spindle Spindle Feed Feed Key
Reset T13 T14 T15 — Rapid + Switch
user user block Stop Start stop start Start Stop
Note:- Cycle stop, Feed stop & Spindle stop-signals are inverted i.e. Normally closed.
Buttons T1 to T15 are free for use by the manufacturer.
The two blanks can be removed to allow the user to add extra buttons/switches/lamps.
Notes
A008
A008
MCP483 Rear Layout
A008
A008
X10
X53
X54 X60 X61
X3 X51
X52
X55
X20
H3
H2
X30 H1 X21
Page 6
X5
S2
Interface Description:- X51 Digital inputs X60 Hand-wheel

S2 Addressing switch. X52 Digital inputs X61 Hand-wheel
X5 Key-switch interface X53 Digital outputs
X10 24V DC supply X54 Digital outputs
X20 Port 1 Ethernet connection in. X55 Digital inputs
X21 Port 2 Ethernet connection out.
X30 Feedrate override interface. LED Indicators:
X31 Spindle override interface. H1 Power OK (Green)
H2 BUSSYNC
H3 BUSFAULT
Notes

MCP310 Front Layout
Spindle Spindle
JOG REP REF VAR T1 T2 T3 100 %
Dec. Inc.
Blank for

spindle over-
Teach Spindle Spindle Spindle ride/ E stop
MDA T13 1 T4 T5 T6
In right stop left
Auto T14 T15 10 T7 T8 T9 X Y Z
Single 4th 5th 6th

Reset T16 100 T10 T11 T12
Block Axis Axis Axis
Feed
Override
Page 7
Cycle Cycle WCS Feed Feed
1000 - Rapid +
Stop Start MCS Stop Start
Key Blank for Blank for Blank for Blank for Blank for Blank for
Switch user user user user user user
Note:- Cycle stop, Feed stop & Spindle stop-signals are inverted i.e. Normally closed.
Buttons T1 to T16 are free for use by the manufacturer.
The six blanks can be removed to allow the user to add extra buttons/switches/lamps.
Notes
A008
A008
A008
MCP310 Rear Layout
X10
X53
X54 X60 X61
X31 X51
X52
X55
X20
H3
H2
H1
X30 X21
X5
S2
Interface Description:- X51 Digital inputs X60 Hand-wheel

S2 Addressing switch X52 Digital inputs X61 Hand-wheel
X5 Key-switch interface X53 Digital outputs
X10 24V DC supply X54 Digital outputs
X20 Port 1 Ethernet connection in. X55 Digital inputs
X21 Port 2 Ethernet connection out.
X30 Feedrate override interface. LED Indicators:
X31 Spindle override interface H1 Power OK (Green)
H2 BUSSYNC
H3 BUSFAULT
Notes

A008
Machine Control Panel Configuration and Addressing Each hardware item connected to the network needs a unique
address.
Determining the MCP start address. This is determined by the setting of S2 on the MCP.
Function Block FB1 is used for configuring the I/O assignment Each switch position from 1 to 8 represents a value which is
of the MCPs. active when the switch position is set to “On”.
Module “A033 PLC Functions” describes the full configuration All switches in the “On” position have their values added to-
procedure for the MCPs. gether to give the address of the MCP.
FB1 is called from within Organisation Block OB100. There are
many parameters associated with FB1. Switch positions 9 & 10 must always set to “Off” to enable
Ethernet operation.
The following is an example of FB1, the parameters for setting
the I/O start addresses for a single MCP. Switch S2: Positions and relevant values.
Switch S2 Value when in

Position “On” state
CALL FB 1 , DB 7(
1 1
MCPNum := 1,
MCP1In := P#I 0.0, 2 2
MCP1Out := P#Q 0.0, 3 4
MCP1StatSend := P#Q 8.0,
MCP1StatRec := P#Q 12.0, 4 8
MCP1BusAdr := 192, 5 16
MCPBusType := B#16#55,
6 32
NCKomm := TRUE,
ExtendAlMsg := FALSE); 7 64
8 128
9 Always OFF
10 Always OFF Switch S2
Parameter description:
The following table shows examples of S2 switch positions and
MCPNum Number of MCPs on the system. the resulting addresses, including the default address of 192.
MCP1In Pointer-The start address of the MCP inputs.

Meaning/
Switch S2
MCP1Out Pointer-The start address of the MCP outputs. address
10 9 8 7 6 5 4 3 2 1
MCP1BusAdr Addressing of MCP, set by dip-switch
Off Off - - - - - - - - Reserved
MCP1BusType Bus type; 55 = Ethernet
- - Off Off Off Off Off Off Off Off 0
- - Off Off Off Off Off Off Off On 1
The MCP is connected to X120 system network.
X120 is a DHCP server with a default IP address of - - Off Off Off Off Off Off On Off 2
192.168.214.1 and a subnet mask of 255.255.255.0. - - Off Off Off Off Off Off On On 3
- - : : : : : : : : :
192 (Delivery
- - On On Off Off Off Off Off Off
setting)
- - : : : : : : : : :
- - On On On On On On On Off 254
- - On On On On On On On On 255
Notes

A008
The following tables show the interface signals for an MCP483. The letter “n” should be substituted for the “Pointer” value
entered when FB1 was parameterised (MCP1IN, MCP2IN, MCP1Out and MCP2Out).
MCP483 PN Signals from machine control panel (keys)

Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
Spindle override Operating Mode
IBn
D C B A JOG TEACH IN MDA AUTO
IBn+1 REPOS REF INC var. 10000 INC INC 1000 INC 100 INC 10 INC 1
Key-switch Key-switch Feed *Feed

IBn+2 Spindle start *Spindle stop NC Start *NC Stop
position 0 position 2 start stop
Key-switch Feedrate override

IBn+3 Reset Single block
position 1
E D C B A
Direction keys Axis selection keys
Rapid Key switch
IBn+4 + - X 4th axis 7th axis
traverse position 3 R10
R15 R13 R1 R4 R7
R14
Axis selection keys
IBn+5 Y Z 5th axis MCS/WCS 8th axis 6th axis
R9
R2 R3 R5 R12 R8 R6
Unassigned customer keys
IBn+6
T9 T10 T11 T12 T13 T14 T15
IBn+7
T1 T2 T3 T4 T5 T6 T7 T8
IBn+10 KT-IN8 (X55.2) KT-IN7 (X55.1) KT-IN6 (X52.3) KT-IN5 (X52.2) KT-IN4 (X52.1) KT-IN3 (X51.3) KT-IN2 (X51.2) KT-IN1(X51.1)
IBn+11 KT-IN9 (X55.3)
MCP483 PN Signals to machine control panel (LEDs)

Machine function Operating mode
QBn
INC 1000 INC 100 INC 10 INC 1 JOG TEACH IN MDA AUTO
Feed *Feed
QBn+1 NC Start *NC Stop REPOS REF INC var. INC 10000
start stop
Single block
QBn+2 Direction Minus X 4th axis 7th axis
Spindle start *Spindle stop
R13 R1 R4 R7 R10
Z 5th axis 8th axis 6th axis Direction Plus

QBn+3 MCS/WCS
R3 R5 R11 R9 R8 R6 R15
Unassigned customer keys Y
QBn+4
T9 T10 T11 T12 T13 T14 T15 R2
QBn+5
T1 T2 T3 T4 T5 T6 T7 T8
QBn+6 Reset R14
KT-OUT6 KT-OUT5 KT-OUT4 KT-OUT3 KT-OUT2 KT-OUT1
QBn+7
(X54.3) (X54.2) (X54.1) (X53.3) (X53.2) (X53.1)
Signals marked with * are inverse signals.
Notes

A008
The following tables show the interface signals for an MCP310. The letter “n” should be substituted for the “Pointer” value en-
tered when FB1 was parameterised.
MCP310 PN Signals from machine control panel (keys)
IBn *NC Stop Spindle - Spindle 100% Spindle + Single block JOG MDA AUTO
NC Start Spindle right *Spindle stop Spindle left Key-switch REF REPOS Teach IN
IBn+1 position 3
Feed start *Feed stop INC var. Key-switch

IBn+2 position 0
INC 1000 INC 100 INC 10 INC 1
Feedrate override
IBn+3 Reset Key-switch Key-switch E (16) D (8) C (4) B (2) A (1)
Direction keys
Rapid KT-IN5 KT-IN4 KT-IN3 KT-IN2 KT-IN
IBn+4
traverse (X52.2) (X52.1) (X51.3) (X51.2) (X51.1)
+ -
IBn+5 Axis selection
T16 KT6(X52.3) 6th axis 5th axis 4th axis Z Y X
IBn+6 T9 T10 T11 T12 WCS MCS T13 T14 T15

IBn+7 T1 T2 T3 T4 T5 T6 T7 T8
IBn+10 KT-IN8 KT-IN7 KT-IN6 KT-IN5 KT-IN4 KT-IN3 KT-IN2 KT-IN
(X55.2) (X55.1) (X52.3) (X52.2) (X52.1) (X51.3) (X51.2) (X51.1)
IBn+11 KT-IN9
(X55.3)
Spindle override
IBn+13
E (16) D (8) C (4) B (2) A (1)
MCP 310 PN Signals to machine control panel (LEDs)

*NC Stop Spindle Dec. Spindle 100% Spindle Inc. Single Block JOG MDA AUTO
QBn
NC RESET REF REPOS Teach In
QBn+1 start
Spindle right *Spindle Stop Spindle left
Feed Start *Feed Stop INC var. INC 1000 INC 100 INC 10 INC 1
QBn+2
QBn+3
Minus Plus Rapid KT-OUT5 KT-OUT4 KT-OUT3 KT-OUT2 KT-OUT1
QBn+4 Direction Direction traverse (X54.2) (X54.1) (X53.3) (X53.2) (X53.1)
QBn+5 T16 KT-OUT6 6th axis 5th axis 4th axis Z Y X
T9 T10 T11 T12 MCS/WCS T13 T14 T15

QBn+6
QBn+7 T1 T2 T3 T4 T5 T6 T7 T8
Signals marked with * are inverse signals.
Notes

A008
Machine Control Panel Interface Signals MCP signal test
User I/O pin assignment The signals to and from the MCP can be checked using the on-
board diagnostic feature of the controller.
The 9 inputs and 6 outputs available on plugs X51 to X55 are To locate the diagnostic screens use the following soft-key
designed for use with switches/buttons and indicator lamps selection:
which can be installed in the blanked holes of the MCP.
Below shows the I/O assignment of each individual plug.
The input terminals in the normally open state measure 5V DC

(Supplied by the MCP)
The inputs work by sinking the 5V DC signals to 0V (M). On the screen it is possible to enter the inputs and outputs of
the MCP and check the functionality of each button/key.
The outputs terminals are supplied with +24Vdc from the MCP.
No external voltages should be applied to the input and output

terminals.
Input Assignment (X51, X52 & X55):
KT-IN1 KT-IN4
1 1
KT-IN2 KT-IN5
2 2
KT-IN3 KT-IN6
3 3
M (0 volts) M (0 volts)
4 4
X51 X52
KT-IN7
1 To ensure that the correct signal is selected, first check the
KT-IN8 FB1 parameterisation for the “Pointer” value (Page 9).
2 Secondly, refer to the relevant Machine Control Panel Interface
KT-IN9 Signal tables (Pages 10 & 11)
3
M (0 volts) Example:
4
X55 To test the NC start button input signal on an MCP310 with a
“Pointer” of 0, the input I1.7 needs to be monitored.
Output Assignment (X53 & X54): Cycle Start button not pressed:
KT-OUT1 KT-OUT4
1 1
2 KT-OUT2 2 KT-OUT5
KT-OUT3 KT-OUT6 Cycle Start button pressed:

3 3
M (0 volts) M (0 volts)
4 4
X53 X54
The outputs are capable of supplying 1.2 Watts per output, it is

not permissible to connect relays, valves or other inductive
devices.
A008: 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 Sinumerik con-
troller and the structure of its interface; this knowledge is required in order to produce a machine tool ori-
ented PLC program which adheres to the relevant safety regulations of the destination 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

A026
Creating a PLC program: Description Create

PLC Program:
START
The Step 7 PLC Programming package is used to create the
machine interface program for the 840D sl Sinumerik Oper-
ate.
In order to use the Step 7 package to its upmost, it is neces-
sary to know the structure of the Sinumerik controller and the Step 7-300
structure of its interface; this knowledge is required in order to PLC
produce a machine tool oriented PLC program which adheres
to the relevant safety regulations of the destination country.
840D sl
Sinumerik
Operate PLC
Integrate
Basic PLC
Basic PLC
Framework
Reserved
Functions and
Function
Blocks
Reserved
Data Blocks
Example:
Base
Program
Create
PLC Program:
END
Notes

A026
Step7 300 PLC PLC

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)
OB 1 (Program entry Cyclic)

....
CALL FCxxx FCxxx
.... ....
Statement List
....
Statement List Ladder diagram
.... ....
BE (Program end)
CALL FBxxx,DBxxx
....
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

A026
840D sl Sinumerik Operate PLC
PLC
Operating system
PII (Periphery Image Inputs)

NCK PLC User IF
Internal IF
DB2 Messages PII (Program Image Inputs)
TO Interface
From
FROM Interface
Interface OB 100 (Program startup)
DB7 FB1 Sinumerik System
To Inter- DB9 Compile Cycles Basic program Parameterisation CALL FB1,DB7
Parameters Startup Functions ——————————————-
face User Program Here
TO Interface Settings
....
FROM Interface .... Ladder diagram
.... BE (Program end)
Statement List
DB10 Mode Group
TO Interface
FROM Interface FC 2 Cyclic to/from BE (Program end)
PLC User / NCK
Internal
DB11 NC OB 1 (Program entry Cyclic)
TO Interface Sinumerik System
FC2 CALL FC2
FROM Interface ———————————-
Sinumerik 840D
User Program Here:
PLC Basic
Program
DB19 HMI INTERFACE
Control CALL FBxxx,DBxxx
TO Interface ....
BE (Program end) Ladder diagram
FROM Interface
Or
DB21 Channel
Statement List
DBxxx Instance FBxxx
TO Interface .... ....
.... Statement List
FROM Interface
.... ....
.... Ladder diagram
.... ....
DB31 Axis BE (Program end)
TO Interface
BE (Program end Cyclic)
FROM Interface
DB71,72,73 PIO (Program Image outputs)

Tool Management
TO Interface
NCK Cyclic to/
from FROM Interface PIO (Periphery Image Outputs)
PLC User IF
PLC
Operating system
Notes

A026
Integrate 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
Hardware configurati-
has to be integrated into the User Project.
on tool; open to se-
lect the PLC hard-
Toolbox Installation: ware.
Toolbox installati-
on CD
Sinumerik Library;
open and copy to
project.
Hardware configuration displaying the Sinumerik Addon

components:
Installation of Basic program

and additional support tools. Hardware
:Sinumerik Addons Configuration
: NC Var Selector
: Symbol generator
Sinumerik
“Addons”
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“
Notes

A026
Basic PLC Framework
Upon successful integration of the “sinumerik Hardware“ and Machine periphery in the Hardware configuration utility, the compi-
lation 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 overwrit-
ten.
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

A026
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

A026
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
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 1) see below: ShopMill, ShopTurn
1000 ... 1099 Reserved for Siemens
1100 ... High Free for user assignment

limit
1)
The actual upper limit of the block number (DB) depends on the PLC CPU on which the selected NCU is lo-
cated. The data blocks of channels, axes/spindles and tool management functions that are not activated may be
assigned as desired by the user.
Notes

A026
Example: Base Program Integration Configure the Profibus network
Create a New Project e.g. 840Dsl Sinumerik Operate.
Start the Step 7 Hardware configuration
Select the Sinumerik controller from menu tree.
Notes

A026
Add additional components Additional axes can be added e.g. NX Boards
Save and compile the project.
Notes

A026
After a successful compilation, the Step7 Program Objects The Library, as it appears in the Step 7 editor.
are available to the user.
The Library and the user program open in the Step 7 editor.
You can now search for the Library which was installed from
the Toolbox, and open it in the Step 7 editor.
Notes

A026
Program blocks in the PLC Basic Program. Copying of the Program Blocks from Library to User program.
Always overwrite OB1 when copying from the Library, otherwi-

se the Basic PLC will not be called with FC2.
The Library blocks are now present in the user project.
Source code in the PLC Basic Program.
Notes

A026
Copying of the Source Blocks from Library to User program After successful integration of the Basic PLC Program, OB1
and OB100 should look the same as in the following two
examples.
OB1:
OB100:
Copying of the Symbol Table from Library to User program.
A026: END
Notes

A034 PLC Interface Structure
Sinumerik
Operate
Module Description:
Information to and from the different system areas of the controller is handled by interfaces. This module
shows how the different areas communicate .
Module Objective:
Upon completion of this module you will know the Sinumerik 840D sl PLC interface structure and use it to
help write the PLC program and also in service cases diagnose PLC faults.
Content:
Sinumerik
Interface Structure Overview
Interface Description
A034
A034

A034
PLC Interface Structure: Description PLC Interface

Structure:
START
Information to and from the different system areas of the
controller are handled by interfaces. This module shows how
the different areas communicate .
Interface
Structure
Overview
Interface
Description
PLC Interface
Structure:
END
Notes

A034
Interface Structure Overview
To enable the user to influence the system, an interface is provided. This interface operates with variables in Bit, Byte, Word &
Double Word formats. e.g:-
Bit:-DB31.DBX0.0
Byte:-DB31.DBB0
Word:-DB31.DBW0
Double Word:-DB31.DBD0
The interface is used to control/monitor the NC, HMI & Drive areas of the system via the user PLC.
Interface Structure:-
PLC User NC
Interface
PLC User
Program
Periphery Drives
Devices-
PP72/48, MCP.
HMI
Notes

A034
Notes

A034
Interface Description
Signals from/to Operator Component
Machine control panel, M version
Signals from machine control panel (keys)

Input display

IB n + 0 Spindle speed override Operating mode
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 Key- Feedrate override
switch posi-
tion 1
Reset Single block 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

A034
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
R2
T9 T10 T11 T12 T13 T14 T15
QB n + 5 Unassigned customer keys
T1 T2 T3 T4 T5 T6 T7 T8
Notes

A034
Machine control panel, T version
Signals from machine control panel (keys)

Input display

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 Keyswitch Feed override
position 1
Reset Single block 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 traver- Travel com- -Y -X +Z
R2 R3 se override mand MCS/ R11 R9 R8 R6
R5 WCS
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
MCS/WCS
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

A034
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 Spindle speed override Operating mode
NC Stop SP - SP 100 % SP + SINGLEB JOG MDA AUTO
QB n + 1 Spindle Machine function

NC Start 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

A034
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-
Notes

A034
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
QB n + 4 Digital display of handheld unit

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

A034
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

A034
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

A034
PLC alarms / messages

FC 10 alarms in DB2 (FB1-Parameter "ExtendAlMsg"=False
Channel areas
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

A034
type)
Channel 2
18 (EM) 520007 520006 520005 520004 520003 520002 520001 520000
19 (OM) 520015 520014 520013 520012 520011 520010 520009 520008
Notes

A034

(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

A034

(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

A034

(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

A034

(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

A034

(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

A034

(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 unrealized
Notes

A034
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

A034
type)
axis/spindle
axis 19 – 31 unrealized
Notes

A034
User areas im 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

A034

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

A034

(Message type)
Notes

A034
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

A034
type)
Channel 1
310 (EM) 510007 510006 510005 510004 510003 510002 510001 510000
311 (OM) 510015 510014 510013 510012 510011 510010 510009 510008
Notes

A034
type)
Channel 2
328 (EM) 520007 520006 520005 520004 520003 520002 520001 520000
329 (OM) 520015 520014 520013 520012 520011 520010 520009 520008
Notes

A034
type)
Channel 3
346 (EM) 530007 530006 530005 530004 530003 530002 530001 530000
347 (OM) 530015 530014 530013 530012 530011 530010 530009 530008
Notes

A034
type)
Channel 4
364 (EM) 540007 540006 540005 540004 540003 540002 540001 540000
365 (OM) 540015 540014 540013 540012 540011 540010 540009 540008
Notes

A034
type)
Channel 5
382 (EM) 550007 550006 550005 550004 550003 550002 550001 550000
383 (OM) 550015 550014 550013 550012 550011 550010 550009 550008
Notes

A034
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

A034
type)
Channel 7
418 (EM) 570007 570006 570005 570004 570003 570002 570001 570000
419 (OM) 570015 570014 570013 570012 570011 570010 570009 570008
Notes

A034
type)
Channel 8
436 (EM) 580007 580006 580005 580004 580003 580002 580001 580000
437 (OM) 580015 580014 580013 580012 580011 580010 580009 580008
Notes

A034
Channel 9
454 (EM) 590007 590006 590005 590004 590003 590002 590001 590000
455 (OM) 590015 590014 590013 590012 590011 590010 590009 590008
Notes

A034
type)
Channel 10
472 (EM) 500007 500006 500005 500004 500003 500002 500001 500000
473 (OM) 500015 500014 500013 500012 500011 500010 500009 500008

(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

A034

(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

A034

(Message
type)
Notes

A034
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

A034

(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

A034

(Message type)
Notes

A034

(Message type)
Notes

A034
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

A034
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

A034
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

A034
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

A034
General signals from NCK (DB10)

DBB104 NCK CPU 1 st
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
DBB106 EMER- Collision detec-

GENCY Stop tion off
active /Z2-M5/
DBB107 Inch system NCU-link Probe actuated

/Z1-G2/ active /Z2-M5/
/Z2-B3/
Probe 2 Probe 1
DBB108 NC Drive ready / Drives in HMI CPU HMI 2 CPU HMI2 CPU
Z1-A2/ Ready Ready
ready /Z1 cyclic opera-
(HMI to (HMI to MPI)
ready
-A2/ 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

A034

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

A034
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

A034
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

A034
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

A034
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

A034
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

A034
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
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

A034
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
/Z1-K1/
REF REPOS TEACH IN
DBB28 Machine functions
Notes

A034
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
SPL_DATA.INSIP [1..32]
DBD54
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

A034

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

A034
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

A034
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

A034
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

A034
SPL user data
DB18 SPL-Signals (PLC  NCK)

DBD256 SPL_USER_DATA[0]
Notes

A034
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/
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

A034
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
DBB32 FunctionSelectionNo. from PLC
PLC à HMI Busy func- Strobe func-

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

A034

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

function function
HMI à PLC
DBB49 Error code for FunctionSelectionNo. (function selection from DBB48)
PLC à 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

A034

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

st
1 online interface
DBB119 TCU index

2nd 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/

PLC writes PAR_MMC_TYP to MMCx_TYP when HMI goes online.
DBB123 MMC1_MSTT_ADR /Z2-B3/

PLC writes PAR_MSTT_ADR to MMCx_MSTT_ADR when HMI goes online.
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/
Notes

A034

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

A034
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

A034
Channel signals (DB21 - DB30)

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

DB21 -
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)
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-
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/
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

A034
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

A034
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
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 
DBB35 Channel status /Z1-K1/ Program status /Z1-K1/

NCK 
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

A034
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

A034
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

A034
Change signals on auxiliary function transfer from NC channel
DB21 –
DB30 Signals from NCK channel (NCKPLC)
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/
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

A034
Transferred M/S functions
DB21 –
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

A034
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

A034
Transferred H/F functions
DB21 -
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

A034
Decoded M signals (M0–M99)
DB21 – Signals from NCK channel (NCKPLC)

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

A034
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

A034
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

A034
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
/F1/A2 active active /FB3/F2/
stopped
/FB1/V1/ /FB3/H2/ /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

A034
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

A034

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

A034
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

A034
Signals from/to NC channel
DB21 – Signals from NCK channel (NCKPLC)

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 conditi- Stop follow-

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

A034
DB21 - Signals to NCK channel (PLC  NCK, NCK  PLC)

DB30
Control pro-
DBB384
gram
PLCàNCK branch
DBB385
DBB386
DBB387
DBB388 Active transformation number
NCKàPLC
DBB389
DBB390
DBB391
Notes

A034
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

A034

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 appro- point appro- point appro-
Axis ach 2 ach 1 ach 0
Activate pro- Suppress

DBB14 gram 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 In- communi- and standstill
tegr. bit value 1 bit value 0 cation failure
Notes

A034

DB61
Activate test SINAMICS Activate end

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

on CTRLOUT_changed: ausgleichs- Achse ern
Drehüber-
Regler
1 0 Kopplung wachung
DBB24 Sollwertausgabezuord. än- Ein unter-
dern 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- OscillA-
DBB28 axis /Z2-P5/ reversal point versal point point /Z2-P2/ Reset xExtReversal
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

A034

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

A034
DB31 – Signale von Achse/Spindel (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

A034

DB61
Modulo limit
DBB74
enabled ac-
Axis tive
JOG- Position JOG fixed-point approach JOG fixed-point approach
DBB75 position rea- JOG active reached active
Axis ched 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
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
Notes

A034

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/
DBB102
Gantry
Syn-
chronism
DBB103
being consi-
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+
n < nx Safe velocity active SG Safe zero
DBB110 speed active
B A
Safety Integr.
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

A034

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

A034
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 Acknow-
tended area ledgemen
(DB1071) t
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

A034
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

A034
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 Acknow-

extended ledgemen
t
area Status = 3
(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

A034
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

A034
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 exten- Reserved Reserved Reserved Reserved Reserved Reserved Acknowl-
ded 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)

Tool new: size left (INT)
DBW n + 30
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

A034
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

A034
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
Multitool location number (tool new)

DBW n+10
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

A034
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

A034
Signals to/from the machine control panel and HHU

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)
Notes

A034 END
A034: END
Notes

A033 PLC Functions
Sinumerik
Operate
Module Description:
The following functions are available in the PLC:
 PLC Start-up parameterisation

 MCP (Machine Control Panel) Transfer
 Reading and Writing of NC Variables
 PI Services
 Reading Global User Data’s
 Starting ASUP
 Axis / Spindle control
Module Objective:
Upon completion of this module you will be able to perform the above listed PLC tasks.
Content:
Sinumerik
PLC Start-up parameterisation
MCP (Machine Control Panel) Transfer
Reading and Writing of NC Variables
PI Services
Reading Global User Data´s
Starting ASUP
Axis / Spindle control
840D sl Sinumerik Operate Page 1 This document was produced for training purposes.
A033
A033

A033
PLC Functions: Description PLC

Functions:
START
The following functions are available in the PLC:
 PLC Start-up parameterisation

 MCP (Machine Control Panel) Transfer PLC Start-up
Parameteri-
 Reading and Writing of NC Variables sation
 PI Services
 Reading Global User Data´s
 Starting ASUP
 Activation of Alarms MCP
 Axis / Spindle control Transfer
 PLC data to NC Program
Reading and
Writing of
NC Variables
PI Services
Reading
Global User
data´s
Starting ASUP
Axis / Spindle
control
PLC
Functions:
END
Notes

A033
PLC Start-up parameterisation In addition to the Interface being configured, various other
functions are implemented.
The PLC interface is made up of a series of Step 7 Data
Blocks, the number and length of the data blocks is determi- including:-
ned by the system on startup.
 Define the number of MCPs
The machine tool builder can also influence this process and
others using the parameterisation possibilities of the PLC Ba-  Define the address range of MCPs
sic program in OB100.
The parameterisation is carried out with the direct parameteri-

 Defining the type of MCP
sation of the Function Block 1 in the OB100 start-up routine,
these values are made available to the PLC Basic program  Hand held unit configuration
through the use of an Instance DB (DB7) of the FB1.
 PLC Communication to NCK option
Example:-
 Alarm configuration
ORGANIZATION_BLOCK OB 100
TITLE =
{ S7_language := '9(1) English (United States) The parameters of FB1 and their meaning can be found on
13.10.2010 16:56:20' } the following pages.
VERSION : 1.0
VAR_TEMP
OB100_EV_CLASS : BYTE ;
OB100_STRTUP : BYTE ;
OB100_PRIORITY : BYTE ;
OB100_OB_NUMBR : BYTE ;
OB100_RESERVED_1 : BYTE ;
OB100_RESERVED_2 : BYTE ;
OB100_STOP : WORD ;
OB100_RESERVED_3 : WORD ;
OB100_RESERVED_4 : 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,
MCP1StatRec := P#Q 12.0,
MCP1BusAdr := 192,
NCKomm := TRUE);
//Insert User program from here
END_ORGANIZATION_BLOCK
Notes

A033
Parameter description of FB1
Signal Type Format Value range Comment
MCPNum I INT Up to 2 Number of active MCP
0: No MCPs available
MCP1In I POINTER E0.0 to E120.0 Start address for input signals of relevant
MCP2In or machine control panel
M0.0 to M248.0
or
DBn DBX0.0 to DBXm.0
MCP1Out I POINTER A0.0 to A120.0 Start address for output signals of rele-
MCP2Out or vant machine control panel
M0.0 to M248.0
or
MCP1StatSend I POINTER A0.0 to A124.0 Currently no significance
MCP2StatSend or
M0.0 to M252.0
or
MCP1StatRec I POINTER A0.0 to A124.0 Currently no significance
MCP2StatRec or
M0.0 to M252.0
or
MCP1BusAdr I INT 1 ... 126 DP slave: PROFIBUS address
MCP2BusAdr 192 .. 223 Ethernet MCP: DIP-Setting
MCP1Timeout I S5time Recommendation: 700 ms Cyclic sign-of-life monitoring for machine
MCP2Timeout control panel
MCP1Cycl I S5time Recommendation: 200 ms Relevant only for PROFIBUS

MCP2Cycl
MCPMPI I BOOL false Available owing to compatibility
MCP1Stop I BOOL 0: Start transfer of machine control

MCP2Stop panel signals
1: Stop transfer of machine control
panel signals
DP slave: Slave deactivated
MCP1NotSend I BOOL 0: Send and receive operation activated

MCP2NotSend
1: Receive machine control panel sig-
nals only
MCPSDB210 I BOOL false Available owing to compatibility
MCPCopyDB77 I BOOL false Available owing to compatibility
MCPBusType I BYTE Righthand half byte (bits 0...3) for MCP1

Lefthand half 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
Notes

A033
Parameter description of FB1 - cont.

BHG I INT 0, 5 Handheld unit interface
0: No HHU
5: HHU on Ethernet
BHGIn I POINTER E0.0 to E124.0 Start address

or PLC receive data
M0.0 to M252.0 from HHU
or
BHGOut I POINTER A0.0 to A124.0 Start address

or PLC transmit data
M0.0 to M252.0 to HHU
or
BHGStatSend I POINTER A0.0 to A124.0 Available owing to compatibility

or
M0.0 to M252.0
or
BHGStatRec I POINTER A0.0 to A124.0 Available owing to compatibility

or
M0.0 to M252.0
or
BHGInLen I BYTE HHU default: Available owing to compatibility
BHGOutLen I BYTE HHU default: Available owing to compatibility
BHGTimeout I S5time Recommendation: 700 ms Available owing to compatibility
BHGCycl I S5time Recommendation: 100 ms Available owing to compatibility
BHGRecGDNo I INT HHU default: 2 Ethernet DIP switch
BHGRecGBZNo I INT HHU default: 2 Available owing to compatibility
BHGRecObjNo I INT HHU default: 1 Available owing to compatibility
Notes

A033

BHGSendGDNo I INT HHU default: 2 Available owing to compatibility
BHGSendGBZNo I Int HHU default: 1 Available owing to compatibility
BHGSendObjNo I INT HHU default: 1 Available owing to compatibility
BHGMPI I BOOL false Available owing to compatibility
BHGStop I BOOL 0: Start transmission

of handheld unit signals
1: Stop transmission
of handheld unit signals
BHGNotSend I BOOL 0: Send and receive operation activated
1: Receive handheld unit signals only
NCCyclTimeout I S5time Recommendation: 200 ms Cyclic sign-of-life monitoring NCK
NCRunupTimeout I S5time Recommendation: 50 s Power-up monitoring NCK
ListMDecGrp I INT 0 ... 16 Activation of expanded

M group decoding
0: Not active
1...16: Number of M groups
NCKomm I BOOL PLC NC communications services

(FB 2/3/4/5/7:
Put/Get/PI_SERV/GETGUD)
TRUE: active
MMCToIF I BOOL Transmission of HMI signals to interface

(modes, program control etc.)
TRUE: Active
HWheelMMC I BOOL TRUE: Handwheel selection via HMI
FALSE: Handwheel selection via user

program
ExtendAlMsg I BOOL Activation extension of the FC10 (see Sec-
tion "Structure and Functions of the basic
program")
MsgUser I INT 0 ... 32 Number of user areas for messages (DB2)
UserIR I BOOL Local data expansion OB40 required for

processing of signals from user
IRAuxfuT I BOOL Evaluate T function in OB40
IRAuxfuH I BOOL Evaluate H function in OB40
IRAuxfuE I BOOL Evaluate DL function in OB40
Notes

A033

UserVersion I POINTER DBxx Pointer to string variable.
The associated string variable is indicated
in the version display
(max. 41 characters).
OpKeyNum I INT 0 ... 2 Number of active
Direct control key modules
0: no Ethernet direct control keys avail-
able.
Op1KeyIn I POINTER P#Ex.0 Start address for the input signals of the
Op2KeyIn or affected direct control key modules
P#Mx.0
or
P#DBn.DBXx.0.
Op1KeyOut I POINTER P#Ax.0 Start address for the output signals of the
Op2KeyOut or affected direct control key modules
P#Mx.0
or
P#DBn.DBXx.0.
Op1KeyBusAdr I INT 1 ... 191 Direct control keys via
Op2KeyBusAdr Ethernet: TCU Index:
Op1KeyStop I BOOL 0: Start transmission
Op2KeyStop of direct control key signals
1: Stop transmission
of direct control key signals
Op1KeyNotSend I BOOL 0: Send and receive operation activated
Op2KeyNotSend
1: Receive
direct control key signals only
OpKeyBusType I BYTE b#16#55 b#16#55: Ethernet
IdentMcpBusAdr I INT 1 ... 254 only IE devices
IdentMcpProfilNo I BYTE 0, 1 Profile of a device
0: complete device
1: only direct control keys
IdentMcpBusType I BYTE b#16#5 only IE devices
IdentMcpStrobe I BOOL Activate query
MaxBAG Q INT 1 ... 10 Number of mode groups
MaxChan Q INT 1 ... 10 Number of channels
MaxAxis Q INT 1 ... 31 Number of axes
ActivChan Q ARRAY[1...10] Bit string for active channels

OF BOOL
Notes

A033

ActivAxis Q ARRAY[1..31] Bit string for active axes
OF BOOL
UDInt Q INT Quantity of INTEGER machine data in
DB20
UDHex Q INT Quantity of hexadecimal machine data in
DB20
UDReal Q INT Quantity of REAL machine data in
DB20
IdentMcpType Q BYTE Type (HT2, HT8, ...)
IdentMcpLengthIn Q BYTE Length info

input data in PLC
IdentMcpLengthOut Q BYTE Length info
output data in PLC
Notes

A033
MCP (Machine Control Panel) Transfer Steps to achieve running function:
Parameterisation of the corresponding Function.
Function Description:
Parameter description of FC19
With the following Step 7 Functions, the Machine Control Pa-
nel signals can be transferred from the MCP periphery to the
Signal Type Format Range of Remark
corresponding signal at the PLC --> NCK Interface.
values
If a standard signal transfer is acceptable then one of the follo-
wing Step 7 Functions can be called, dependant upon the BAGNo I BYTE 0 - b#16#0A No. of mode group to
MCP type. and which the mode sig-
b#16#10 - nals are transferred.
FC19 MCP 19“ Milling b#16#1A BAGNo >= b#16#10
means access to the
FC25 MCP 19“ Turning second machine con-
trol panel.
FC24 MCP small
ChanNo I BYTE 0 - B#16#0A Channel no. for the
channel signals
FC26 HT6
SpindleIFNo I BYTE 0 - 31 Number of the axis
The following group signals are transferred: (B#16#1F) interface declared as a
spindle
Mode Groups FeedHold Q BOOL Feed stop from MCP,
modal
Axis selections
SpindleHold Q BOOL Spindle stop from
WCS/MCS switchover commands MCP, modal
Traversing keys
Overrides
Key-operated switch
Prerequisites for the Function:
MCP Hardware available.
HMI Requirement:
None
Drive requirement (Sinamics):

None
NCK Requirement:
None
PLC Requirement:
Parameterisation of the corresponding Step 7 Function.
Notes

A033
Reading and Writing of NC Variables Steps to achieve running function:
Before parameterising FB2 or FB3 the address of the variab-

Function Description: le has to be known,and stored in a user Data Block.
This is carried out with the NC Var selector tool.
During the manufacturing process it may be necessary to have In order to create the address data the following steps should
data available to the NC program from the automation system be followed:
in order to optimize the NC machining process.
This could take the form of a numerical value being transferred Start the NC Var Selector
to an R Parameter or a machine setting data receiving from
the automation system an optimised value.
In the opposite direction it may be necessary to influence the
automation system dependent upon the current NC machining
process, positional data available in the automation system is
an example of this.
Two function blocks are available for the function of :
Reading NC data - FB2

Writing NC data - FB3
Start a new Project
In addition to the FBs, a tool is available for the engineering
PC, this tool is required for generating the necessary parame-
ter values for the two function blocks.
The tool is called (NC Var selector).
The parameter values which are obtained from the NC Var

selector point to the storage location within the NC which are
required as destination or as source, determined by a READ
or WRITE function.
The NC Var selector is part of the PLC Toolbox.

The correct variable database has to be selected with
The prerequisite for the function, is the parameter: each new project, in the case of Sinumerik Operate
(2.6)
NCKomm := True
The parameter belongs to FB1 which is parameterised

in OB100.
HMI Requirement:
None
Drive requirement (Sinamics):
None
NCK Requirement:
None
PLC Requirement:
Parameterisation of FB2 or FB3 in the PLC
Notes
840D sl Sinumerik Operate Page 11

A033
Upon database selection, a complete list of the available vari-

ables are displayed.
The variables can be inserted into the users project using the
The name and the address of the required variable can now right mouse button, in some cases an input window will ap-
be selected from the list af available variables. pear, further parameterisation can be carried out at this point.
In order to make the selection of the variable easier, a E.g. Channel / axis number etc...
comprehensive help file is available.
Notes

A033
It can be seen in the following screenshot that the possibilty When the user has completed the selection of the necessary
exists also to parameterise a variable with the value zero (0). variables, the user variable table can be saved.
In this case the user structure which is generated by the NC The file can be saved to a project directory, this directory is
Var selector can be further parameterised in the PLC user free for the user.
program, thus offering an even higher degree of flexibility to The format of the file is „Step 7 source code“ with the data
the user. type STRUCT. The STRUCT is contained in a Data Block
container, this Date Block can be configured in the Code se-
lections menu.
Configuration of user DB
In the following screenshot. Two R parameters are used as

an example. Saving of var file (variable file)
The first with fixed parameterisation, not parameterising with
zero, and the second using parameterised value zero.
It is therefore possible to manipulate the number of the R
parameter in the user PLC program.
Notes

A033
The following describes how the STRUCT information is It is recommended that the option „transfer DB and Symbol“
transferred into the Step 7 project. be set.
The following screenshot shows the DB number and symbol
In the following screenshot, the marked area indicates the link name in the Step 7 Symbol table.
where the user can select the AWL file name and generate
the foresaid file.
This AWL can now be opened in the Step 7 editor, and can
be compiled into S7 DB Format for useage as a parameter
value to the FB2 or FB3.
The AWL file can be inserted directly into the Step 7 project
with the marked icon green.
A window allows the project and path to be defined, and with

OK you will find your AWL information in the source file folder
of your Step 7 project.
Notes

A033
GET FB2
After successful compilation in Step 7
values
Req I BOOL Job start with positive
signal edge
NumVar I INT 1 ... 8 Number of variables to
(corresponds be read
to use of Addr1
to Addr8)
Addr1 to I ANY [DBName]. Variable identifiers from
Addr8 [VarName] NC Var selector
Unit1 to Unit8 I BYTE Area address, optional
for variable addressing
Column1 to I WORD Column address, op-
Column8 tional for variable ad-
dressing
Line1 to I WORD Line address, optional
Line8 for variable addressing
Error Q BOOL Negative acknowledg-
ment of job or execution
of job impossible
NDR Q BOOL Job successfully exe-
cuted Data are available
State Q WORD See error identifiers

RD1 to RD8 I/Q ANY P#Mm.n BYTE Target area for read
x... data
P#DBnr.dbxm.
n BYTE x
PUT FB3
values
The call and parameterisation of the FB2 and FB3 can now Req I BOOL Job start with positive
take place according to the following parameter description: signal edge
NumVar I INT 1 to 8 Number of variables to
(corresponds to be written
use of Addr1 to
Addr8)
Addr1 to Addr8 I ANY [DBName]. Variable identifiers from
[VarName] NC Var selector
Unit 1 to Unit 8 I BYTE Area address, optional
Column 1 to I WORD Column address, op-
Column 8 tional for variable ad-
dressing
Line 1 to Line 8 I WORD Line address, optional
ment of job or execu-
tion of job impossible
Done Q BOOL Job successfully exe-
cuted
SD1 to SD8 I/Q ANY P#Mm.n BYTE Data to be written
x...
P#DBnr.dbxm.
n BYTE x
Notes

A033
Reading and Writing of NC variables is only possible with the Symbol table showing the Symbol name and Absolute name
FB1,DB7 variable: NCKomm:= true of the VAR Data Block
TITLE =
{ S7_language := '9(1) English (United States) 13.10.2010
16:56:20' }
VERSION : 1.0
BEGIN
NETWORK
TITLE =
CALL FB 1 , DB 7 (
MCPNum := 1,
MCP1In := P#I 0.0,
MCP1Out := P#Q 0.0,
MCP1BusAdr := 192,
NCKomm := TRUE); Option Content of VAR DB with symbol name.
Example Reading and writing R parameter.

// -------------------------------------------------------
// File : E:\NCVar Projects\DBData.awl
FUNCTION "Read-Write NC" : VOID //
TITLE = // Source File : E:\NCVar Projects\DBData.var
VERSION : 0.1 // Generation Date: 16/12/2010 Time: 16:02:55
// -------------------------------------------------------
BEGIN
NETWORK DATA_BLOCK DB 120 Ncvar = Symbol name
TITLE =Read R parameter VERSION : 0.0
A I 17.0;
FP M 110.0; // Transition Marker STRUCT
S M 110.1;
A M 110.3; C1_RP_rpa1_1:
FP M 110.4; // Transition Marker STRUCT
R M 110.1; SYNTAX_ID : BYTE := B#16#82;
CALL "GET" , DB 110 ( Area_Unit : BYTE := B#16#41;
Req := M 110.1, Column : WORD := W#16#1;
NumVar := 1, Line : WORD := W#16#1;
Addr1 := "ncvar".C1_RP_rpa1_1, BlockType : BYTE := B#16#15;
Error := M 110.2, NumOfLine : BYTE := B#16#1;
NDR := M 110.3, DataType : BYTE := B#16#F;
State := MW 111, Length : BYTE := B#16#8;
RD1 := MD 113); END_STRUCT ;
NETWORK C1_RP_rpa0_1:
TITLE =Write R parameter STRUCT
SYNTAX_ID : BYTE := B#16#82;
A I 17.1; Area_Unit : BYTE := B#16#41;
FP M 117.0; // Transition Marker Column : WORD := W#16#1;
S M 117.1; Line : WORD := W#16#0;
A M 117.3; BlockType : BYTE := B#16#15;
FP M 117.4; // Transition Marker NumOfLine : BYTE := B#16#1;
R M 117.1; DataType : BYTE := B#16#F;
CALL "PUT" , DB 111 ( Length : BYTE := B#16#8;
Req := M 117.1, END_STRUCT ;
NumVar := 1,
Addr1 := "ncvar".C1_RP_rpa0_1, END_STRUCT ;
Line1 := W#16#2,
Error := M 117.2, BEGIN
Done := M 117.3, END_DATA_BLOCK
State := MW 118,
SD1 := MD 113);
END_FUNCTION
Notes

A033
PI Services Function Description: cont.
PI services are typically mimics of Operator actions which

can be carried out from the PLC.
A typical example is the setting and the resetting of the pass-
The following PI services are available: word, this is an action which is often carried out by the ope-
rator but can also be automated using the PLC program.
PI service Function
It is therefore possible to automate the deactivation of the
ASUP Assign interrupt password at system startup,
CANCEL Execute cancel
CONFIG Reconfiguration of tagged machine data Prerequisites for the Function:
NCK prerequisite is dependant upon the function.
DIGION Digitizing on
DIGIOF Digitizing off PLC Prerequisite:
FINDBL Activate block search

The prerequisite for the function, is the parameter:
LOGIN Activate password
LOGOUT Reset password NCKomm := True
HMI Requirement:
NCRES Trigger NC-RESET None
The parameter belongs to FB1 which is
parameterised in OB100.
SELECT Select program for processing for one
channel
SETUDT Sets the current user data to active
SETUFR Drive requirement (Sinamics):
Activate user frame
None
PI service Function
NCK Requirement:
CRCEDN Create new cutting edge Dependant upon function
CREACE Create cutting edge
PLC Requirement:
CREATO Generate tool Parameterisation of FB4 or FB7 in the PLC
DELECE Delete a cutting edge
Steps to achieve running function:
DELETO Delete tool
MMCSEM Semaphores for various PI services
TMCRTO Create tool TITLE =
{ S7_language := '9(1) English (United States) 13.10.2010
TMFDPL Empty location search for loading 16:56:20' }
VERSION : 1.0
TMFPBP Empty location search
BEGIN
NETWORK
TMGETT T-number for the specified tool identifier TITLE =
with duplo number
TMMVTL Prepare magazine location for loading, CALL FB 1 , DB 7 (
unload tool MCPNum := 1,
TMPOSM Position magazine location or tool MCP1In := P#I 0.0,
MCP1Out := P#Q 0.0,
TMPCIT Set increment value for workpiece counter MCP1StatRec := P#Q 12.0,
MCP1BusAdr := 192,
TMRASS Reset active status MCPBusType := B#16#55,
NCKomm := TRUE); Option
TRESMO Reset monitoring values
TSEARC Complex search using search screen //Insert User program from here
forms
Notes

A033
Parameter description of FB4 Example of Password Login and Logout

Signal Type Format Range of values Remark FUNCTION "PIServices" : VOID
Req I BOOL Job request A I 17.2;
FP M 122.0; // Transition Marker
PIService I ANY [DBName]. PI service S M 122.1;
[VarName] description1) A M 122.3;
Standard is: "PI". FP M 122.4; // Transition Marker
[VarName] R M 122.1;
CALL "PI_SERV" , DB 112 (
Unit I INT 1... Area number Req := M 122.1,
PIService := "PI".LOGOUT,
Addr1 to I ANY [DBName]. Reference to strings Unit := 1,
Addr4 [VarName] specification accord- Error := M 122.2,
ing to selected PI Done := M 122.3,
State := MW 123);
service
WVar1 to I WORD 1... INTEGER or WORD A I 17.3;
WVar10 variables. Specifica- S M 125.1;
tion according to A M 125.3;
selected PI service, FP M 125.4; // Transition Marker
R M 125.1;
Error Q BOOL Negative acknowl- CALL "PI_SERV" , DB 113 (
edgment of job or Req := M 125.1,
PIService := "PI".LOGIN,
execution of job im- Unit := 1,
possible Addr1 := P#DB120.DBX78.0 BYTE 10,
Error := M 125.2,
Done Q BOOL Job successfully Done := M 125.3,
executed State := MW 126);
END_FUNCTION
Error codes
Parameter part for Addr1 -- PI Login
State Significance Note
3 Negative acknowledg- Internal error, try:

ment, job not NC RESET
executable
6 FIFO full Job must be repeated
since queue is full
7 Option not set BP parameter
"NCKomm" is not set
9 Transmission occupied Job must be repeated
13 (0x0d) ANY data reference String date required has
incorrect not been parameterized
14 (0x0e) PIService parameter No valid PI description

reference incorrect
15 (0x0f) String too long Addr1.. Check Addr4
strings
In order to use the LOGIN PI service, a string variable has to

be available as parameter source.
The string variable is the name of the Password, it is contai-
ned in a user DB using data type STRING.
STRING[8] := `SUNRISE ` NOTE 8 Characters - use SPACES
Notes

A033
Reading Global User data´s ORGANIZATION_BLOCK OB 100

TITLE =
{ S7_language := '9(1) English (United States)
13.10.2010 16:56:20' }
VERSION : 1.0
BEGIN
NETWORK
Global User Data´s can be both read and written to by the TITLE =
automation system (PLC).
CALL FB 1 , DB 7 (
MCPNum := 1,
Global User Data´s are often referred to as GUD´s . The OEM MCP1In := P#I 0.0,
is able to define his own user variables in this way. MCP1Out := P#Q 0.0,
Dependant upon the OEM functionality of the relevant GUD it MCP1StatSend := P#Q 8.0,
may be necessary in process to read the current value to the MCP1BusAdr := 192,
PLC or to write the value from the PLC. MCPBusType := B#16#55,
With the Function Block FB5 you are able to read the value of //Insert User program from here
a GUD.
Because GUD´s are generated by the OEM (user), it is not

possible to obtain the internal address of the variable with the
NC Var selector in order to write the GUD. Parameter description of FB5
Signal Type Format Value Comment
By reading the content of the variable with FB5 and with additi- range
onal paramerterisation of the FB5 the internal address can be
obtained as a result parameter of the FB5, this result / output Req I BOOL Job start with positive
parameter can be used as a destination parameter with the signal edge
FB2 PUT allowing an indirect way to write the GUD´s. Addr I ANY [DBName]. GUD variable name in a
[VarName] variable of data type
STRING
Area I BYTE Area address:
Prerequisites for the Function: 0: NCK variables
GUD Data´s available in the NC 2: Channel variables
Unit I BYTE NCK area: Unit:=1
Channel area: Channel
Plus the parameter: no.
Index1 I INT Field index 1 of variable
NCKomm := True
Variable has the value 0
if no field index is used.
The parameter belongs to FB1 which is
parameterised in OB100. Index2 I INT Field index 2 of variable
Variable has the value 0
HMI Requirement: if no field index is used.
None CnvtToken I BOOL Activate generation of a
10 byte variable token
Drive requirement (Sinamics): VarToken I ANY [DBName]. Address to a 10-byte
None [VarName] token (see example)
ment of job or execution
NCK Requirement: of job impossible
GUD Data available
Done Q BOOL Job successfully exe-
cuted
PLC Requirement: State Q WORD See error identifiers
Parameterisation of FB5 in the PLC RD I/Q ANY P#Mm.n data to be read
BYTE x...
P#DBnr.db
Steps to achieve running function: xm.n
BYTE x
Notes

A033
Error codes Create and activate GUD file and variables
State Meaning Note
WORD H WORD L
0 1 Access error
0 2 Error in job Incorrect compilation of

Var. in a job
0 3 Negative ac- Internal error, try:
knowledgment, NC RESET
job not executa-
ble Syntax in order to generate an NCK GUD Array variable with
the name __GJ
0 4 Data areas or Check data to be
data types do not read in RD
tally
1 4 Insufficient local read variable is longer
user memory than specified in RD
available
0 6 FIFO full Job must be repeated,
since queue is full
0 7 Option not set BP parameter
"NCKomm" is not set
Example reading GUD PLC Parameterisation
0 8 Incorrect target RD may not be local
area (SD) data FUNCTION "Read_a_GUD" : VOID
0 9 Transmission Job must be repeated TITLE =
occupied A I 17.4;
0 10 Error in address- Unit contains value 0 FP M 128.0; // Transition Marker
S M 128.1;
ing A M 128.3;
0 11 Address of vari- Address check (or vari- FP M 128.4; // Transition Marker
R M 128.1;
able invalid able name), area, unit
1 ... 8 13 (0x0d) ANY data refer- String/NcVar data re- CALL "GETGUD" , DB 114 (
ence incorrect quired has not been pa- Req := M 128.1,
Addr := P#DB120.DBX68.0 BYTE 10,
rameterized Area := B#16#0,
0 15 (0x0f) String more than GUD variable name too Unit := B#16#1,
Index1 := 2,
32 characters long Index2 := 0,
Error := M 128.2,
Done := M 128.3,
State := MW 129,
RD := MD 131);
In order to read a GUD value, the OEM must first generate END_FUNCTION
and activate the GUD file using the HMI function available in
the System explorer.
The name of the GUD name has to be parameterised as a

STRING variable to the function block, at parameter; Addr. The variable in the NC viewed on HMI in settings.
If the GUD variable is an Array, then the array index can be
parameterised also.
According to the description , field index refers to Array index.
You can additionally use the parameters, to obtain the

address of the GUD for parameterisation with FB3 PUT
CnvtToken Activate generation of a 10 byte variable token

VarToken [DBName].[VarName] Address to a 10-byte token
Notes

A033
Starting ASUP Steps to achieve running function:
An ASUP (Asynchronous Subroutine) is an NC Subroutine ORGANIZATION_BLOCK OB 100

written normally by the OEM, this subroutine is started from TITLE =
the automation system (PLC). If a user NC Program is current- { S7_language := '9(1) English (United States)
13.10.2010 16:56:20' }
ly active, it will be interrupted according to the parameterisati- VERSION : 1.0
on of the PLC user program.
BEGIN
NETWORK
The ASUP function is carried out in two steps: TITLE =
1) ASUP Preparation CALL FB 1 , DB 7 (

MCPNum := 1,
PI Service ASUP FB4 MCP1In := P#I 0.0,
Only possible in NCK Reset State MCP1Out := P#Q 0.0,
2) ASUP Start MCP1StatRec := P#Q 12.0,
MCP1BusAdr := 192,
Parameterisation and call of FC9 MCPBusType := B#16#55,
ASUP available in the NC

Plus the parameter:
Signal Type Format Value Remark
NCKomm := True range
The parameter belongs to FB1 which is Start I BOOL

parameterised in OB100. ChanNo I INT 1 ... 10 No. of the NC channel
IntNo I INT 1 ... 8 Interrupt No.
HMI Requirement: Active Q BOOL 1 = Active
None
Done Q BOOL 1 = ASUP completed
Error Q BOOL 1 = Interrupt switched
Drive requirement (Sinamics): off
None StartErr Q BOOL 1 = Interrupt number
not assigned or deleted
NCK Requirement: Ref I/Q WORD Global 1 word per FC 9 (for
ASUP available variable internal use)
(MW,
DBW,..)
PLC Requirement:
Parameterisation of FB4 and FC9 in the PLC
Notes

A033
Prior to calling FC9, the ASUP has to be initialised with the

PI service ASUP. Currently running program to be interrupted
The following example shows the initialisation and the call of
the ASUP with FC9.
The PI service PI.ASUP requires two strings to be defined in
a user DB, the strings being the „Path“ and the name of the
ASUP.
Example of initialisation and call of ASUP
FUNCTION "ASUP_TEST" : VOID

TITLE =
VERSION : 0.1
BEGIN
NETWORK
TITLE =
A I 17.5;
S M 135.1;
A M 135.3;
FP M 135.4; // Transition Marker ASUP Interruption
R M 135.1;
CALL "PI_SERV" , DB 115 (
Req := M 135.1,
PIService := "PI".ASUP,
Unit := 1,
Addr1 := "ncvar".Path,
Addr2 := "ncvar".PName,
WVar1 := W#16#1,
WVar2 := W#16#1,
WVar3 := W#16#0,
WVar4 := W#16#0,
Error := M 135.2,
Done := M 135.3,
State := MW 136);
A I 17.6;
FP M 135.4;
S M 135.5;
A M 135.7;
FP M 135.6;
R M 135.5;
CALL "ASUP" (
Start := M 135.5,
ChanNo := 1,
IntNo := 1,
Activ := M 138.0,
Done := M 135.7,
Error := M 138.1,
StartErr := M 138.2,
Ref := MW 139);
END_FUNCTION
Notes

A033
Axis / Spindle control
Function Description: values
Start I BOOL Start spindle control from PLC
With axis / spindle control it is possible to move an axis or a Stop I BOOL Stop spindle control from PLC
spindle from the automation system.
Funct I BYTE 1 to B#16#0B 1: Position spindle
2: Rotate spindle
The following is an example of what can be carried out with the
3: Oscillate spindle
block: 4: Indexing axis
Position spindle 5: Positioning axis metric
6: Positioning axis inch
Rotate spindle 7: PosAxis metric with hand-
wheel override
Oscillate spindle 8: PosAxis inch with hand-
wheel override
Indexing axes 9: Rotate spindle with
automatic gear stage selec-
Positioning axes tion
Prerequisites for the Function: A: Rotate spindle with con-
stant cutting rate (m/min)
The axis has to be defined as a concurrent positioning axis in B: Rotate spindle with con-
stant cutting rate (feet/min)
the NC machine data. MD30450
Mode I BYTE 0 to 5 0: Pos to absolute pos
HMI Requirement: None 1: Pos incrementally
2: Pos shortest path
Drive requirement (Sinamics): None 3: Pos absolute, positive ap-
proach direction
4: Pos absolute, negative
NCK Requirement: Concurrent positioning axis
approach direction
5: Rotational direction as for
PLC Requirement: Parameterisation of the FC18 in the PLC M4
AxisNo I INT 1 - 31 No. of axis/spindle to be trav-
Steps to achieve running function: Parameterisation of FC18 ersed
Pos I REAL 0,1469368 I -38 Rotary axis: Degrees
to Indexing axis: Indexing posi-
FUNCTION FC 114 : VOID tion
0,1701412 I
TITLE = Linear axis: mm or inches
VERSION : 0.1 +39
BEGIN FRate I REAL 0,1469368 I -38 Rotary axis and spindle: rev/
NETWORK min
to
TITLE =
A I 17.7; 0,1701412 I See under table containing
FP M 141.0; +39 info about FRate
S M 141.1; InPos Q BOOL 1 = Position reached,
A M 141.3;
FP M 141.4; or function executed
R M 141.1; Error Q BOOL 1 = error
R M 141.7;
A I 16.0; State Q BYTE 0 to 255 Error code
FP M 141.6;
S M 141.7;
CALL "SpinCtrl" (
Start := M 141.1,
Stop := M 141.7,
Funct := B#16#5,
Mode := B#16#1,
AxisNo := 1,
Pos := 5.000000e+003,
FRate := 1.000000e+005,
InPos := M 141.3,
Error := M 141.5,
State := MB 142);
END_FUNCTION
Notes

A033
Reference material
Data Block content for examples:
A033: 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 stoppages.
Alarms/messages are sub-divided into the following ranges:

 NCK
 HMI
 SINAMICS
 PLC (PLC messages are explained in Module A031)
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

A037
NCK Alarms and Messages: Description NCK Alarms and

Messages:
NCK Alarms and messages are essential to inform operators, START
maintenance personnel etc. of the state of the machine.
The effect an alarm has on the system is described and how
to acknowledge an alarm.
The SINUMERIK control system offers various possibilities NCK Alarms

for diagnosis, e.g. displaying of active NCK alarms. and Messages:
Structure
Alarms/messages are sub-divided into the following number
and function ranges:
Message/
Function range
Alarm-Nr. Alarm Display
Description.
000 000 -
NCK
079 999
100 000 -
HMI
149 999
201 000 -
SINAMICS Alarm
259 999
Acknowledgement
400 000 -
PLC-Alarms/messages
810 009
The PLC alarms/messages are dealt with in Module A031.
Alarm Log.
Suppress
Alarm
Function.
NCK Alarms and

Messages:
END
Notes

A037
NCK Alarms and Messsages:Structure
The NCK alarm structure is divided sub divided into three Message/Alarm Nr. Function range
areas. Each area has been assigned a separate range of
alarm/message numbers. SINAMICS-Alarms
201000 - 203999 Control unit (CU)
204000 - 204999 Reserved
Message/Alarm
Function range 205000 - 205999 Power Unit
Nr.
NCK-Alarms/Messages 206000 - 206999 Infeed
000000 - 009999 General alarms 207000 - 207999 Drive
010000 - 019999 Channel alarms 208000 - 208999 Option board
020000 - 029999 Axis/spindle alarms 209000 - 209999 Reserved
060000 - 064999 Cycle alarms SIEMENS 213000 - 213002 Licence
065000 - 069999 Cycle alarms user 230000 - 230999 Drive CLiQ component power unit
070000 - 079999 Compile cycles Manufacturer and OEM 231000 - 231999 Drive CLiQ component encoder 1
HMI-alarms/messages 232000 - 232999 Drive CLiQ component encoder 2
100000 - 100999 Basic system 233000 - 233999 Drive CLiQ component encoder 3
101000 - 101999 Diagnosis 234000 - 234999 Reserved
102000 - 102999 Services 235000 - 235999 Terminal Module 31 (TM31)
103000 - 103999 Machine 236000 - 236999 Reserved
104000 - 104999 Parameter 240000 - 240999 Controller extension (NX32)
105000 - 105999 Programming 241000 - 248999 Reserved
106000 - 106999 Reserved 249000 - 249999 Sinamics GM7SM7GL
107000 - 107999 OEM 250000 - 250999 Communication board (Comm Board)
108000 - 108999 HiGraph 250500 - 259999 Reserved
109000 - 109999 Distributed systems (M to N)

110000 - 110999 Cycles
111000 - 111999 ShopMill, ShopTurn
113000 - 113999 Expanding User Interface (Easy screen)
114000 - 114999 HT6
119000 - 119999 OEM
120000 - 129999 HMI advanced messages
130000 - 139999 OEM
142000 - 142099 RCS Host/Viewer
149000 - 149999 ePS
Notes

A037
Alarm Display Description A full list of alarms can be seen in the “Diagnostics” area.
When an alarm is activated it will be displayed on the top line

of the controller display.
To see extra information, highlight an alarm and select the

“Help” key.
Alarm No. Alarm acknowledge method.
The information will be displayed in a pop-up box.
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. 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.

With values of less than 500 there is no rotation cycle. Values
of 500 to 10000 (milliseconds) set the time that each alarm/
Used to open the link to the help-file from a keyword or
message is displayed for.
search item.
The machine data is activated with an NC reset.
Returns to the keyword or search item.
Exits the help screens.
Notes

A037
Alarm Acknowledgement. Alarm Log
When an alarm has occurred and the cause rectified, the A log of alarms that have occurred can be seen by selecting
alarm will need to be acknowledged. the “Alarm protocol” soft key.
The type of acknowledgement depends upon the type/
seriousness of the alarm.
Some alarms needs a reset of the system while others re-
quire acknowledgement via a pushbutton.
Acknowledgement types:
This shows the time when the alarm occurred and when it
The required acknowledgement is indicated to the right of the
was cleared.
alarm number on the alarm display line.
Requires action by the operator before continuing with

the Cycle Start. Alarm can also be cleared by the MCP
“Reset” button
Controller needs to be powered off/on or an NCK

power on via the “Reset (po)” soft-key in the “Setup”
area.
Acknowledgement is via the MCP “Reset” button.

This will also reset the machining program.
The “Display new” soft key is used to refresh the list and
display any alarms that have recently occurred.
Acknowledgement is via the NC keyboard “Alarm can-

cel” button.
This should not reset the machining program.
Acknowledgement is via the “Delete HMI alarm” in the

“Diagnostic” area.
The “Settings” soft key is used to refresh the list and display
This is specifically related to PLC user alarms. any alarms that have recently occurred.
An button/key/switch should be provided by the manu-
facturer to facilitate the acknowledgement of the
alarms.
Notes

A037
Time controlled:
The log will be saved at the interval entered in the Write inter-
val area (max. 32000 seconds).
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.
This will cause less wear and tear of the CF card but still car-
Write mode file: ries similar risk of damage to the CF card.
Off: No storing of the log file will take place to the internal
flash memory (Compact flash card)
At every event: Each time an alarm occurs this will be 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.
The HMI will require restarting for the changes to become

effective
Notes

A037 END
Suppress Alarm Function.
Certain alarms can be suppressed via General Machine Data

11410 & 11415
The bit editor is viewed by pressing the “select” key.
More detailed information is viewed with the “Help” key
A037: END
Notes

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 ma-
chine.
Alarms and messages can be configured to have different behaviour on the operation of the machine.
User help files can be created to give a more detailed description of each alarm/message.
This module describes how the alarms and messages are activated.
The effect an alarm has on the system is described and how to acknowledge an alarm.
Module Objective:
Upon completion of this module you can configure, activate and set the attributes of
messages and alarms and create user help files.
Content:
Sinumerik
General Information
Alarm and Message Screens
Alarm Configuration
Entering the Alarm Text
User Help Files
Alarm Log
A031
A031

A031
PLC Alarms
PLC Alarms and Messages: Description
And
Messages:
START
Alarms and messages are essential to inform operators,
maintenance personnel etc. of the state of the machine.
Alarms and messages can be configured to have different
behaviour on the operation of the machine.
User help files can be created to give a more detailed de- General
scription of each alarm/message. Information
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.
The system categorises the alarms into separate ranges. The

following table shows the range of alarm numbers used for Alarm
each alarm type category. Configuration
The PLC alarms/messages fall into the numerical range of
400000 to 810009
Message/ User Help

Function range Files
Alarm-Nr.
000 000 - NCK
079 999
100 000 - HMI
142 999
201 000 - SINAMICS Alarm Log
259 999
400 000 - PLC-Alarms/messages
810 009
PLC Alarms
And
Messages:
END
Notes

A031
General information Alarms/messages appear at the top of the screen
The PLC alarms/messages are sub-divided into the following

ranges:
Message/Alarm No. Function
2)
400000 - 499999 * PLC-messages in general
1)
500000 - 599999 * PLC-messages for channel
1)
600000 - 609999 * PLC-messages for axis and spindle
1)
700000 - 709999 * PLC-messages for user
2) PLC-messages for sequence chains/

800000 – 899999 *
graphics
Alarm/message details.
2)
810000 - 810009 * PLC system messages
Alarm/
message Alarm
number clearance
*1)
Messages/alarms within these ranges are activated via
the user PLC. Each message/alarm has an interface bit
within DB2 to facilitate the activation of each individual
alarm.
The reaction of the machine to alarms within the
500000/600000 range is predefined by the system.
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. Indication that Alarm/
further alarms are message
*2) active. description.
Messages/alarms within these ranges are system
generated and cannot be configured by the user.
A list of active alarms/messages can be viewed.
As soon as a fault occurs on the machine, the corresponding

alarm will be dispalyed in the message line at the top of the
screen.
The alarm number, acknowledgement method and a short text
description will be displayed. The alarms and messages are categorised and accessed via
different soft-keys
Further alarms are indicated by a downward pointing arrow, to
the right of the alarm number.
The “Alarm list” screen displays serious alarms
which result in the machining process being halted.
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 “Messages” screen displays less serious
The alarm/message text can be input via the controller or cre- alarms which may not necessarily result in the ma-
ated offline. chining process being halted.
Notes

A031
The alarms displayed at the top of the screen can be made to
cycle in turn after a set time. Alarm/
This is controlled by Display Machine Data 9056. Alarm/ message
message Colour
number. selection
Alarm/ Selection of a
message pop-up box
description. when alarm
is active.
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. When the texts have been completed it is necessary to switch
The units are milliseconds. the controller off/on to activate the changes.
The machine data is activated with an NC reset.
The data is now saved to an xml file in the following location:
NCU: SystemCF card\oem\sinumerik\hmi\lng
PCU: F:\HMI\hmisl\oem\sinumerik\hmi\lng
The file name is:

oem_alarms_plc_eng.ts. The “eng” part of the name is the
language identifier.
Alarm Configuration
Language identifier examples:
The alarm/messages list can be entered directly on the con- eng = English
troller: deu = German
fra = French
ita = Italian
esp = Spanish
chs = Chinese (Simplified)
cht = Chinese (Traditional)
kor = Korean
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.
NCU: Location of the alarm text file.
Notes

A031
PCU: Location of the alarm text file. To make the alarm system operational it is necessary to call
and parameterize FC10 in the user PLC program.
Calling FC10
See below for description
Declaring the alarm clear signal.

(e.g. I3.7 (MCP reset button)
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.
FC10 parameter : ToUserIF:=TRUE

Error messages/alarms in the 500000 and 600000 ranges
(Set via DB2) will be displayed. The controller will automati-
The entries made previously on the controller can be seen in cally issue feed-hold, read-in disables etc.
the file.
Channel Alarms 510000 to 511315:
The following table is a sample of DB2. This shows the inter-

face signals for alarms 510000 to 511315. These are alarms
for channel 1. (See Module A034 for additional channel sig-
nals)
The red text denotes that the alarm is classed as an Error

Message. Alarms in the blue text classifies them as Operator
Messages.
Error messages, when activated, will appear on the “Alarm

list” screen and require an acknowledgement to clear.
(FC10 “Quit” function e.g. I3.7)
Operator Messages will appear on the “Messages” screen

and remain displayed until the interface bit is set to 0.
The effect of a message on the system is also shown for each
byte. This is only if FC10 parameter ToUserIF:= True.
User PLC Requirements
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.
A list of all the interface signals is found in Module A034 PLC

Interface.
Notes

A031
DB2 interface signals for alarms 510000 to 511315: Axis and Spindle Alarms 600000 - 609999
Alarms in the 600000 - 699999 range are used for creating a

DB2 feed/spindle stop.
Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
Byte Two bytes are reserved for each axis/spindle. The first of
510007 510006 510005 510004 510003 510002 510001 510000 which is defined as error messages (EM) while the second
0 byte is defined as operator messages (OM).
Feed and read-in disable-Error message (EM)
510015 510014 510013 510012 510011 510010 510009 510008
1
Feed and read-in disable-Operator message (OM)
DB2 interface signals for alarms 600100 to 600415:
510107 510106 510105 510104 510103 510102 510101 510100
2
Feed and read-in disable-Error message (EM)
510115 510114 510113 510112 510111 510110 510109 510108 DB2 Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
3
Feed and read-in disable-Error message (EM) Byte
510123 510122 510121 510120 510119 510118 510117 510116
4 144 600107 600106 600105 600104 600103 600102 600101 600100
Feed and read-in disable-Operator message (OM)
Feed stop/spindle stop for axis/spindle 1
510131 510130 510129 510128 510127 510126 510125 510124
5 145 600115 600114 600113 600112 600111 600110 600109 600108
Read-in disable-Operator message (OM)
510207 510206 510205 510204 510203 510202 510201 510200 146 600207 600206 600205 600204 600203 600202 600201 600200
6 Feed stop/spindle stop for axis/spindle 2
Read-in disable-Error message (EM)
510215 510214 510213 510212 510211 510210 510209 510208 147 600215 600214 600213 600212 600211 600210 600209 600208
7
Read-in disable-Error message (EM) 148 600307 600306 600305 600304 600303 600302 600301 600300
510223 510222 510221 510220 510219 510218 510217 510216 Feed stop/spindle stop for axis/spindle 3
8
Read-in disable-Operator message (OM) 149 600315 600314 600313 600312 600311 600310 600309 600308
510231 510230 510229 510228 510227 510226 510225 510224
9 150 600407 600406 600405 600404 600403 600402 600401 600400
Read-in disable-Operator message (OM)
Feed stop/spindle stop for axis/spindle 4
510307 510306 510305 510304 510303 510302 510301 510300
10 151 600415 600414 600413 600412 600411 600410 600409 600408
NC start disable-Error message (EM)
510315 510314 510313 510312 510311 510310 510309 510308 User PLC Alarms 700000 - 709999
11
NC start disable-Operator message (OM)
511107 511106 511105 511104 511103 511102 511101 511100 Alarms in the 700000 - 709999 range are free for configuring
12
Feed stop Geometry axis-Error Message (EM) in the user PLC program.
511115 511114 511113 511112 511111 511110 511109 511108
The effect the alarm has on the system is entirely the respon-
13 sibility of the machine manufacturer.
Feed stop Geometry axis-Operator message (OM)
The alarms are separated into error messages (EM), and
511207 511206 511205 511204 511203 511202 511201 511200 operator messages (OM)
14
Feed stop Geometry axis-Error Message (EM)
511215 511214 511213 511212 511211 511210 511209 511208
15
Feed stop Geometry axis-Operator message (OM) DB2 interface signals for alarms 700000 to 700063:
511307 511306 511305 511304 511303 511302 511301 511300
16
Feed stop Geometry axis-Error Message (EM) DB2 Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
511315 511314 511313 511312 511311 511310 511309 511308 Byte
17
Feed stop Geometry axis-Operator message (OM)
180 700007 700006 700005 700004 700003 700002 700001 700000
181 700015 700014 700013 700012 700011 700010 700009 700008
182 700023 700022 700021 700020 700019 700018 700017 700016
183 700031 700030 700029 700028 700027 700026 700025 700024
184 700039 700038 700037 700036 700035 700034 700033 700032
185 700047 700046 700045 700044 700043 700042 700041 700040
186 700055 700054 700053 700052 700051 700050 700049 700048
187 700063 700062 700061 700060 700059 700058 700057 700056
Notes

A031
Alarm Activation The search function can be used to search for text or alarm
numbers.
The interface signals have to be set in the user PLC. The option to search forward or backward is available as well
The following example shows how alarms 700000 (EM) and as a case sensitive option.
700032 (OM) can be activated. Use the cursor/select keys to make the necessary choices.
The search is started when the “OK” soft key is pressed.
The “Continue search” soft key can be used to identify any
further matches.
The cursor and page up/down keys can also be used for find-
ing a particular alarm.
Example: Using the search function to locate alarms associ-

ated with the word “Pressure”.
When the interface signals are high, the alarms/message will

be displayed on the relevant screen.
When the search soft-key is selected further options are re-

vealed which can be used to locate alarms and text in the
alarm list.
Takes the user the beginning of the list.
Takes the user the end of the list.
Can be used to find a specific word and replace it

with another.
Cancels the search operation.

Alarm list editing:
Confirms data entry/starts the search function.
The alarm text editing screen has search, copy, paste

and delete functionality.
This is useful when editing existing alarm texts.
Notes

A031
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 (HyperText Markup 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
Chinese (Simplified) - chs\sinumerik_alarm_plc_pmc
Chinese (Traditional) - cht\sinumerik_alarm_plc_pmc
Portuguese - ptb\sinumerik_alarm_plc_pmc
Korean - kor\sinumerik_alarm_plc_pmc
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

A031
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 con-
tents 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 be left as it is. This determines the content type and text format.
Notes

A031
Creating the help files/directories on the controller Cursor to the “hlp” directory and select the “New” soft-key.
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. Select the “Directory” soft-key, this is usually already selected
NCU: System CF-Card\oem\sinumerik\hmi\hlp by default.
PCU: F:\HMI\hmisl\oem\sinumerik\hmi\hlp
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.
NCU “hlp” folder location:
Below: Creating a folder for English help files.
Highlight the “eng” folder and select the “New” soft-key.
PCU “hlp” folder location:
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.
Notes

A031
Testing the help file on the controller
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.
Type in the help file name

“sinumerik_alarm_oem_plc_pmc.html“.
The alarm will appear in either the “Alarmlist” or “Messages”
screen depending how it has been configured.
Or
If several alarms exist, cursor to the correct one.
The file will automatically open in readiness for the HTML code
to be entered.
The file is closed with the “exit” soft-key:
Creating the help files/directories on an external PC
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 HELP function is activated by the “HELP” key.
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:
TCU:
System CF card\user\sinumerik
\hmi\hlp\eng\sinumerik_alarm_plc_pmc
“System CF card\oem\sinumerik
\hmi\hlp\eng\sinumerik_alarm_plc_pmc
PCU:
F:\HMI\hmisl\user\sinumerik\hmi\hlp\eng\ sinume-
rik_alarm_plc_pmc
F:\HMI\hmisl\oem\sinumerik\hmi\hlp\eng\ sinume-
rik_alarm_plc_pmc
Notes

A031
Alarm Log
A log of alarms that have occurred can be seen by selecting

the “Alarm protocol” soft key.
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:
This shows the time when the alarm occurred and when it
was cleared. Number of entries:
This sets the maximum number of alarms displayed on the
alarm log page.
Write mode file: OFF

No storing of the log file will take place to the internal flash
memory (Compact flash card) or hard disk drive.
Write mode file: At every event

Each time an alarm occurs this will be recorded to the com-
pact flash card/hard disk drive.
When this option is selected, a warning is displayed.
By leaving this option permanently set, the life of the internal
compact flash card/hard disk drive will be reduced.
The “Display new” soft key is used to refresh the list and
display any alarms that have recently occurred.
The “Settings” soft key is used to refresh the list and display
any alarms that have recently occurred.
Notes

A031 END
Write mode file: Time controlled
The log will be saved at the interval entered in the Write interval
area (max. 32000 seconds).
This will cause less wear and tear of the CF card/hard disk
drive.
The HMI will require restarting for the changes to become ef-
fective
A031: 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: Description

PLC Onboard
Diagnostics:
The 840D sl SINUMERIK controller has onboard PLC START
diagnostic capabilities to aid users with the fault finding
procedure.
The status of inputs, outputs, timers etc can be easily
monitored.
User PLC
Variables
System
Variables
Onboard
Diagnostics:
Detailed
Description
NC/PLC Trace
Function
PLC Onboard
Diagnostics:
END
Notes

A058
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

A058
To locate the PLC Diagnostics screen use the following soft- Format description:
key sequence:
Formats Description
B Binary
H Hexadecimal
D Decimal without sign
±D Decimal with sign
The following screen will be displayed, it is possible that there
are entries already present on the screen. F Floating point number (for double words)
A ASCII characters
The variable will be displayed in the selected 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:
Variable Possible Format

Inputs Ix.x, IBx, IWx, IDx
Outputs Qx.x, QBx, QWx, QDx
Bit memory Mx.x, MBx, MWx, MDx
The status of the PLC variable to be checked should typed into
the “Variable” column (Bit, byte, word, double word). Timers Tx
Example, using inputs to show the different format possibilities Counters Cx

Data Blocks DBx.DBXx.x, DBx.DBBx, DBx.DBWx,
DBx.DBDx
Timers can only be viewed in the “Decimal” format.

Counters can be viewed “Decimal”, Binary” and Hexadecimal”
format.
Format
The variable value can be viewed in different formats. The for- Entries can be edited by using the Insert, and Cursor keys
mat has to be selected from the list: found on the NC keyboard.
Notes

A058
System Variables Choose the variable from the list, e.g. “aaRef Axis is ref-
erenced”.
A list of available system variables is displayed via the “Insert
variable” soft-key.
The available variables are listed when the soft-key is se-
lected.
The variable used in this example is an axis variable, therefore

an axis has to be chosen.
The types of variable available for selection are:
System variables
NC
Axis
Channel
Mode groups
Global user data
PLC The chosen variable will appear on the screen.
The filter is used to narrow down the variables on view.
The values within the square brackets identify the individual

variables e.g:
The search window can be used to locate the required variable. [U1= Channel No. , 1 = Axis No.]
Partial or whole names can be entered.
Notes

A058
Onboard Diagnostics: Detailed Description The operand in question has to be highlighted and the new
value entered and confirmed with the “OK” soft key.
Operand +/-:
The “Operand +” and “Operand -”soft-keys are used for locating

operands (Variables) within the same group.
or
Enter the new value e.g. 1
Display Comments:
Further information about the variable can be displayed by

selecting the “Display Comments” and “Details” soft-key.
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-
The comments can be edited if necessary. In the case of user
chine manufacturer.
PLC inputs and outputs, the comments will require adding.
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.
Delete All:
Details: The “Delete all” soft-key will delete all entries in the list.
The details of the variable can be viewed:
Change:
For test purposes it may be necessary to manually change

(Force) an operand. This is achieved with the “Change” soft
key.
Notes

A058
Individual entries can be cleared via the ”Delete” soft-key Enter a suitable name for the file, e.g. Toolchange signals:
found on the NC keyboard.
Further functions
Further functions are available when the “Menu extension/

page right” soft-key is pressed:
Load mask:
When required, the saved file can easily be loaded.
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.
The variable will now appear on the status screen.

The file can be saved locally or externally to a USB device or
networked PC. It is always useful to have the file stored
locally.
Choose a suitable destination e.g. User\Variable masks.
Load symbols:
If a symbols file (*.snh) is available, this can be loaded with the

“Load symbols” soft-key.
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
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:
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.
The trace can now be started:
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
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.
Colour of Show/hide
trace. trace
Style of
trace line
The trace can be examined in detail using the zoom functions.

The trace time and various other settings can be modified:
Up to 16 variables can be traced at once.
Traces can be saved and loaded from external sources in

“xml” format.
A058: END
Notes

A058 END

A053 Axis and Drive Diagnostics
Sinumerik
Operate
Module Description:
In the event of a problem with the machine it may be necessary to check the status of an axis/drive.
The information obtained from these status screens can be very useful to technical personnel and help
speed up the fault finding process.
Module Objective:
Upon completion of his module you will be able to use the Axis & Drive diagnostic functions.
Content:
Sinumerik
Service Overview Screen
Axis Diagnostics
Drive Diagnostics
A053
A053

A053
Axis and Drive
Axis and Drive Diagnostics: Description Diagnostics:
START
In the event of a problem with the machine it may be neces-

sary to check the status of an axis/drive.
The information obtained from these status screens can be
very useful to technical personnel and help speed up the fault
finding process. Service
Overview
Screen
Axis
Diagnostics
Drive
Diagnostics
Axis and Drive

Diagnostics:
END
Notes

A053
Service Overview Screen The displayed axes can be changed to suit personal prefer-
ences.
To navigate to the relevant diagnostics page please use the
following key presses.
The “Active axes” soft-key will only display axes

that are currently active. Axes disabled via machine
data or parked axes will not be displayed.
The screen shows the status of various enable/monitoring
signals via indicators. The “All axes” soft-key will display any axes that are
currently configured as active or inactive.
The “Selected axis” soft-key allows selected axes to

be viewed.
Example below shows how to view axes 1 and 3
only.
The indicators change appearance depending on the condition

of the signal.
The signal is healthy, in the case of an enable, the

signal is high. For a monitoring signal there is no fault
present.
The signal is missing i.e. low (Enable signals only).
The signal is indicating a fault (Monitoring signals

only).
The signal is inactive/not in use.
Example: The diagnostics page showing a motor over tem-

perature problem on Axis 1. In this case the encoder cable
was not connected to the drive.
Notes

A053
Axis Diagnostics Drive Diagnostics
Axis specific information. Drive specific information
For more detailed information regarding each individual drive,

select the “Service drive” soft key.
This detailed information can very useful when a problem

occurs on the machine.
The drive diagnostics screen shows useful information regard-

The selected axis is displayed at the top of the diagnostics ing the motor and drive states such as motor temperature, DC
screen. link voltage etc.
More diagnostics information is revealed by

Each axis is displayed individually, changing to another axis
using the page/cursor keys
is done with the “Axis +” and “Axis -” soft keys.
OR
Drive System.
An alternative method of selecting the required axis is via the Further drive diagnostic information, specifically Sinamics re-
“Axis selection” soft key. lated, can be found by selecting the “Drive system” soft key.
This the quickest method on a machine with many axes.
The status of the DriveCliQ drive objects can be seen.
A healthy drive object, fully enabled ready for

operation.
Useful information about the axis in question ranging from A drive object with a warning e.g. enable missing.
positional data to current and torque readings is available.
Further information can be seen by using the page/cursor
keys. A drive object with a fault.
Notes

A053
The CU is the only drive object displayed, to view the other Example: The “Status indicator” information indicates that axis
drive objects press the “Input” key. is in commissioning mode.
The lower half of the screen offers further information.
Use the “Drive object +” & “Drive object -” soft-keys to check

the status of other axes.
OR
The following screen shows a healthy system, indicated by the
green tick symbols.
A more serious situation is indicated by the appearance of
red/white cross symbol.
Example– MX1 (Servo 1) axis showing a fault with encoder 1
(SMI20).
Drives not ready or in a fault condition will display yellow or

red symbols.
The following example shows MSP1 exhibiting a problem.
The screen will display information regarding the cause of
To see more information about the cause, cursor to the failed
the problem.
axis and select the “Details” soft-key.
Notes

A053
Two further soft-keys are also available for displaying further

information.
Selecting the “Warning” soft-key displays more infor-

mation which indicates a problem with encoder 1.
The alarms and warnings can also be seen on the alarm

screen.
Selecting the “Faults” soft-key also displays more

information which indicates a problem with encoder
1, drive component 18.
The alarms displayed can be filtered via machine data 13150

“SINAMICS_ALARM_MASK”.
The “Help” key, found to the lower right of the vertical soft-
keys can be used to get more information about Warnings/
Faults.
Notes

A053
Many alarms are generated when the system detects a com- Drive component renaming
ponent error. The machine data is used to filter out alarms
which may be confusing. The default value is 0909 this sets The component names can be changed to a more suitable
bits 0, 3, 8 & 9. For service and commissioning work it maybe name if desired:
necessary to view more alarms. Setting the machine data to
FFFF will result in all alarms being displayed.
The default value should always be re-entered when the ser-
vice/commissioning work is complete.
Topology
The topology of the drive system can be seen when the

“Topology” soft-key is selected.
Topology shows the DriveCLiQ interconnections of the drive
objects and components.
CU (Drive object 1) is connected

via X100 to a motor module
(Drive object 2) socket X200.
Example: Renaming of Motor_Module_2 to Spindle.
Press the “OK” soft-key to confirm the changes, wait for the
dialogue box to clear.
The topology display can also be used to help identify faults.
When a drive object has a fault, the text

will be displayed in red or grey.
Notes

A053
Display options
The topology display can be changed via the “Display op-

tions” soft-key:
Firmware:
Firmware is a software that is written to the internal flash
memory of the DriveCLiQ components. Firmware updates are
used to keep the components up to date with the latest tech- When the process is running the Top LED of the drives will
nological advances. The firmware version is dependant upon flash red. Other DriveCLiQ components will also indicate the
the current system software version. process in a similar way.
When the update has finished a complete power off/on of the
Automatic Firmware Update: controller/drives is required.
When replacement drive hardware is fitted it is important that
the firmware version is correct. In normal circumstances the
system automatically loads the firmware to any modules not
at the correct firmware level. If the firmware is not automati-
cally updated the “Load firmware” soft-key can be used.
The configuration area has several further functions:
Manual Firmware Update:

The “Load firmware” soft-key located in the Configuration
area which is accessed via the “Configuration” soft-key.
Notes

A053
The Drive Object and Component names can be changed via The “Sort” soft-key is used to view the components in a par-
the “Change” soft-key. ticular order according to Drive Object, Wiring, Component
The system assigns default names to the objects/components. number or Axis number:
It is not always apparent from these names what the function of
each object/component is.
Using more suitable names can help with object identification in
the event of a problem.
The changes are accepted when the “OK” soft-key is pressed.
Electronic Rating Plates
Useful information is displayed when the “Details” soft-key is

selected.
These are known as the ”Electronic Rating Plates”.
Display Settings
Example: Details of MX1 axis Motor Module:
The level of displayed information about the components can
be controlled with the “Display options” function.
Example: Details of MX1 Servo Motor:
Comparison Levels:
Some of the information on the screen can only be viewed by

using the cursor left/right keys.
Notes

A053
To the right of the screen, a column named “C.level” can be
seen.
This is used to set the comparison level for the DriveCLiQ
components.
The system compares the stored details of the electronic rat-
ing plate of each object with the actual components con-
nected to the DriveCLiQ bus.
Once the drive system is configured it is continually moni-
tored. Alarms will be displayed if a fault occurs or an unknown
object is detected.
Comparison Levels:
High-Compares the complete electronic rating plate
Medium– Compares the component type and order number
Low– compares the component type
Minimum– Compares the component class.
Service case 1: If a new component is to be fitted to a system

to replace a faulty one it is not necessary to change the com-
parison level. The system should automatically load the cor-
rect firmware to the new component.
To change the level of comparison select the “Change” soft- Service case 2: If two existing components are to be inter-
key and then the “Insert” key. changed to prove a fault e.g. Motor Module 1 & Motor Module
2, the system will detect this and issue alarms
depending on the setting of the comparison level.
In this case setting the comparison level to low would allow
the modules to be interchanged without alarms occurring.
Notes

A053 END
Diagnostics Parameters The status of the Drives can be viewed via Drive MD r2.
The status of the CU can be viewed via CU MD r2.
When the parameter is highlighted and the select key is

pressed a list of operating status numbers and their meanings
is displayed.
A053: END
Notes

A084 Encoder Adjustment
Sinumerik
Operate
Module Description:
All positioning axes require referencing in order for the controller to position them. The procedures for the
referencing of incremental and absolute encoders is described along with the most important machine data.
Module Objective:
Upon completion of this module you will be able to synchronise/adjust the measuring system for the Sinu-
merik 840D sl controller.
Content:
Sinumerik
Referencing Incremental Encoders
Referencing Absolute Encoders
Machine Data Information
Automatic Referencing
A084
A084

A084
Encoder
Encoder Adjustment: Description Adjustment:
START
All positioning axes require referencing in order for the con-

troller to position them. The procedures for the referencing of
incremental and absolute encoders is described along with
the most important machine data.
Referencing
Incremental
Encoders
Referencing
Absolute
Encoders
Machine Data
Information
Automatic
Referencing
Encoder
Adjustment:
END
Notes

A084
Referencing Incremental Encoders
General Information
Axes equipped with incremental encoders require referencing
each time that the NCK is powered off/on or reset.
This usually entails traversing the axis to a switch which then
initiates the referencing procedure. Certain machine data's are
available to influence this procedure and adjust it to individual
requirements.
Some axes have a second encoder fitted for positioning opera-
tions. It needs to be checked which measuring system is active,
as that will be the one which requires referencing.
To check which measuring system is active we can look at the
“Axis diagnostics” area.
Machine data 30240[0] & [1] can also be checked.
If the active measuring circuit is 1, machine data 30240[0]

Look for the “Measuring system 1 active” and “Measuring sys- should be used to identify the encoder type.
tem 2 active”. A green tick symbol indicates which measuring
system is active for each axis., typically the motor encoder. A If the active measuring circuit is 2, machine data 30240[1]
2nd measuring circuit is typically a linear scale on an axis or an should be used to identify the encoder type.
encoder for a spindle.
Some manufacturers may also switch between measuring sys- Incremental encoder = 1
tems. If there is uncertainty about this please contact the manu- Absolute encoder =4
facturer for information.
To reference an axis fitted with an incremental encoder, an
interface signal needs to be switched high in the user PLC
program. This is usually done with a switch positioned at a
suitable place on the axis slide way.
During the reference procedure the axis will traverse towards
the switch, on activation of the switch the interface signal will
be set.
A sequence of axis moves will then take place which are con-
trolled by the NC and influenced by machine data.
(Further details are shown on the following pages)
Example of an axis reference switch input activating a refer-

ence point approach interface bit.
If it is uncertain whether an axis has an incremental or abso-

lute encoder fitted, this can be checked via axis machine data
30240.
To check the machine data use the following soft key se-
quence. Interface signal DB3x.DBX12.7 “Delay Ref. Pt approach”
needs to be set to high to initiate the referencing procedure.
Each axis has its own variable which is identified by chang-
ing the x for a numerical value which represents the axis,
see below-
1st axis - DB31.DBX12.7

Ensure that the correct axis is selected. 2nd axis - DB32.DBX12.7
3rd axis - DB33.DBX12.7
Or etc.
Notes

A084
Before referencing can be initiated the controller needs to be
placed into Reference Mode by selecting the “REF.POINT”
button on the machine control panel. The LED should Illumi-
nate, the “JOG” mode LED remains illuminated.
Confirmation that the correct mode is selected can be seen

at the top of the screen.
Each axis can be referenced individually. It is also possible

to reference the axes automatically. This usually set up by
the machine builder and will be explained in more detail later
in the module.
To reference an individual axis select the correct axis via the

machine control panel.
The axis must now be moved in the direction of the refer-

ence switch. This can be done manually via the axis jog
keys or automatically if automatic referencing is set-up.
The direction of movement is set via machine data.
The axis should move uninterrupted towards the reference
switch. Some systems require that the jog direction button is
continually depressed throughout the reference cycle, it is
more common to find that the axis will continue to move
even when the jog direction button is released.
Notes

A084
Referencing sequence diagram for incremental encoder
In the event of the values of machine data 34080 & 34090 equalling less than the stopping distance of the axis, the controller will
automatically readjust to the correct position.
34040 $MA_REFP_VELO_SEARCH_MARKER = 0
34080 $MA_REFP_MOVE_DIST + 34090 $MA_REFP_MOVE_DIST_CORR = > 0
Velocity
Reference point cam
switch activated
0 1
MD34020 Ref. point approach velocity
34070 Ref. point position velocity
MD34040 Ref. point search marker velocity
Position
Cam switch 1 0
Axis referenced. Marker pulse detected Reverse direction
The control receives a reference axis command, the axis accelerates to the feed-rate in machine data
34020 $MA_REFP_VELO_SEARCH_CAM then searches for the reference switch input to become high.
The reference switch is operated and the axis decelerates.
The axis reverses direction at the feed-rate set in machine data.

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

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

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

A084
When an axis is referenced the controller issues interface
signals:
1st axis DB31.DBX0.4 1st measuring circuit is referenced

1st axis DB31.DBX0.5 2nd measuring circuit is referenced
2nd axis DB32.DBX0.4 1st measuring circuit is referenced
2nd axis DB32.DBX0.5 2nd measuring circuit is referenced
etc.
The position display will indicate the axis is referenced and dis-
play any values stored in machine data:
34100 $MA_REFP_SET_POS
Symbol indicating the axis is referenced.
The procedure requires that the axis be moved to a know

mechanical position e.g. 150mm. Locate machine data
34100 $MA_REFP_SET_POS and enter 150.
Value from Axis MD 34100
Referencing Absolute Encoders
General information
Absolute encoders need referencing on first commissioning Check that machine data 34200 ENC_REFP_MODE is set to 0
and remain referenced until a problem occurs with encoder or This enables the control to take over the value in machine data
the NCK. Re loading of an archive will also necessitate the 34100 $MA_REFP_SET_POS.
referencing of the encoder. Check that machine data 34210 ENC_REFP_STATE is set to
Procedure: 1. This is to enable encoder calibration to take place.
First it must be ascertained that the encoder is of the absolute
type. This can be done by checking the motor data rating plate
(In the case of an integrated motor encoder)
Checking with the supplier of the encoder is another method
of determining the correct type.
Machine data 30240[0] & [1] can also be checked.
If the active measuring circuit is number 1, then the value of

machine data 30240[0] should be used to identify the encoder
type.
Check whether machine data
If the active measuring circuit is 2, machine data 30240[1] 34010 REFP_CAM_DIR_IS_MINUS is set to 0 OR 1.
should be used to identify the encoder type.
The following values determine the encoder type:
Incremental encoder =1
Absolute encoder =4
Notes

A084
The axis to be referenced should be moved to the known

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

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

placed into Reference Mode by selecting the “REF.POINT”
button on the machine control panel. The LED should Illumi-
nate, the “JOG” mode LED remains illuminated.
Machine Data Information
If a machine does not have reference switch cam it is possi-

Confirmation that the correct mode is selected can be seen at ble to reference from the zero mark by changing machine
the top of the screen. data- 34000 $MA_REFP_CAM_IS_ACTIVE (Default value 1)
A value of 0 will deactivate the cam.
This is used for example on axes that have only one refer-
ence mark along the entire traversing range and rotary axes
that have only one reference mark per revolution.
The direction that the axis approaches the reference switch

can be changed by machine data-
34010 $MA_REFP_CAM_DIR_IS_MINUS (Default value 0)
The default value will result in the reference point approach in
a positive direction. To reverse the direction a value of 1 has
to be entered.
The initial approach speed for referencing is determined by

machine data- 34020 $MA_REFP_VELO_SEARCH_CAM
(Default value 5000.0 mm/min)
If the axis fails to reach the reference cam it is probably due

to machine data-34030 $MA_REFP_MAX_CAM_DIST
(Default value 10000 mm) This is the maximum distance to
the reference cam.
The controller will issue alarm:-20000 Channel %1 axis %2
The A axis of the training equipment is fitted with an absolute reference cam not reached.
encoder.
When the reference switch is activated the axis reverses di-
rection in search of the reference marker. This search speed
is determined by machine data- 34040
$MA_REFP_VELO_SEARCH_MARKER (Default value
300.0 mm/min).
The direction that the reference marker search direction is

Select the axis to be referenced and then press the same di- changed by machine data-
rection key used to position the axis earlier. 34050 $MA_REFP_SEARCH_MARKER_REVERSE
The A axis of the training equipment is fitted with an absolute (Default value 0)
encoder. The default value cause the axis to search for the reference
The axis will not physically move but the position display will cam in the opposite direction to the direction specified in ma-
change to show the axis is referenced symbol and the refer- chine data 34010 $MA_REFP_CAM_DIR_IS_MINUS.
ence point set position will be shown as the position of the Entering a value of 1 in machine data 34050 will reverse the
axis (150 mm). cam search direction.
Machine data 34210 will have changed to 2 to indicate a
successful procedure.
Notes

A084
If the axis fails to reach the reference marker it is probably due

to machine data-
34060 $MA_REFP_MAX_MARKER_DIST (Default value 20
mm) This is the maximum distance the axis can travel without
finding the marker..
The controller will issue alarm:-20002 Channel %1 axis %2
zero mark missing.
When the marker is detected the axis will either stop or move
to a position determined by the values of two machine data
(34080 & 34090 see below for further explanation)
The speed at which this position sought is determined by ma-
chine data-
34070 $MA_REFP_VELO_POS (Default value 10000.0 mm/
min).
34080 $MA_REFP_MOVE_DIST (Default value -2.0 mm).

Once the marker has been detected it is advisable to move
the axis away from the marker (Into the machining area). This
is achieved by putting a value in machine data 34080.
If the axis was asked to reference again while still on the
marker this could result in the axis going toward the end of the
slide.
To initiate the automatic cycle the necessary interface bit
(DB21.DBX1.0 ) has to be set.
34090 $MA_REFP_MOVE_DIST_CORR (Default value 0.0
mm) This machine data is used to accurately set the position
Example of how the automatic referencing cycle can be initi-
and correct discrepancies caused by an encoder exchange or
ated:
mechanical work.
The values in machine data 34080 & 34090 are added to-
gether to determine the distance the axis moves.
Usually the position display shows zero after an axis has been
referenced. This can be changed by machine data 34100
$MA_REFP_SET_POS (Default value 0.0 mm)
The value entered in here will be displayed on the screen as
soon as referencing is complete.
This is used when the reference position is not the mechanical
zero of the machine. The machine data does not result in the
axis physically moving.
Automatic Referencing Ref Mode active NC start request Activate

(Mode group 1) (Channel 1) referencing
Automatic referencing cycle (Channel 1)
To set the automatic referencing function it has to be decided
in what order you want the axes to referencing. It is common
for example that on a milling machine the Z axis needs to be
referenced first, this helps eliminate the chance of a collision. Interface signal DB21.DBX33.0 changes to 1 while the
The order is set by axis machine data referencing cycle is active.
$MA_REFP_CYCLE_NR (Default 1)
Possible entries:-
0 = no referencing cycle participation.
1 to 15 = allowable range for setting the sequence.
-1 = no reference required for Cycle start.
Up to eight axes can be referenced at the same time.
A084: END
Notes

A084 END

A011 Easy Screen
Sinumerik
Operate
Module Description:
Easy Screen is a function of the 840D sl which allows the manufacturer to write custom screens.
The screens are intended as an interface to the specific functions offered by the OEM
Module Objective:
Upon completion of this module the course participant will be able to
 Create Easy Screens.
Content:
Sinumerik
General Information
Basic Configuration Information.
Creating Easy Screen User Files.
Parameters and Variables Description.
A011
A011

A011
Easy Screen: Description
Easy Screen:
Easy Screen is a function of the 840D sl which allows the START
manufacturer to write custom screens.
The screens are intended as an interface to the specific func-
tions offered by the OEM
General
Information
Basic
Configuration
Information
Creating
Easy Screen
User Files
Parameters
and
Variables
Description
Easy Screen:
END
Notes

A011
General Information Basic Configuration Information
The Easy Screen function is configured using ASCII files. Configuration files are used to create the screens.
These files contain the descriptions of the user interface. These configuration files are automatically interpreted by the
controller.
As standard, up to 5 screens can be configured. Further The files are not available as standard and have to be cre-
screens are available via a licensed option. ated by the user with an ASCII editor (e.g. Notepad® or di-
(Sinumerik Operate Runtime OA Easy Screen, order No rectly on the controller).
6FC5800-0AP64-0YB0).
The “easyscreen.ini“ file is a master file which is required to
In order to create images for the screens, a graphic pro- specify which other files are to be used to create a user
gramme is required. Paint Shop Pro® and Paint® are pro- screen.
grammes which are compatible with the 828D controller. These files contain the information which determines what is
displayed on a particular screen.
Easy Screen can be used for the following functions: The screen is split into different areas:
1. Display of dialogs and provision of:
 Soft-keys

 Variables, (tables This function will be available with a

later level of implementation.)
 Text and help text 
 Graphic displays and help displays
2. Calling up dialogs by means of: 
 The (entry) soft-keys 
 PLC selection

3. Dynamic re-structuring of dialogs:
 Changing or deleting soft-keys
 Defining and designing variable fields
 Showing, replacing and deleting (language-dependent/
independent) display texts 1 Main dialog area
 Showing, replacing and deleting display texts 2 Title bar containing screen name (Left) and
detailed variable description (Right)
(Language dependent/individual)
3 Variable input/output field
4. Initiating actions when:
4 Variable name-short description
 Showing dialogs 5 Graphics related text
 Entering values (variables) 6 Unit text
 Pressing soft-keys
Closing dialogues Operating areas overview
5.. Exchange of data between dialogs.
6. Variables Operating area Permissible positions for start soft-keys
 Reading (NC, PLC, user variables)
Machine JOG HSK6
 Writing (NC, PLC, user variables)
Machine MDA HSK6
 Linking with mathematical, comparative or logic
operators Machine AUTO HSK6
7. Executing functions:
 Subroutines
Parameter HSK7
 File functions Program HSK6

 PI Services Program-Manager HSK2-8, 12-16, if not used for logical drives
8. Taking into account levels of protection defined for user
groups. Diagnostics HSK7
Commissioning HSK7
Notes

A011
To enable custom screens in other area of the controller, the Creating Easy Screen User Files
“easyscreen.ini” file has to be modified.
There are eight areas in total:- The files required for the Easy Screen function need to be
created. This can be done directly on the controller by navigat-
Machine Area-Sub divided into:- ing to the relevant folders. Use the following key sequence to
Jog locate the “System data” area.
MDA
Auto
Parameter Area
Program Edit Area
Program Manager Area
Diagnosis Area
Start-up Area
The three Machine Areas are specified by the by “Screen”

entry.
SlMaJogScreen = Jog screen
SlMaAutoScreen = Auto screen
SlMaMdaScreen = MDA screen
Each area should have a “com” file specified.
Example of how all the areas are specified within the

“easyscreen.ini” file:- Creating the “easyscreen.ini” file on the controller
[STARTFILES] This file sets up the links to the files which are to be used to
StartFile01 = area := AreaMachine, dialog := SlMachine, create the user screens, it also determine which operating
screen := SlMaJogScreen, startfile := ma_jog.com areas these files are available in. The file has to be located in
any of the following paths/directories:-
StartFile02 = area := AreaMachine, dialog := SlMachine, “System CF card\oem\sinumerik\hmi\cfg”
screen := SlMaAutoScreen, startfile := ma_auto.com “System CF card\user\sinumerik\hmi\cfg”
StartFile03 = area := AreaMachine, dialog := SlMachine, Use the cursor keys to locate and open this directory.
screen := SlMaMdaScreen, startfile := ma_mda.com
StartFile04 = area := AreaParameter, dialog := SlParame-

ter, startfile := param.com
StartFile05 = area := AreaProgramEdit, dialog := SlPro-

gramEdit, screen := EditorScreen , startfile := aeditor.com
StartFile06 = area := AreaProgramManager, dialog :=

SlPmDialog, startfile := progman.com
StartFile07 = area := AreaDiagnosis, dialog:=SlDgDialog,

startfile := diag.com
StartFile08 = area := AreaStartup, dialog:=SlSuDialog,

startfile := startup.com
Notes

A011
To create the file select the “New” soft-key and ensure that the The latter is usually a more comfortable method than stood at
“Any” soft-key is selected. the controller.
The any soft-key allows the file type to be determined. In the These files have to be transferred to the controller and placed in
dialogue box type in the name of the file and confirm with the the correct folders.
“OK” soft-key. This can be done via the USB /CF Interfaces or with the RCS
The file name must be in lowercase due to the LINUX operat- Commander software.
ing system. The file needs to contain information about which soft-key is to
be used, the text for the soft-key and what is to be displayed on
the screen.
The example will use the 7th horizontal soft-key and display the
text “Easy Screen”. The screen will display R parameters 0 to 3
with descriptive texts.
Example:-
//S(START)
HS7=("Easy %nScreen")
PRESS(HS7)
LM("mask1")
END_PRESS
//END
//M(Mask1/"Workpiece Dimensions")
The newly created file will be automatically opened in prepara-
Def Var1=(R2///"Length of component","R0 X Length"///"$R[0]")
tion for editing.
Def Var2=(R2///"Width of component","R1 Y Width"///"$R[1]")
Def Var3=(R3///"Height of component","R2 Z Height"///"$R[2]")
Example:-
Def Var4=(I///"Main spindle speed","R3 Spindle speed"///"$R[3]")
The following example will demonstrate how to place a selec-
VS8=("EXIT")
tion of R variables on a user screen accessed via a user soft-
PRESS(VS8)
key.
EXIT
The first step is to enter the header called “Startfiles” enclosed
END_PRESS
in square brackets. Beneath this header we type the area of
the controller where the start file is to be active
//END
(AreaParameter) and the name of the startfile (param.com).
When the area in question is accessed the system will locate
To aid clarity, the file with the descriptions is shown below:
the specified startfile and act upon the instructions typed within.
//S(START) Opens the dialogue for defining the soft-key menu.
[STARTFILES]
HS7=("Easy %nScreen") Defining the text for horizontal soft-key
StartFile04 = area := AreaParameter, dialog := SlParameter,
7 (HS7) as “Easy Screen” (%n = new line)
startfile := param.com
PRESS(HS7) When HS7 is pressed the load mask (LM) com-
mand is processed.
Creating the “param.com” file on the controller
LM("mask1") In this example the system searches for “mask1’
and acts upon the contents of this mask.
The “param.com” file needs to be created. This can also be
END_PRESS
done on the controller in the following paths/directories:
//END
NCU:
//M(Mask1/"Workpiece Dimensions") Opens the dialogue for
“System CF card\oem\sinumerik\hmi\proj”
“mask1” The name of the mask (Within the speech marks) will be
“System CF card\user\sinumerik\hmi\proj”
displayed on the left of the title bar.
PCU:
“F:\HMI\hmisl\oem\sinumerik\hmi\proj”
“F:\HMI\hmisl\user\sinumerik\hmi\proj”
VS8=("EXIT") Defines the text for vertical soft-key 8 as “EXIT”

Creating the User Files on an external PC
PRESS(VS8) When VS8 is pressed, exit the screen.
EXIT
As mentioned previously it is possible to create the Easy
END_PRESS
Screen files directly on the controller or offline using an ASCII
//END
editor (e.g. Notepad®).
Notes

A011
To see the results of the example we have to locate the Detailed Analysis
“parameter” area of the control.
R parameter 0 as a real number to 2 decimal places, sets the
component length:
The 7th horizontal soft-key contains the text specified in the

“param.com” file. HS7=("Easy %nScreen").

component width:

component height:
To view the custom screen press the “Easy Screen” soft-key.

R parameter 3 as an integer, sets the spindle speed:
//M(Mask1/"Workpiece Dimensions") Name of Mask1:
The four variables defined in the “param.com” file are

displayed along with the specified texts and number formats.
HS7=("Easy %nScreen") Determines the text for horizontal soft-
key 7 as “Easy Screen”:
Notes

A011
Parameters and Variables Descriptions
VS8=("EXIT") Determines the text for vertical soft-key 8 as
“EXIT”: When a variable is assigned certain properties can be set.
These properties are contained rounded brackets, each prop-
erty is separated by a forward slash (/)
If a property is not used, the slash still needs be present.
Basic description:
Checking the entered values DEF Var1=( 1 /2 / 3 / 4 / 5 / 6 / 7 / 8 / 9 / 10)
Values can be entered directly on the custom screen. These 1. Variable type
values are transferred directly to the variables. 2. Limit values, toggle field or table identifier
This can be checked by viewing the variables on the standard 3. Default
screen by pressing the “User variable” soft-key. 4. Texts
5. Attributes
6. Help display
7. System or user variable
8. Position of short text
9. Position of I/O field (Left, top, width, height)
10. Colours
Detailed description:
1. Variable type
R[x] Real number, “x” indicates the number of decimal
places displayed
I Integer.
S[x] String,”x” indicates the string length.
C Character (Individual character)
B Boolean number
V Variant type
2a. Limit values-

A minimum and a maximum value can be specified. The values
are separated by a comma, the minimum value is specified first.
Values can be in I, C and R decimal formats or as characters in
the format “A” , “F”
The limit value also works in conjunction with the limit attrib-
ute, see the attribute property for more information.
2b. Toggle field-

Creates a list of predefined entries in the I/O field. The list is
initiated by the “*” character.
The entries can be assigned a value.
The Limit value is interpreted as a list for the Toggle field.
If only a “*” is used, a variable Toggle field is generated.
2c. Table Identifiers-

Identifiers can be assigned to tables containing NCK/PLC val-
ues of the same type. The “%” character is used to differentiate
an identifier from a toggle field or limit value.
A comma is required after the identifier, the file name containing
the table information is then typed.
3. Default setting-
The value in the assigned variable can take on various states.
This depends on whether a default value, system or user vari-
able (Or both) has been assigned to the variable field (I/O or
toggle field)
Toggling is not possible until a valid value is assigned to the
variable.
Notes

A011
DEF Var1=(1 / 2 / 3 / 4 / 5 / 6 / 7 / 8 / 9 / 10) 5. Attributes (continued)-
4. Texts- Font size:-
Text possibilities are- Attribute Effect
 Long text = text displayed when each element is high- fs1 8pt. font size (Default)
lighted. fs2 16pt font size
 Short text = name of the element
 Graphics text = text relating to the graphics, if used. The Clearance between lines is defined. The default font size
 Unit text = unit of the variable e.g. mm, rpm etc allows 16 lines. The graphics and unit text can only be
configured in the default font size.
The texts types are separated by commas and need enclosing
in speech marks:- /”Long”, “Short”, “Graphics”, “Unit”/ Limits:-
5. Attributes- Checking whether the value of the variable are is within the lim-
The following properties can be influenced by the attributes its specified by the limit values.
Input mode
Attribute Effect
 Access level
li0 No check.
 Alignment of short text li1 Check with respect to minimum
 Font size li2 Check with respect to maximum.
 Handling limit values li3 Check with respect to minimum and maximum.
 Response when screen is opened (Change block)
Behaviour when opening (Change block):-
The attributes are separated by commas, and are not valid for
toggle fields. Attribute Effect
cb0 The change block defined for this variable is
Input mode:- processed when the screen opens (Default)
Attribute Effect cb1 The change block defined for this variable is
wr0 I/O field invisible, short text visible. processed if there is a change in the value of the
wr1 Read only, no inputting of data, short text visible. variables
(Default setting)
wr2 Read & write possible, long and short text visible. The “cb” attributes, specified in the variables definition, take
wr3 As with wr1 but with I/O field visible, long and short precedence over the globally specified attributes in the “screen
text visible. form” definition.
wr4 All elements invisible.
wr5 As wr2 except entries are immediately active. 6. Help Display-
with wr2 the entry becomes active exiting the field
or pressing enter/input/return. The name of the PDF file containing the help text needs to be
typed in speech marks. The display appears automatically if the
Access level:- cursor is positioned on the variable.
Attribute Level Password/Key position
ac7 7 Not released 7. System or user variables-
ac6 6 SUNRISE
ac5 5 EVENING The variable to be viewed is entered here, these have to be
ac4 4 CUSTOMER contained within speech marks. The variable must be
ac3 3 Key switch pos 3 addressed in the correct way.
ac2 2 Key switch pos 2
ac1 1 Key switch pos 1 Addressing Variables.
ac0 0 Key switch pos 0
Machine Data Syntax
Alignment of short text:-
Attribute Effect Global machine data $MN_...
al0 Left justified (Default)
al1 Right justified Axis specific machine data $MA_...
al2 Centred
Channel specific machine data $MC_...
Notes

A011
Setting Data 8. Position of short text
Global setting data $SN_... The Short Text defined in attribute No.4 positioned using
Axis specific setting data $SA_... parameter No.8.
The measurements are in pixels and relate to the top left
Channel specific setting data $SC_... corner of the main dialogue body.
System variable Three values can be entered to define the position from the left,
the position from the top and the width of the short text.
R parameter 1 $R[1] Each entry has to be separated by a comma.
PLC Data The following example would position the text “Short text” 200
pixels from the left and 100 pixels from the top with a width of
Byte y of bit z of data block x DBx.DBXy.z 250 pixels:
Byte y of data block x DBx.DBBy Def Var1=(R2///" ","Short text"///"$R[0]"/200, 100, 250//)
Word y of data block x DBx.DBWy 9. Position of I/O field
Double word y v. of data block x DBx.DBDy
The I/O field can be positioned and sized using parameter No.9.
String y with length z from data block x DBx.DBSy.z The measurements are in pixels and relate to the top left
corner of the main dialogue body.
Real y of data block x DBx.DBRy
Four values can be entered to define the position from the left,
Flag byte x bit y Mx.y the position from the top and the width and length of the I/O box.
Each entry has to be separated by a comma.
Flag byte x MBx
Flag word x MWx The following example would position the I/O box for the
defined variable, 600 pixels from the left and 100 pixels from the
Flag double word x MDx top with a width of 100 pixels and a height of 150 pixels:
Input byte x bit y Ix.y Def Var1=(R2///" "," "///"$R[0]"//600, 400, 100, 150/)
Input byte x IBx 10. Colours
Input word x IWx
The foreground and background colours of the I/O field can be
Input double word x IDx chosen by using parameter No.10.
The default colours are foreground: Black, background: White.
Output byte x bit y Qx.y These are determined by the “Write mode” (See parameter 5)
Output byte x QBx
The following table shows index number to bused to
Output word x QWx achieve the required colour.
The foreground colour is defined first, followed by a
Output double word QDx comma and the background colour:
Soft-key Status
Visible (Default) Se1 Index Colour

1 Black
Disabled (Grey text) Se2
2 Red/brown
Displayed(Last soft-key used) Se3 3 Dark green
4 Light grey
5 Dark grey
6 Blue
7 Red
8 Brown
9 Yellow
10 White
A011: END
Notes

A006 Electrical Cabinet Design
Sinumerik
Operate
Module Description:
Technological advances have resulted in the reduction in size of electronic equipment. The result
being that the equipment is more prone to heat, dust and moisture damage.
By calculating the power loss of the components and therefore ensuring the correct cooling
requirements of a particular cabinet, it is possible to reduce the failure rate of these and other components.
It is also essential that the cabinets are designed to prevent/minimise the ingress of contaminants.
Module Objective:
Upon completion of this module you will know the design criteria of electrical cabinets.
Content:
Sinumerik
Module Theory and Objective
Choice of Cabinet
Cabinet Cooling
Equipment Mounting.
Cables, plugs and sockets..
Cabinet Sealing.
Miscellaneous.
A006

A006
Electrical Cabinet Design: Description
Electrical Cabinet
Failure to construct an electrical cabinet to the requirements Design: START
set out in this module will result in premature failure of elec-
tronic components. This could be due to heat, dust moisture
etc. Miscellaneous
The following list shows the Seven Deadly Sins which must be
avoided.
Choosing a
Seven Deadly sins Cabinet
The key to building a good electrical cabinet is avoiding certain

“Sins” which will cause Electrical Cabinet
premature equipment failure and sporadic faults. Design: END
 Sin 1 Cooling units must be able to handle the heat

generated by the electrical equipment. Arrhenius’
Law
 Sin 2 Air circulation must be controlled in a manner
which will prevent condensation forming and must make
use of the natural convection of warm air.
 Sin 3 Shielding of cables should be done with pur-

posely made clamps and not with a wire tail.
Cabinet
 Sin 4 Cabinets should be fully sealed including unused Cooling
cable entries.
 Sin 5 Electrical equipment must be installed in such a

way that the air can flow freely,
recommended air gaps around the equipment
must be adhered to.
 Sin 6 Electrical cables must be routed so that sensitive Equipment

signal cables are kept separate from the power cables. Mounting
 Sin 7 DC link bus-bar connections must be

tightened to the recommended torque.
Cables, plugs
and sockets
Cabinet
Sealing
Notes

A006
Choosing a Cabinet Cabinet Ambient Temperature
Most of the heat within an electrical control cabinet is produced The ideal ambient temperature for the cabinet is 35°C.
by the drive The cooling unit should be set to achieve this temperature.
components. If the temperature is allowed to get too high the lifetime of the
components will be reduced.
Sinamics drives are available in internally or externally cooled If the temperature is set too low there is a risk of condensation
variants. forming on the electronic components which can also be
The internally cooled drive types dissipate heat within the detrimental to the equipment.
cabinet and will usually require a cooling unit to remove this
heat.
The externally cooled drive types dissipate heat to the outside
of the cabinet and may not require cooling units.
It may be preferable to always use cooler units as this allows

the cabinet to be sealed which is the best option for stopping
the entry of contaminants. Within the cabinets it may also be
necessary to install fans to ensure the air is circulated and
prevent “Hot spots” from forming.
The technical specifications of the individual hardware compo-

nent will provide details of the power loss measured in Watts.
Calculations are made to see if the cabinet can dissipate the
heat naturally.
The cabinet manufacturer can supply details of the heat-loss of
the cabinet.
Natural heat dissipation occurs through the cabinet walls
providing the wall is in free air and not against a wall for
example.
A general rule is that the energy dissipated is approximately
50Watts/m² of free cabinet wall assuming a 10° temperature
difference between the cabinet and the outside air.
Example 1:- A cabinet with a width of 3 m, a height of 2 m and

a depth of 1 m sited with its back to a wall has an effective
surface area of approximately 13 m².
2m x 3m = 6m² (Front)
2m x 1m = 2m² (left side)
2m x 1m = 2m² (Right side)
3m x 1m = 3m² (Top)
Total = 13m²
Therefore this cabinet is able to dissipate approximately 650 W.

(50W x 13m²)
If the actual losses of the cabinet equipment are higher than
this, other cooling measures have to be implemented.
Example 2:-
Internally cooled 36Kw Active Line Module-Power loss = 630W
Internally cooled 18A Single Motor Module-Power loss = 165 W
Internally cooled 30A Single Motor Module-Power loss = 630 W
These few items alone add up to 1425 W which would require

extra cooling if fitted into the cabinet described in example 1.
Notes

A006
Arrhenius Law
The following graph demonstrates Arrhenius Law and shows the effects that increased temperature has on the lifetime of elec-
tronic components.
It can be seen that an increase in temperature by 10 will result a 50% increase in the failure rate (50% reduction in life time).
Expected
Life Defect
Time Rate
120% — 9.00
— 8.00
100%
— 7.00
80% — 6.00
— 5.00
60%
— 4.00
40% — 3.00
— 2.00
20%
— 1.00
0% — 0.00
-10K -5K 0K 5K 10K 15K 20K 25K 30K
Temperature Change
Notes

A006
Cabinet Cooling. Cabinets with cooling units.
Cabinet cooling is usually accomplished using fans and filters Correct installation of cooling units.
or cooling units.
The cool air should be directed to the bottom of the drive. The
The fans and filter option would normally be used on low internal drive fans and natural convection will draw the air
power installations or where the drive units are of the through the drives.
externally cooled type.
A drawback of this method is that the fans pull air from outside The cool air from the cooling unit should not be directed
the cabinet via filters. Even if the filters are serviced regularly it straight onto/into the drives, it should be allowed to mix with
is impossible to keep all contaminants out of the cabinet. the warmer air already in the cabinet, This will minimise the
risk of condensation forming.
Cooling units allow the cabinets to be air-tight as the air within
the cabinet is re-circulated through the cooling unit. Cabinet top mounted cooling units require a method of direct-
A thermostat should be employed to regulate the temperature ing the cool air from the cooling unit to the bottom of the
to the recommended 35°C. drives.
If a higher temperature is unavoidable (max 50°C) the drive
units have to be de-regulated. In the case of a door mounted unit it may be necessary to
direct the cool air with the use of baffles.
It is important to position the cabinet and cooling devices to
ensure correct operation. Example of cabinet cooling with roof mounted cooling units:
A cabinet placed in such a position where it restricts the venti-
lation inlet/outlet can prevent the cabinet from being cooled
correctly or result in the cooling unit becoming damaged due
to excessive work cycles.
The cooling device should also be positioned to ensure the Outlet Cooling
cool air is reaching the desired areas and that the warm air is unit
extracted and not allowed to cause hot spots within the cabi- Inlet
net.
The inlets and outlets of the cooling units must have a

clearance of at least 200mm.
Example:
≥ 200mm Ducting
Roof mounted
cooling units
Outlet
m
≥ 200mm 0m
20
≥
t
Drive
t
le
le
In
In
equipment
Potential
obstruction
Electrical Electrical
cabinet cabinet
Temperature
Measuring point
The use of baffles is recommended to prevent ventilation short

circuits where the exhaust air is taken directly into the cooling
units.
Cabinet top mounted cooling unit.
Notes

A006
Example of cabinet cooling with door mounted cooling units: Cabinet cooling sins.
The following diagrams are examples of cabinet cooling sins:
Outlet Cooling
unit
Inlet
Outlet
≥ 200mm Cooling
unit Air short circuit due
Drive to lack of ducting
equipment
Baffle
Temp.
Meas. Drive
point Inlet equipment
Cabinet door mounted cooling unit.
It is advisable that the cooling units are switched off

automatically when the cabinet door is opened.
Large differences between the outside air temperature and the

cabinet temperature can lead to condensation forming when
the cabinet doors are opened. This should be taken into
Cabinet top mounted cooling unit with-
consideration when the cabinet thermostat is set. out ducting
A by-product of cooling units is water. For obvious reasons it

must be ensured that this water is not allowed to enter the
electrical cabinet . This is particularly important for roof
mounted cooling units as any leaking water could drip directly
onto the drive equipment.
The outside of the cooling unit must be protected from any

possible contamination such as coolant, machine waste etc.
Notes

A006
Cabinet cooling sins continued. Cabinet cooling sins continued.
Air intake restricted due to

narrow gap between cooling
unit and drive equipment. Cold air outlet at the
top of the cooling
unit.
< 200mm
Drive Drive
equipment equipment
Cold air directed straight

onto drive equipment will Warm air intake at the
cause condensation bottom of the cooling
problems. unit.
Wrong type of cooling unit used.
Air short circuit/contamination

due to cabinet sealing problems
≥ 200mm
Drive
equipment
Baffle
Temp.
Meas.
point
Air short circuit/contamination due to

cabinet sealing problems
Notes

A006
Cabinets Without Cooling Units
For cabinets with externally cooled drive units it is possible that

the cooling can be achieved with fans drawing air from the
outside via a filter.
Natural convection causes the warm air to exit via a filter.
The fact that air is being drawn directly from the outside means
that this system can never be airtight.
Having a fan for the inlet side only ensures that the cabinet is
positively pressurised which helps keep contaminants from
entering.
It is extremely important that the filters are service regularly to
avoid ingress of contaminants and to maintain the efficiency of
the cooling process.
Example: Cabinet with externally cooled drive units.
Outlet
via filter
Drive
equipment
Temperature
Measuring points
Inlet via
Fan &
filter unit
Fan & filter type cooling system
Notes

A006
Equipment Mounting
Example:- Externally cooled
The correct mounting of equipment is important with respect drive module heat-sinks
to the cooling process and for Electromagnetic compatibility protruding from the rear of a
measures. cabinet with a cut-out ready to
accept another module.
Air flow to drive units:
It is essential that the air flow to the drive units is unrestricted.

Other electrical equipment, including cable ducting and ca-
bles, must be mounted a suitable distance away from the top
and bottom sides of the drive units. The minimum clearance
distance for Sinamics S120 drives is 80mm.
Examples: Correct mounting methods for drive equipment.
Cable
ducting Example:- Externally cooled
drive modules with heat-sink
≥ 80mm cover and fan/filter.
The fan takes air in at the
bottom and the cover creates
a chimney effect to give a
good cooling effect.
Drive
equipment
≥ 80mm
Cable
ducting
Diagram showing minimum Photograph of correctly

distance between drive units installed drive units. Cables
and other cabinet components. and ducting are not causing
restrictions to the air flow.
Notes

A006
Equipment Mounting continued.
Example of a filter, reactor and line module installation.
Electromagnetic Compatibility (EMC)
To cut down on the interference effects caused by the high

frequency drive equipment certain measures can be taken.
One of these includes the positioning of the equipment within
the cabinet. Filter
By positioning the line module, reactor and filter in close prox-
imity to each other, cables lengths can be kept to a minimum
thus cutting down on emissions.
Further reductions in emissions can be achieved by screening
the cables.
The mounting plate for the equipment should be one of bare
metal, this acts as a central earth point and also improves the
EMC. Cable screen
ground point
Example: A bare metal backplane ready for the drive modules

to be mounted, note the earth bonding cables, one for each
drive module.
Reactor
Line Module
Right:- Example of a filter, reactor and line module installation.

Example: How shielded cable can be grounded.
Notes

A006
Equipment mounting continued
A typical cabinet layout demonstrating the close proximity of the filter, reactor and line module in order to reduce the interference
effects of the high frequency drive current.
The use of shielded cables is also necessary to further eliminate this Interference.
Shielding plates offer the best method for grounding the shields.
The power cables and the signal cables should also be run separately from each other throughout the machine and not just in
the electrical cabinet.
It is not permissible to connect any other equipment between the line module and the filter and reactor.
Remaining
Equipment
Filter
Shielded DriveCliq
Cables
Shielded Power Cables
Comb Power Module Add.

Axis
Line Module and Module
Main
4 Motor Modules
Switch
Filter Reactor
Protection
Shield plate for

≥ 100mm grounding the shields
Shielded Power Cables

Shielded Motor Cables
Notes

A006
Cables, Plugs and Sockets. Example: An Incorrectly shielded cable
Shielding
Shielded power cables are recommended between the Sinam-

ics line filter, reactor and line module. If the cable length is 1m
or less the cables can be twisted and not shielded.
Signal cables and power cables should be kept separate by a

distance of at least 0.2m.
Cables should be kept as close as possible to objects with a

ground potential, this reduces crosstalk between cables.
Where the cable shield is grounded it should be done with the

use of grounding plates, this allows a large surface area of the
shield to be connected. The use of a wire to connect the shield
to ground is not permitted as the wire then becomes an aerial
which can introduce problems. Shielding that is connected via a plug & socket housing must
use a metallic housing with a continuous metallic contact.
Failure to observe all of the above can lead to intermittent Metalized housings are not permitted, over a period of time the
faults. metalized coating becomes worn and fails to be conductive to
the levels required.
The shielding of cables has a downside in that it causes addi- To maintain the airtight properties of the cabinet, cable outlets
tional losses in the line filter, reactor, in-feed and motor mod- should use methods
ules. This becomes worse the longer the cable length and can which form a seal and any unused openings blanked off.
cause overheating of the drive components.
A maximum of 50m is allowed for each motor module and a
maximum of 150m for each drive system.
Examples of cabinet cable entries:

Example: Correctly shielded cables
With plugs and sockets
Notes

A006
Cabinet Sealing
Cables, Plugs and Sockets.
A cabinet that isn’t sealed correctly can lead to a multiple of
Cabling Sins problems. Poor Sealing can be caused by cable entries, poorly
fitting doors, etc.
A poorly sealed cabinet can:-

Encoder and power cables in close proximity:
 Influence the air circulation and cause overheating due
to hotspots forming and air short circuits.
 Lead to a high moisture content which can in turn lead

to component failure.
 Emit electrical interference, causing problems with

other nearby equipment.
 Allow harmful, conductive contaminants to enter

causing component failure.
The cabinet door should always be closed and locked during

normal running operation, access should only be with a key or
tool and by authorised personnel.
Below:-An example of a poorly fitting cabinet door.
Top
Encoder and motor cables in close proximity.
Bottom
Notes

A006
Miscellaneous
Coil Suppression
Poor Electromagnetic compatibility can also affect other

cabinet mounted components.
To deal with this suppressing devices can be used on any item
with a coil. (Except servo motors)
AC components use RC networks for suppression while DC
components use diodes.
Below:-Example of 3 phase AC suppressors
AC Suppressor
A006: END
Notes

A006 END

A103 Service Used Cases for 840D sl
Sinumerik
Operate
Module Description:
If a fault occurs on the machine, this module describes a method for the diagnostics and thus for locating the
possible cause. Most of the checks shown can be performed without any further equipment with the tools
already integrated in the system. In certain cases, a PG with STEP 7 software and a suitable connecting ca-
ble is required. The aim of this guide is to keep the machine downtime as small as possible through quick
analysis of the cause of the problem.
Learn about the numerous options for the diagnostics of a fault and the subsequent fault rectification.
Module Objective:
Content:
Sinumerik
Diagnostics of the operating panel

Diagnostics of the machine control panel
Check of the handwheels
Check of the probe inputs and configuration
Diagnostics of the line module
Diagnostics of the PLC module
Diagnostics of the safety modules
Diagnostics and replacement of an NX module
Diagnostics and replacement of an SMC module
Replacement of a motor module
Replacement of a double motor module
Replacement of an axis motor
Cross exchange of two SMC modules
A103
A103

A103
Service Used Cases for 840D sl: Description

Service Used Cases
for 840D sl:
START Diagnostics
If a fault occurs on the machine, this module describes a and replace-
method for the diagnostics and thus for locating the possible ment of an
cause. Most of the checks shown can be performed without SMC module
any further equipment with the tools already integrated in the Diagnostics
system. In certain cases, a PG with STEP 7 software and a of the opera-
suitable connecting cable is required. The aim of this guide is ting panel
to keep the machine downtime as small as possible through Replacement
quick analysis of the cause of the problem. of a motor
module
Diagnostics
of the machi-
ne control
panel Replacement
of a double
motor modu-
le
Check of the
handwheels
Replacement
of an axis
motor
Check of the
probe inputs
and
configuration Cross ex-
change of
two SMC
modules
Diagnostics
of the line
module
Service Used Cases
for 840D sl:
END
Diagnostics
of the PLC
module
Diagnostics
of the safety
modules
Diagnostics
and replace-
ment of an
NX module
Notes :

A103
Diagnostics of the operating panel
Operating panel is dark

Operating panel is defective
A positive check must have the following status:

1. TFT: Power LED green (power supply)
2. TFT: Temperature LED not on (temperature monitoring - lights up briefly when switching on)
3. TCU: Ethernet LED green (connection)
4. TCU: Ethernet LED orange (data communication)
TFT TFT TCU External video

Power LED Temp. LED Ethernet LED
Off Off Off Power supply
Off Off On TCU/TFT ribbon cable con-

nector
Off Off On OK Screen defective
On Off On OK
Notes :

A103
PCU defective (distributed configuration with the PCU in the cabinet)
If a PCU50 is used and the following message appears on the display, then there is no communication with the PCU.
A positive check must have the following status:

1. TFT: Power LED green
2. TFT: No temperature LED on permanently
3. PCU: Ethernet LED on
4. PCU: Diagnostics display on the PCU must show “00”
5. The BIOS version must be displayed briefly when switching on
Notes :

A103
7-segment display
The following is a list of the customer-relevant POST codes in the order in which they occur. Please
contact the Customer Support for all other POST codes.
Display Meaning Description

(hex)
16H TP_CHECKSUM BIOS Checksum test
28H TP_SIZE_RAM DRAM Determine the size
2AH TP_ZERO_BASE Set 64 KB base RAM to 0
2CH TP_ADDR_TEST Check address lines
2EH TP_BASERAML Base RAM low
30H TP_BASERAMH Base RAM high
38H TP_SYS_SHADOW BIOS will be copied to the

DRAM
3AH TP_CACHE_AUTO Determine CPU cache
22H TP_8742-TEST Test keyboard controller Check whether keyboard is

connected or defective
3CH TP_ADV_CS_CONFIG Configure advanced chip set By way of trial, switch the
hardware components off in
the setup
49H TP_PCI_INIT Initialize PCI interface By way of trial, switch the

the setup
or remove the installed ex-
tension modules on the bus
module
55H TP_USB_INIT Activation of the Removal of USB

USB hardware devices
4AH TP_VIDEO Initialization of the video inter-
face
5CH TP_MEMORY_TEST Test of the system memory
Notes :

A103
Display Meaning Description
(hex)
60H TP_EXT_MEMORY Test of the complete memory
62H TP_EXT_ADDR Test of the address lines
90H TP_FDISK Initialization and Disconnect hard disk,

test of the replace, if required
hard disk hardware
95H TP_CD Initialization and

test of the
CD hardware
98H TP_ROM_SCAN Find BIOS extensions By way of trial, switch the

the setup
or remove the installed exten-
sion modules on the bus mod-
ule
BCH TP_PARITY Test of the
memory modules
00H BIOS Power On self

test completed.
Operating system will be
loaded.
Source: SIMATIC Box PC 627B, 12-2, Operating Instructions, 05/2007, A5E00927392-01
In addition to the listed POST codes, there are also the following beep codes:
 3x short beeps: INSERT key is pressed at the start of the system:

If an external graphics card is not detected on the bus PCB, you can attempt to activate this card by
pressing the INSERT key. The "INSERT" key activates special enumerations in order to activate
a PCI-VGA card.
 1x long 8x short beeps: Error occurred when reading the MPI system information:
Please contact the Customer Support.
 4x short beeps: MPI firmware has been updated:

This can occur once after a BIOS update.
 2x short beeps: Error occurred during the checksum test of the BIOS:
Can occur after a battery replacement or when the battery is empty.
Notes :

A103
TCU with message on HMI
If the following message appears on the display (no PCU50 available), then the communication with the NCU is faulty.
This can have various causes:
 Has the NCU booted correctly and is the 7-segment display at 6
 Check the Ethernet connection
 Is the HMI on the NCU switched on
Notes :

A103
TCU replacement
After booting, the “Unknown/New TCU” menu appears because the system has detected a new network adapter.
Press the F2 key to replace the old network address with the new address and save it. The HMI screen is immediately opened
again after another Power On.
Notes :

A103
Diagnostics of the machine control panel
Machine control panel (Ethernet) flashes or is dark
A simple data packet can be sent to the machine control panel. You must connect a computer to the NCU and then open a DOS
window.
You can send a data packet to a destination address in the DOS shell operating area with the PING command. The response of
the node is shown accordingly.
The PING command requires the destination address as a further parameter.
In the standard configuration, the destination address is 192.168.214.192.
Therefore, a communication test can be performed with the command “PING 192.168.214.192”.
A good and a bad example are shown in the following
Successful transmission of data to and receipt of data from the machine control panel.
No communication with the component.
Notes :

A103
DIP switch on machine control panel
The address that is set can be read at DIP switch S2.

The last number of the Ethernet address must be set here.
Example: Address = 192.168.214.192
1 = off
2 = off
3 = off
4 = off
5 = off
6 = off
7 = on
8 = on
9 = off  always off
10 = off  always off
Check the Ethernet connection
Is the Ethernet LED on?
DIP
switch
Ethernet connection
to the TCU
Ethernet connection
from the HUB
Notes :

A103
Check of the handwheels
Handwheels do not work
The handwheel signals between the NCK and HMI are displayed as of DB10.DBB68.
Handwheel
connection
Handwheel connection on the control panel
Notes :

A103
The hardware segment to which the handwheel is connected is set in parameter 10350. A distinction is made between setting
“5” PROFIBUS and setting “7” Ethernet.
Description:
The machine data specifies the HW segment to which the handwheel is connected:
0 = SEGMENT_EMPTY; no handwheel
1 = SEGMENT_840D_HW; handwheel on 840D HW
2 = SEGMENT_802DSL_HW; handwheel on 802D sl HW
5 = SEGMENT_PROFIBUS; handwheel on PROFIBUS
7 = SEGMENT_ETHERNET; handwheel on Ethernet
Notes :

A103
The probe input is entered in parameter p680 of the control unit.
Notes :

A103
Check of the probe inputs and configuration
No signal from the probe
The NCK->PLC interface must be checked in DB10.DBB107 when the probe signal is missing.
The switching of the probe is displayed here by the signal change (from 1->0 or 0->1 depending on the setting).
If the probe does not switch here, check parameter r722 of the control unit.
If there is also no probe signal here, check the connecting cable of the NCU connector X122 (or X132).
 Is the ground connection from X122.12 to the probe connected correctly?
 Is the power supply from X122.11 to the probe connected correctly?
If there should be a signal change here, check the hardware configuration in STEP 7.
Notes :

A103
Diagnostics of the line module
Line module is defective
Error display when a line module fails
In this case, message 201481 is the decisive error message. Further diagnostics must be performed at Diagnostics / Drive sys-
tem.
Notes :

A103
Check of the defective module
Check in “Diagnostics / Drive system”
Notes :

A103
Check in topology
Note: Modules displayed in gray are modules that are missing in the actual topology.
In this example, this means that the line module connected to the NCU has failed. The module is connected to the NCU DRIVE-
CLiQ connection X100.
Notes :

A103
Replacement of the hardware
Only a hardware replacement is required. After switching on, the controller boots without errors and you can continue working
with the machine.
Notes :

A103
Smart Line Module as of 16 KW with ET connection
In preparation
Notes :

A103
Diagnostics of the PLC module
PLC module has a fault

Alarm list when a PLC module fails
Further details are available at the extension softkey of the Bus TCP/IP diagnostics.
Notes :

A103
Diagnostics of the safety modules
Safety module has a fault

Alarm list when a PROFIsafe module fails
Further details are available at the extension softkey of the Bus TCP/IP diagnostics.
Notes :

A103
Diagnostics and replacement of an NX module
Replacement of an NX15 module
Error display when an NX15 module fails (connected drives are integrated in SI)
Check of the defective module in the topology overview
In this example, this means that the CU module (CU_S_2) connected to the NCU720 has failed.
The module is connected to the NCU DRIVE-CLiQ connection X105.
Notes :

A103
Only a hardware replacement is required. After switching on, the controller boots without error messages and you can continue
working with the machine.
Notes :

A103
Diagnostics and replacement of an SMC module
Replacement of an SMC module
Error display when an SMC module with motor encoder connection and with Safety Integrated fails
In this example, this means that the SMC module of the C axis connected to the double motor module of the C/B axis has failed.
The module is connected to the motor module DRIVE-CLiQ connection X202.
Notes :

A103
Confirmation of the SI checksum
The following diagnostics display is shown after rebooting:
This means that the SI checksum must be confirmed after replacement of the module:
“Select menu”  “Commissioning”  “>“  “Safety”  “Confirm SI data”.
Notes :

A103
Confirm with “OK”.
Then confirm again with “OK” and switch the machine OFF/ON.
Notes :

A103
Component update:
Note:
In order to align the firmware version of the replaced module with the active drive version, a firmware update of the replaced
component must also be performed without error display.
If this is not performed automatically, it must be performed manually by the service personnel.
“Select menu”  “Commissioning”  “Drive system”  “Drive unit”

 select the replaced module with the cursor
Press the “Load firmware...” softkey.
Notes :

A103
When the following message appears:
Remove the EP terminals (X21) at the top of the infeed and the motor modules.
Confirm the message with “OK”.

Then press “Load firmware...” again.
Press the “Selected” softkey.
Notes :

A103
The update is started. The following message appears during the update.
and the LED on the SMC flashes red.
After completion, the following message appears,
which can be acknowledged with “OK”. The machine must then be switched OFF/ON.
Note:
After the successful replacement, the new checksums with the associated date must be changed in the Safety Integrated accep-
tance report. The replacement of the components must also be documented in this report.
Notes :

A103
Replacement of a motor module
Replacement of a defective motor module
Error display when a motor module, whose axes have been integrated in Safety Integrated, fails
Diagnostics in drive system
Notes :

A103
Details in drive system
Alarms and faults in drive system
Notes :

A103
Notes :

A103
Replacement of a double motor module
Replacement of a defective double motor module
Error display when a double motor module, whose axes have been integrated in Safety Integrated, fails
Note: Modules displayed in red are modules that are missing in the actual topology.
In this example, this means that the double motor module of the X axis connected to the double motor module of the C4 axis has
failed .
The module is connected to the motor module DRIVE-CLiQ connection X201.
Notes :

A103
Two-encoder system, but only motor encoder in SI
Error display when an axis motor with motor encoder connection and with Safety Integrated fails
Error simulation: DRIVE-CLiQ SMI disconnected
Note: Modules displayed in red are modules that are missing in the actual topology.
In this example, this means that the SMI module of the X motor has failed .
The module is connected to the motor module Y/Z, to the DRIVE-CLiQ connection X202.
Notes :

A103
Confirmation of the SI checksum
The SI checksum must be confirmed after replacement of the module:
Component update
Normally, the firmware is updated automatically. If this is not the case, you can also perform this manually.
Note:
After the successful replacement, the new checksums with the associated date must be changed in the Safety Integrated accep-
tance report. The replacement of the components must also be documented in this report.
Notes :

A103
Cross exchange of two SMC modules
Cross-exchange of two SMC modules
For diagnostic purposes, a cross-exchange of two SMC modules of the same type can be performed.
The following description is performed for the following configuration:

- Both SMCs are assigned to the CU
- Both SMCs are for direct measuring systems without SI
- SMCs of the axes B and C
Note:
- The DRIVE-CLiQ connections and the measuring system connections must be reconnected “one to one”
- Do not overstretch the cable as this can result in defective cable connections
- The modules must be re-arranged if the cables are too short
After the hardware re-arrangement and a reboot, the following diagnostic messages appear:
Now press the “Confirm SI HW” softkey.
Notes :

A103
The machine can now run again after successful confirmation of the hardware.
Now only the acceptance test has to be performed for the new HW components.
A103: END
Notes :

A043 Technology Settings
Sinumerik
Operate
Module Description:
The Technology settings for Milling and Turning are located in Machine Data areas.
This module shows the different areas.
The Machine Data numbers are within the following ranges:-

51xxx = General Machine Data
52xxx = Channel Machine Data
53xxx = Axis Machine Data
54xxx = General Setting Data
55xxx = Channel Setting Data
56xxx = Axis Setting Data
Module Objective:
Upon completion of this module you will know the 840D sl Sinumerik Operate Technology machine data ar-
eas and be able to carry out adjustments if required.
Content:
Sinumerik
General Machine Data
Channel Machine Data
Axis Machine Data
General Setting Data
Channel Setting Data
Axis Setting Data
A043
A043

A043
Technology Settings: Description Technology

Settings:
START
The Technology settings for Milling and Turning are located in
different logical Machine Data areas.
This module shows the different areas.
The Machine Data numbers are within the following ranges:-

General
51xxx = General Machine Data
Machine Data
52xxx = Channel Machine Data
53xxx = Axis Machine Data
54xxx = General Setting Data
55xxx = Channel Setting Data
56xxx = Axis Setting Data
Channel
Machine
Data
Axis Ma-
chine Data
General Setting
Data
Channel Setting
Data
Axis Setting
Data
Technology
Settings:
END
Notes

A043
MD Identifier Description Old MD/GUD
51000 DISP_RES_MM Display resolution in mm

A043
51001 DISP_RES_MM_FEED_PER_REV Display resolution in mm feedrate/rev

51002 DISP_RES_MM_FEED_PER_TIME Display resolution in mm feedrate/min
51003 DISP_RES_MM_FEED_PER_TOOTH Display resolution in mm feedrate/tooth
51004 DISP_RES_MM_CONST_CUT_RATE Display resolution constant cutting speed m/min
51010 DISP_RES_INCH Display resolution in inch 9011
51011 DISP_RES_INCH_FEED_P_REV Display resolution in inch feedrate/rev
51012 DISP_RES_INCH_FEED_P_TIME Display resolution in inch feedrate/min
51013 DISP_RES_INCH_FEED_P_TOOTH Display resolution in inch feedrate/tooth
51014 DISP_RES_INCH_CUT_RATE Display resolution constant cutting speed ft/min
51020 DISP_RES_ANGLE Display resolution of angle
51021 DISP_RES_SPINDLE Decimal places in speed entry field 9010, 9664
Page 4
51022 DISP_RES_ROT_AX_FEED Display resolution of rotary axis feedrate
51023 ACT_VALUE_SPIND_MODE Only display spindles in actual values window
This affects the display of the spindles in the axis actual values window.
0 = Spindles are always displayed
1 = Spindles are displayed only if in axis mode
((This affects the display of the spindles in the axis actual values window.
0 = all spindles are displayed
1 = only those spindles in axis mode are displayed)
51025 FRAMES_ACT_IMMEDIATELY Active data (frames) are activated immediately after change 9440
51026 AXES_SHOW_GEO_FIRST When the machine data value is 1, the geometry axes of the channel are displayed 9421
first.
51027 ONLY_MKS_DIST_TO_GO Distance-to-go display in work window 9420
51028 BLOCK_SEARCH_MODE_MASK Bit mask for available block search modes
Bit 0: Block search with calculation without approach
Bit 1: Block search with calculation with approach
Bit 2:
Bit 3: Skip EXTCALL programs
Bit 4: Block search without calculation
Bit 5:


51029 MAX_SKP_LEVEL The machine data defines how many skip levels are made available for operation. 9423
51030 SPIND_MAX_POWER Maximum value of the permissible spindle power rating in percent; the display bar in the 9428
machine image is shown in green within the range between 0 and the value stored in

SPIND_MAX_POWER.
51031 SPIND_POWER_RANGE Scale end value for spindle power rating in percent; value must be equal to or greater than 9429
SPIND_MAX_POWER.
The display bar in the machine image is shown in red in the range between the values of
SPIND_MAX_POWER and SPIND_POWER_RANGE.
51032 STAT_DISPLAY_BASE Number basis for display of articulated joint STAT 9042
00: no display
02: binary value display
10: decimal value display
16: hexadecimal value display
51033 TU_DISPLAY_BASE Number basis for display of rotary axis position TU 9243
00: no display
Page 5
02: binary value display
10: decimal value display
16: hexadecimal value display
51034 TEACH_MODE Teach mode to be activated 9026
Bit 0: Default teach-in
Taught-in block is transferred to the program using the Accept softkey.
Bit 1: Acceptance of teach block can be blocked by the PLC.
DB19.DBX13.0 = 0 block is accepted.
DB19.DBX13.0 = 1 block is not accepted.
Bit 2: Block selection only explicitly
Bits 16-31 Reserved for OEM.
51035 WRITE_FRAMES_FINE_LIMIT Input limit for all work offsets fine
51036 ENABLE_COORDINATE_REL Display REL coordinate system
0 = no relative coordinate system selectable
1 = REL coordinate system can be selected as an alternative of the WCS/SZS coordinate
system
51037 ENABLE_COORDINATE_ACS Activate settable coordinate system 9424
0 = WCS coordinate system is displayed.
1 = SZS coordinate system is displayed.
A043
(SZS is WCS reduced by the offset components defined in MD24030)
A043
A043
51038 SET_ACT_VALUE Set actual value selection 9422
0 = Set actual value is not offered.
A043
1 = If a user frame (settable work offset e.g. G54) is active, it will be used. In G500 Set ac-
tual values is not offered (system frame is no longer used).
51039 PROGRAM_CONTROL_MODE_MASK Options for machine - program influence:

Bit 0: Program test function available
51040 SWITCH_TO_MACHINE_MASK Automatic operating area switchover to machine
Bit 0: When selecting a program in the program manager, the operating area does not auto-
matically switch over to Machine.
Bit 1: When switching the type of operation via the MCP, the operating area is not automati-
cally switched over to Machine.
51041 ENABLE_PROGLIST_USER Activates the PLC program list of the USER area. The programs entered there can be se-
lected by the PLC for processing.
51042 ENABLE_PROGLIST_INDIVIDUAL Activates the PLC program list of the INDIVIDUAL area. The programs entered here can be
selected by the PLC for processing.
51043 ENABLE_PROGLIST_MANUFACT Activates the PLC program list of the MANUFACTURER area. The programs entered here
Page 6
can be selected by the PLC for processing.
51044 ACCESS_SHOW_SBL2 Display protection level SBL2 9227
51045 ACCESS_TEACH_IN Protection level TEACH IN 9219
51046 ACCESS_CLEAR_RPA Protection level delete R variables 9221
51047 ACCESS_READ_GUD_LUD Read user variable protection level 9211
51048 ACCESS_WRITE_GUD_LUD Write protection level of user variables
51049 ACCESS_WRITE_PRG_COND Write program control protection level 9214
51050 ACCESS_WRITE_PROGRAM Write part program protection level 9217
51051 ACCESS_WRITE_RPA Protection level write R variables 9222
51052 ACCESS_WRITE_SEA Protection level write setting data 9215
51053 ACCESS_WRITE_BASEFRAME Write basic work offset (basic frame) protection level
51054 ACCESS_WRITE_CYCFRAME Write cycle frame protection level 9186

51055 ACCESS_WRITE_EXTFRAME Write external work offset protection level 9188


51056 ACCESS_WRITE_PARTFRAME Write table reference protection level 9184
51057 ACCESS_WRITE_SETFRAME Write basic reference protection level
51058 ACCESS_WRITE_TOOLFRAME Write basic tool reference protection level 9183

51059 ACCESS_WRITE_TRAFRAME Write transformation frame protec. level 9187
51060 ACCESS_WRITE_USERFRAME Write settable work offset (G54 ... G599) protection level
51061 ACCESS_WRITE_WPFRAME Write workpiece reference protection level 9185
51062 ACCESS_WRITE_FINE Write protection level for fine offset of all work offsets 9203
51063 ACCESS_SET_ACT_VALUE Set actual value protection level 9220
51064 ACCESS_WRITE_PROGLIST Write protection level of program list in USER area
51065 NUM_DISPLAYED_CHANNELS Number of channels displayed simultaneously 9034
51066 ORDER_DISPLAYED_CHANNELS Channel numbers of the channels displayed
Contains the numbers of the channels to be displayed under machine in the multi-
Page 7
channel view, in the desired order and separated by commas, semicolons or spaces.
51200 ACCESS_WRITE_TM_GEO Write tool offset geometry data protection level 9201
51201 ACCESS_WRITE_TM_WEAR Write tool offset wear data protection level 9202
51202 ACCESS_WRITE_TM_WEAR_DELTA Protection level for restricted writing of tool wear values 9203
S. MD 54213: TM_WRITE_DELTA_LIMIT
51203 ACCESS_WRITE_TM_SC Write tool offset sum offset protection level 9204
51204 ACCESS_WRITE_TM_EC Write tool offset use offsets protection level 9205
51205 ACCESS_WRITE_TM_SUPVIS Write tool offset monitoring data protection level 9206
One authorization applies to all limit values: quantity, service life, wear and the monitor-
ing type.
51206 ACCESS_WRITE_TM_ASSDNO Write tool offset unique D number protection level 9207
51207 ACCESS_WRITE_TM_ASSDNO Write tool offset wear groups (magazine location / magazine) protection level 9208
51208 ACCESS_WRITE_TM_ADAPT Write tool offset tool adapter geometry data protection level 9209
A043
A043
A043
51209 ACCESS_WRITE_TM_NAME Write tool offset tool name and duplo data protection level 9240
A043
51210 ACCESS_WRITE_TM_TYPE Write tool offset tool type protection level 9241
51211 ACCESS_READ_TM Read tool offset data protection level 9200

51212 TM_WRITE_WEAR_ABS_LIMIT With TM_WRITE_WEAR_ABS_LIMIT, the max. possible value of a tool wear is limited 9639
absolutely, independently of the current protection level (keyswitch position), i.e. also
independently of ACCESS_WRITE_TM_WEAR. Absolute and incremental wear limita-
tion can be combined, i.e. the wear can be changed incrementally up to the absolute
limit. S. MD 51213.
51213 TM_WRITE_WEAR_DELTA_LIMIT When entering tool offsets, the value of the change from the previous value to the new 9450
value cannot exceed the value set here.
With TM_WRITE_WEAR_DELTA_LIMIT, the change to a tool wear can be limited incre-
mentally, if the current protection level is the same as or higher than the one set in AC-
CESS_WRITE_TM_WEAR_DELTA. With the current protection level being the same or
higher than ACCESS_WRITE_TM_WEAR, an incremental limitation is no longer per-
formed. incremental wear limitation can be combined, i.e. the wear can be changed up
to the absolute limit. S. MD 51212
Page 8
51214 TM_WRITE_LIMIT_MASK Validity of the restricted tool wear input 9449
Bit 0: Use for cutting edge data, wear
Bit 1: Use for SC data, sum offsets
Bit 2: Use for EC data, use offsets
Bit 0+1+2: Use for all data, wear, SC, EC
51226 FUNCTION_MASK_SIM Function mask Simulation
Bit 0: No automatic start on simulation selection
51230 ENABLE_LADDER_DB_ADDRESSES Activation of DB addresses in PLC Ladder Viewer
51231 ENABLE_LADDER_EDITOR Activation of PLC Ladder Editor
51235 ACCESS_RESET_SERV_PLANNER Protection level for acknowledgement of maintenance tasks
51600 MEA_CAL_WP_NUM The workpiece probe calibration data refer to the workpiece coordinate system (WCS)!
In the data fields, the workpiece probe calibration data of the technologies Milling and
Turning are stored!
51601 MEA_CAL_EDGE_NUM The gauging block is exclusively used to calibrate the workpiece probe of the Turning
technology!


51602 MEA_CAL_TP_NUM The geometry data and calibration data of the tool probe refer to the machine coordinate system
(MCS)!
51603 MEA_CAL_TPW_NUM The geometry data and calibration data of the tool probe refer to the workpiece coordinate system
(WCS)!

51606 MEA_INPUT_PIECE_PROBE Selection of NC measuring input for measuring the workpiece 9750
$MCS_MEA_INPUT_PIECE_PROBE[0] corresponds to NC measuring input 1
$MCS_MEA_INPUT_PIECE_PROBE[1] corresponds to NC measuring input 2
This parameter must be applied in conjunction with$MCS_MEA_INPUT_TOOL_PROBE[n]!
Either a workpiece probe or a tool probe can be connected to each of the NC measuring inputs!
Value:
=0: No workpiece probe connected/active
=1: Workpiece probe connected/active
51607 MEA_INPUT_PIECE_PROBE Selection of NC measuring input for measuring the tool 9751
$MCS_MEA_INPUT_TOOL_PROBE[0] corresponds to NC measuring input 1
$MCS_MEA_INPUT_TOOL_PROBE[1] corresponds to NC measuring input 2
This parameter must be applied in conjunction with$MCS_MEA_INPUT_PIECE_PROBE[n]!
Either a workpiece probe or a tool probe can be connected to each of the NC measuring inputs!
Page 9
Value:
=0: No tool probe connected/active
=1: Tool probe connected/active
51608 MEA_WP_PROBE_INPUT_SUB Workpiece probe available/active on the counter spindle

=0: Workpiece probe not available/active on the counter spindle
=1: Workpiece probe available/active on the counter spindle
51609 MEA_T_PROBE_INPUT_SUB Tool probe available/active on the counter spindle 9828
=0: Tool probe not available/active on the counter spindle
=1: Tool probe available/active on the counter spindle
51610 MEA_TOOLCARR_ENABLE Support of orientatable tool holders
0: No support of orientatable tool holders.
1: Support of a probe or tool positioned using an orientatable tool holder (kinematics type "T")
with reference to the special tool holder positions 0°, 90°, 180° and 270°.
51612 MEA_MONO_COR_POS_ACTIVE Monoprobe position offset GUD_CBIT[8]
0: No offset
1: If the workpiece probe is a monoprobe, the orientation of its switching direction (spindle posi-
tion) is offset by the angle value in _CORA.
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51614 MEA_PROBE_LENGTH_RELATE Length reference of the workpiece probe, measurement technology milling GUD
0: Tool length L1, referring to the centre of the probe sphere _CBIT14]
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1: Tool length L1, referring to the sphere volume of the probe sphere 9778
51616 MEA_CAL_MONITORING Activation of calibration status monitoring for measuring in automatic mode GUD
0: Calibration monitoring inactive _CBIT16]
1: Calibration monitoring active
Between calibration and measuring the status of the following states is monitored:
- Working plane (G17, 18, 19)
- Probe type (monoprobe, multiprobe)
- Length reference of the probe (centre point of the probe sphere, probe sphere volume)
- Programmed probe speed
For "Measure in JOG" these monitoring modes are always active and cannot be deactivated.
51618 MEA_CM_ROT_AX_POS_TOL Entries in parameter $MN_MEA_CM_ROT_AX_POS_TOL are effective only if

$MN_MEA_TOOLCARR_ENABLE=1
The real angle position of the rotary axes can deviate from the programmed one (exact stop fine
window).
This deviation depends on the position control features of the axis. The maximum deviation ex-
pected on the concrete axis must be entered in this parameter. When the tolerance is exceeded,
Page 10
alarm 61442 "Toolholder not in parallel with the geometry axes" is displayed.
51750 J_MEA_M_DIST This parameter defines the measuring path in front of and behind the measuring setpoint. 9752
51751 J_MEA_M_DIST_MANUELL Measuring path, manual measurement ((for "Measure in JOG")) [mm] (in front of and behind the 9753
measuring setpoint)
51752 J_MEA_M_DIST_TOOL_LENGTH Measuring path for tool length measuring. 9754
51753 J_MEA_M_DIST_TOOL_RADIUS Measuring path for tool radius measuring. 9755
51755 J_MEA_MEASURING_FEED Measuring feed for workpiece measurement and calibration of the workpiece probe, for "Measure 9756
in JOG"
51757 J_MEA_COLL_MONIT_FEED Feedrate in the working plane with active collision detection. 9757
51758 J_MEA_COLL_MONIT_POS_FEED Feedrate of the infeed axis with active collision detection, for "Measure in JOG". 9758
51770 J_MEA_CAL_RING_DIAM Calibration ring diameter, for probe sphere calibration in the plane, for "Measure in JOG"
51772 J_MEA_CAL_HEIGHT_FEEDAX Calibration height in the infeed axis for probe length calibration, for "Measure in JOG"
The calibration height must be entered with reference to the the workpiece coordinate system
(WCS)!


51774 J_MEA_T_PROBE_TYPE For the "cube" tool probe type, the three-dimensional geometric dimensions of the cube probe are 9763
entered in the three field elements of this parameter. Cube-shaped probes are mainly used for
turning tool measuring.
0 : Cube
101 : Wheel in XY, working plane G17

201 : Wheel in ZX, working plane G18
301 : Wheel in YZ, working plane G19
51766 J_MEA_T_PROBE_ALLOW_AX_DIR Permissible axis directions during tool probe calibration for milling tool measuring, for "Measure in 9764
JOG"
In the default setting, X and Y correspond to the plus and minus direction, Z only to the minus di-
rection.
The parameter is divided into three elements the functions of which must be assigned to calibra-
tion data records 1, 2 and 3!
The calibration data records are assigned to tool measuring in working planes G17 (1), G18 (2)
and G19 (3)!
Meaning of the parameter elements

Decimal position:
Ones: 1st geometry axis (X)
Tens: 2nd geometry axis (Y)
Page 11
Hundreds: 3rd geometry axis (Z)
Value:
=0: Axis not possible
=1: Only minus direction possible
=2: Only plus direction possible
=3: Both directions possible
51778 J_MEA_T_PROBE_DIAM_LENGTH Effective grinding wheel diameter of the tool probe for length measurement on milling tools, for 9765
"Measure in JOG"
51780 J_MEA_T_PROBE_DIAM_RAD Effective grinding wheel diameter of the tool probe for radius measurement on milling tools, for 9766
"Measure in JOG"
51782 J_MEA_T_PROBE_ALLOW_AX_DIR Distance between the upper edge of the tool probe and the lower edge of the tool for radius meas- 9767
urement on milling tools, for "Measure in JOG"
51784 J_MEA_T_PROBE_APPR_AX_DIR Approach direction in the plane on the tool probe, for "Measure in JOG" 9768
= 0 positive direction
= -1 negative direction
51786 J_MEA_T_PROBE_MEASURE_DIST Measuring path for tool probe calibration and tool measuring with stationary spindle, in front of and 9772
behind the expected switching position.
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51787 J_MEA_T_PROBE_MEASURE_FEED Measuring feed for tool probe calibration and tool measuring with stationary spindle, for "Measure 9773
in JOG".
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52000 DISP_COORDINATE_SYSTEM With this MD you adapt the operator panel of the coordinate system to the machine's coordinate 9650
system. Depending on the selected position, all help screens, the sequence graphic, the simula-
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tion and the input fields with the circular direction specified will change automatically.
Also note MD 52210 $MCS_FUNCTION_MASK_DISP, bit 1.
52005 DISP_PLANE_MILL Plane selection Milling 9660

0: plane selection on the operator panel
17: always G17
18: always G18
19: always G19
52006 DISP_PLANE_TURN Plane selection Turning
0: plane selection on the operator panel
17: always G17
18: always G18
19: always G19
52010 DISP_NUM_AXIS_BIG_FONT Number of actual values with large font
52200 TECHNOLOGY Technology 9020
0: no specific configuration
Page 12
1: turning
2: milling
Also note MD 52201 $MCS_TECHNOLOGY_EXTENSION.
52201 TECHNOLOGY_EXTENSION Extended technology
0: no specific configuration
1: turning
2: milling
Also note MD 52200 $MCS_TECHNOLOGY.
Example:
Turning machine with milling technology
MD 52200 $MCS_TECHNOLOGY = 1
MD 52201 $MCS_TECHNOLOGY_EXTENSION = 2
52205 NUM_AXIS_USED Number of axes used in the channel (axis gaps are also counted). 9650

52206 AXIS_USAGE Meaning of the axes in the channel 9703, 9704,

0 = no special meaning 9705, 9706,
1 = tool spindle (driven tool) 9707, 9708,
2 = auxiliary spindle (driven tool) 9720, 9802,
3 = main spindle (turning) 9803, 9804,

4 = C axis of the main spindle (turning) 9805, 9806,
5 = counter spindle (turning) 9807, 9808.
6 = C axis of the counter spindle (turning)
7 = linear axis of the counter spindle (turning)
8 = tailstock (turning)
9 = steady rest (turning)
10= B axis (turning)
52207 AXIS_USAGE_ATTRIB Axis attributes 9822, 9832,
Bit 0: Rotates around the 1st geometry axis (applies to rotary axes) 9824, 9825.
Bit 1: Rotates around the 2nd geometry axis (applies to rotary axes)
Bit 2: Rotates around the 3rd geometry axis (applies to rotary axes)
Bit 3: Displayed positive direction of rotation is counterclockwise (applies to rotary axes)
Bit 4: Displayed direction of rotation for M3 is counterclockwise (applies to spindles)
Bit 5: Direction of rotation M3 corresponds to rotary axis minus (applies to spindles)
Page 13
This bit must be set analog to PLC bit DBnn.DBX17.6!
(nn = 31 + machine data index)
52210 FUNCTION_MASK_DISP Function mask Display

Bit 0: Measuring system for programs always in the base system 9626 Bit 9
Bit 1: Use school coordinate system with G17 9719
Bit 2: Hide soft key T,S,M
Bit 3: Automatic generation of M30 in MDA
52212 FUNCTION_MASK_TECH Function mask Cross-technology
Bit 0: Enable Swivel 9723
Bit 1: No optimized travel along software limit switches
Bit 2: Approach logic for step drill (ShopTurn)
Bit 3: Call block search cycle for ShopMill/ShopTurn
Bit 4: Approach logic through cycle (ShopTurn)
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52214 FUNCTION_MASK_MILL Function mask Milling

Bit 0: Reserved
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Bit 1: High Speed Settings cycle (CYCLE832) Unhide input field Technology
Bit 2: High Speed Settings cycle (CYCLE832) Tolerance input field or table
[0 = Tolerance input field (values 0 ... 0.999 real value)]
[1 = Selection field (toggle) Tolerance table (values 1,2,3 .. 9 or higher)
The tolerance table is stored in the CYC_832T manufacturer cycle.
Bit 3: Enable inside/rear machining
Bit 4: Enable spindle clamping (C axis) 9843
Developers’ documentation:
Bit 0: Enable cylinder surface transformation for milling 9721
52216 FUNCTION_MASK_DRILL Function mask Drilling
Bit 0: CYCLE84 Unhide input fields Technology
Bit 1: CYCLE840 Unhide input fields Technology
52218 FUNCTION_MASK_TURN Function mask Turning
Bit 0: Enable zoom under manual for tool measurement 9840
Bit 1: Enable parts gripper for cut-off 9841
Bit 2: Enable tailstock 9842
Bit 3: Reserved
Page 14
Bit 4: Enable spindle control of main spindle above surface 9897Bit 0
Bit 5: Enable spindle control of tool spindle above surface 9897Bit 1
Developers’ documentation:
Bit 6: Enable mask Taper angle 9897Bit 2
52229 ENABLE_QUICK_M_CODES Enable fast M functions
Bit 0: Coolant OFF

Bit 1: Coolant 1 ON
Bit 2: Coolant 2 ON
Bit 3: Coolant 1 and 2 ON
52230 M_CODE_ALL_COOLANTS_OFF M code for all coolants OFF 9686
52231 M_CODE_COOLANT_1_ON M code for coolant 1 ON 9680
52232 M_CODE_COOLANT_2_ON M code for coolant 2 ON 9681
52233 M_CODE_COOLANT_1_AND_2_ON M code for coolant 1 + 2 ON 9668
52240 NAME_TOOL_CHANGE_PRO Tool change program for G code steps


52241 SPINDLE_CHUCK_TYPES Spindle jaw type 9829
0 = Clamp from outside
1 = Clamp from inside
Elements:
[0]: Main spindle

[1]: Counter spindle
52242 MAIN_SPINDLE_PARAMETER Parameters for main spindle
[1]: Chuck dimension
52243 NUM_AXIS_USED Parameters for counter spindle
[0]: Chuck dimension

[1]: Stop dimension
[2]: Jaw dimension
52244 SUB_SPINDLE_PARK_POS_Y Parking position of the Y axis with counter spindle 9849
52246 TAILSTOCK_DIAMETER Tailstock diameter 9836
52247 TAILSTOCK_LENGTH Tailstock length 9837
Page 15
52248 REV_2_BORDER_TOOL_LENGTH Limit value of tool length X for 2nd revolver: 9838
Limit value = 0: There is only one revolver
Tool length < limit value: Tool belongs to 1st revolver/multifix
Tool length >= limit value: Tool belongs to 2nd revolver/multifix
52250 M_CODE_CHUCK_OPEN M code for Open chuck with non-rotating spindle.

Example: "M34" or "M1=34"
Elements:
[0]: Main spindle
52251 M_CODE_CHUCK_CLOSE_OPEN_ROT M code for Open chuck with rotating spindle.
Elements:
[0]: Main spindle
52252 M_CODE_CHUCK_CLOSE M code for Close chuck
Elements:
[0]: Main spindle
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A043
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52270 TM_FUNCTION_MASK Function mask Tool management

Bit 0: Create tool on magazine location not allowed. Tools can only be created outside the 9478 Bit 3
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magazine.
Bit 1: Load/unload disable, if machine is in reset. Tools can only be loaded/unloaded, if the ap- 9478 Bit 9
propriate channel is in reset state.
Bit 2: Load/unload disable on Emergency stop. Tools can only be loaded/unloaded, if Emer- 9478 Bit 12
gency stop is not active.
Bit 3: Load/unload tool to/from spindle is disabled. Tools cannot be loaded to or unloaded from 9478 Bit 15
the spindle.
Bit 4: Loading is executed directly in the spindle. Tools are loaded exclusively directly in the 9478 Bit 20
spindle.
Bit 5: Reserved
Bit 6: Reserved
Bit 7: Create tool using the tool number. Specify the tool's T number when creating the tool.
Bit 8: Fade out Relocate tool. The function 'Relocate tool" is faded out on the user interface.
Bit 9: Fade out Position magazine. The function 'Position magazine' is faded out on the user
interface.
Bit 10: Reactivate tool using Position magazine. Prior to reactivating the tool is positioned on the
loading position.
Bit 11: Reactivate tool in all monitoring modes. When reactivating a tool, all monitoring modes
Page 16
enabled in the NC are reactivated for this tool, even the monitoring modes, which have
not been set for the relevant tool, but are available in the background only.
Bit 12: Fade out Reactivate tool. The function 'Reactivate tool' is faded out on the user interface.
52271 TM_MAG_PLACE_DISTANCE Distance between individual magazine locations. 9479

Is used for graphical display of magazine and tools in tool management.
52272 TM_TOOL_LOAD_DEFAULT_MAG Default magazine for tool loading 9671

0 = No default magazine
52273 TM_TOOL_MOVE_DEFAULT_MAG Default magazine for tool relocation 9687

0 = No default magazine
52281 TOOL_MCODE_FUNC_ON M code for tool-specific function ON 9739, 9741,
Value -1 means that the M function is not output. If both M commands of a function equal -1, the 9743, 9745.
corresponding field will not be displayed in the user interface.
52282 TOOL_MCODE_FUNC_OFF M code for tool-specific function OFF 9740, 9742,
Value -1 means that the M function is not output. If both M commands of a function equal -1, the 9743, 9745.
corresponding field will not be displayed in the user interface.

52480 MILL_PARALLEL_AX1_NAME Channel axis name of first parallel axis (tool axis) for CYCLE69.
The first parallel axis is the third geometry axis, if geometry axis interchange is not active (e.g.
axis ZZ with G17)
The channel axis name must be different from the name of the geometry axis (e.g. channel axis
name ZZ, name of geometry axis Z)

52481 MILL_PARALLEL_AX2_NAME Channel axis name of the second parallel axis (in tool direction) for CYCLE69
52482 MILL_PARALLEL_AX3_NAME Channel axis name of the third parallel axis (in tool direction) for CYCLE69
52483 MILL_ROUND_AX_NAME Channel axis name of the rotary axis for CYCLE69
During positioning, the Parallel axes cycle (CYCLE69) can also support a rotary axis (e.g. rotary
table B).
52485 FUNCTION_MASK_MILL_PARAXES Function mask Parallel axes CYCLE69
Bit 0: Always move parallel axes individually, (e.g. with M command in case of parallel axes
clamping)
Bit 1:
Bit 2: Value of the workpiece reference (compensation value) still active after Reset
In CYCLE69, the value is transferred globally to data management
52605 MEA_TURN_CYC_SPECIAL_MODE Functional behavior of a third geometry axis (Y axis) in the turning technology based on the G18
Page 17
working plane!
=0: an existing third geometry axis (Y axis; applicate); is not supported by the measuring cycles!
=1: specified setpoint and parameterization (SETVAL, _TUL, _TLL, SZO) refer to the third geome-
try axis (Y axis).
However, tool length offset or work offset are performed in the components active in the second
geometry axis (X axis, ordinate) (i.e. measurement in Y and offset in X). The offset target can be
influenced using the _KNUM parameter!
52750 J_MEA_FIXPOINT Z value for measuring against fixed point 9748
52715 J_MEA_MAGN_GLAS_POS Zoom position for tool measurement: 9820, 9821

[0] = Position in 1st axis
[1] = Position in 2nd axis
52800 ISO_M_ENABLE_POLAR_COORD Polar coordinates
0: OFF
1: ON
52802 ISO_ENABLE_INTERRUPTS Interrupt process
0: OFF
1: ON
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52804 ISO_ENABLE_DRYRUN Machining skipped during tapping G74/G84 at DRY RUN
0: OFF
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1: ON
52806 ISO_SCALING_SYSTEM Basic system:
0: not defined
1: METRIC
2: INCH
52808 ISO_SIMULTAN_AXES_START Simultaneous approach to the boring position on all programmed axes
0: OFF
1: ON
52810 ISO_T_DEEPHOLE_DRILL_MODE Select the type of deep hole drilling
0: deep hole drilling with chip breaking
1: deep hole drilling with stock removal
Axis Machine Data
Page 18
53230 SIM_START_POSITION Axis position for simulation

SD Identifier Description Old MD/GUD

54215 TM_FUNCTION_MASK_SET_ Function mask Tool management
Bit 0: Diameter display for rotating tools. For rotating tools the diameter is displayed instead of 9663
the radius value.
Bit 1: Default direction of rotation for all turning tools is M4. When creating turning tools the di- 9826
rection of rotation is defaulted with M4.

Bit 2: Create tool without name suggestion. 9478 Bit 4
Bit 3: Input disable for tool name and tool type in loaded tools. When tools are loaded, the tool 9478 Bit 7
name and tool type can no longer be changed.
Bit 4: Input disable for loaded tools, if the channel is not in Reset. 9478 Bit 6
Bit 5: Clear tool wear input additively. Wear data are input additively to the already existing wear 9478 Bit 10
value.
Bit 6: Numerical input of the tool ident. Only numbers are permissible for tool ident input. 9478 Bit 11
Bit 7: Fade out tool monitoring parameters. The tool monitoring parameters are faded out on the
user interface.
Bit 8: Diameter display for transverse axis - Geometry. The geometry value of the transverse
axis is displayed as diameter value.
Bit 9: Diameter display for transverse axis - Wear. The wear value of the transverse axis is dis-
played as diameter value.
Bit 10: Enable load/relocate tool on buffer locations. In the load dialog the magazine number can 9478 Bit 25
be entered. Thus it is possible to access the buffer using magazine number 9998.
Page 19
Bit 11: Creating tool in gripper disabled.
54600 MEA_WP_BALL_DIAM Effective sphere diameter of the probe sphere for the workpiece probe. GUD =_WP[x,0]
The value of this parameter is created by the operation "Calibrate workpiece probe"!
54601 MEA_WP_TRIG_MINUS_DIR_AX1 Trigger point of the 1st measuring axis (abscissa) in negative traversing direction (X at G17) of the GUD =_WP[x,1]
workpiece probe.
The term "negative traversing direction" refers to the currently active workpiece zero point refer-
ence!
54602 MEA_WP_TRIG_PLUS_DIR_AX1 Trigger point of the 1st measuring axis (abscissa) in positive traversing direction (X at G17) of the GUD =_WP[x,2]
workpiece probe.
The term "positive traversing direction" refers to the currently active workpiece zero point refer-
ence!
54603 MEA_WP_TRIG_MINUS_DIR_AX2 Trigger point of the 2nd measuring axis (ordinate) in negative traversing direction (Y at G17) of the GUD =_WP[x,3]
workpiece probe.
ence!
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A043
A043
54604 MEA_WP_TRIG_PLUS_DIR_AX2 Trigger point of the 2nd measuring axis (ordinate) in positive traversing direction (Y at G17) of the GUD =_WP[x,4
workpiece probe.
A043
ence!
54605 MEA_WP_TRIG_MINUS_DIR_AX3 Trigger point of the 3rd measuring axis (applicate) in negative traversing direction (Z at G17) of GUD =_WP[x,5]
the workpiece probe.
ence!
54606 MEA_WP_TRIG_PLUS_DIR_AX3 Trigger point of the 3rd measuring axis (applicate) in positive traversing direction (Z at G17) of the GUD =_WP[x,6]
workpiece probe.
ence!
54607 MEA_WP_POS_DEV_AX1 The position deviation in the 1st measuring axis represents a geometrical offset of the centre point GUD =_WP[x,7]
of the probe sphere related to the electrical centre point of the probe in this axis!
Page 20
54608 MEA_WP_POS_DEV_AX2 The position deviation in the 2nd measuring axis represents a geometrical offset of the centre GUD =_WP[x,8]
point of the probe sphere related to the electrical centre point of the probe in this axis!
54609 MEA_WP_STATUS_RT Calibration status of the axis positions reserved for internal use! GUD =_WP[x,9]
54610 MEA_WP_STATUS_GEN Calibration status in general reserved for internal use! GUD =_WP
The value of this parameter is created by the operation "Calibrate workpiece probe"! [x,10]
54615 MEA_CAL_EDGE_BASE_AX1 Calibration groove base of the 1st measuring axis (abscissa, Z at G18) GUD =_KB[x,2]
This parameter is a geometrical component of the calibration groove and must be supplied by the
user!
54617 MEA_CAL_EDGE_PLUS_DIR_AX1 Calibration groove edge in positive direction of the 1st measuring axis (abscissa, Z at G18) GUD =_KB[x,3]
user!
54618 MEA_CAL_EDGE_MINUS_DIR_AX1 Calibration groove edge in negative direction of the 1st measuring axis (abscissa, Z at G18) GUD =_KB[x,4]
user!


54619 MEA_CAL_EDGE_BASE_AX2 Calibration groove base of the 2nd measuring axis (ordinate, X at G18) GUD =_KB[x,6]
user!
54620 MEA_CAL_EDGE_UPPER_AX2 Calibration groove upper edge of the 2nd measuring axis (ordinate, X at G18) GUD =_KB[x,5]

user!
54621 MEA_CAL_EDGE_PLUS_DIR_AX2 Calibration groove edge in positive direction of the 2nd measuring axis (ordinate, X at G18) GUD =_KB[x,0]
user!
54622 MEA_CAL_EDGE_MINUS_DIR_AX2 Calibration groove edge in negative direction of the 2nd measuring axis (ordinate, X at G18) GUD =_WP
This parameter is a geometrical component of the calibration groove and must be supplied by the [x,10]
user!
54625 MEA_TP_TRIG_MINUS_DIR_AX1 Trigger point of the 1st measuring axis in negative direction (abscissa, X at G17, Z at G18) GUD =_TP[x,0]
The trigger point refers to the machine coordinate system (MCS).
Prior to calibration the approximate trigger point must be entered in the machine coordinate sys-
tem!
The exact value of this parameter is created by the operation "Calibrate tool probe"!
Page 21
54626 MEA_CAL_EDGE_PLUS_DIR_AX1 Trigger point of the 1st measuring axis in positive direction (abscissa, X at G17, Z at G18) GUD =_TP[x,1]
tem!
54627 MEA_TP_TRIG_MINUS_DIR_AX2 Trigger point of the 2nd measuring axis in negative direction (ordinate, Y at G17, X at G18) GUD =_TP[x,2]
tem!
54628 MEA_TP_TRIG_PLUS_DIR_AX2 Trigger point of the 2nd measuring axis in positive direction (ordinate, Y at G17, X at G18) GUD =_TP[x,3]
tem!
54629 MEA_TP_TRIG_MINUS_DIR_AX3 Trigger point of the 3rd measuring axis in negative direction (applicate, Z at G17, Y at G18) GUD =_TP[x,4]
tem!
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54630 MEA_TP_TRIG_PLUS_DIR_AX3 Trigger point of the 3rd measuring axis in positive direction (applicate, Z at G17, Y at G18) GUD =_TP[x,5]
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tem!
54631 MEA_TP_EDGE_DISK_SIZE Effective edge length or grinding wheel diameter of the tool probe. GUD =_TP[x,6]
Milling tools are normally measured with wheel-shaped probes while turning tools are measured
with square probes.
54632 MEA_TP_AX_DIR_AUTO_CAL Enabling axes and traversing directions for "Automatic calibration" of milling tool probes. GUD =_TP[x,7]
The default setting refers in X and Y to the plus and minus direction respectively, in Z only to the
minus direction.
The parameter is divided into three components the functions of which are to be assigned to cali-
bration data records 1, 2 or 3!
The calibration data records are firmly assigned to tool measuring in the working planes G17 (1),
G18 (2) and G19 (3)!
Meaning of the parameter components

Decimal position:
Page 22
Value:
= 0: Axis not enabled
54633 MEA_TP_TYPE Tool probe type GUD =_TP[x,8]
0: Cube
101: Wheel in XY, working plane G17
201: Wheel in ZX, working plane G18
301: Wheel in YZ, working plane G19
54634 MEA_TP_CAL_MEASURE_DEPTH Distance between the upper tool probe edge and the lower milling tool edge. GUD =_TP[x,9]
For tool probe calibration this distance defines the calibration depth and for milling tool measuring
the measuring depth!
This parameter does not apply to turning tool measuring!

54640 MEA_TPW_TRIG_MINUS_DIR_AX1 Trigger point of the 1st measuring axis in negative direction (abscissa, X at G17, Z at G18) GUD =_TPW[x,0]
The trigger point refers to the workpiece coordinate system (WCS).
Prior to calibration the approximate trigger point must be entered in the workpiece coordinate sys-
tem!

54641 MEA_TPW_TRIG_PLUS_DIR_AX1 Trigger point of the 1st measuring axis in positive direction (abscissa, X at G17, Z at G18) GUD =_TPW[x,1]
tem!
54642 MEA_TPW_TRIG_MINUS_DIR_AX2 Trigger point of the 2nd measuring axis in negative direction (ordinate, Y at G17, X at G18) GUD =_TPW[x,2]
tem!
54643 MEA_TPW_TRIG_PLUS_DIR_AX2 Trigger point of the 2nd measuring axis in positive direction (ordinate, Y at G17, X at G18) GUD =_TPW[x,3]
Page 23
tem!
54644 MEA_TPW_TRIG_MINUS_DIR_AX3 Trigger point of the 3rd measuring axis in negative direction (applicate, Z at G17, Y at G18) GUD =_TPW[x,4]
tem!
54645 MEA_TPW_TRIG_PLUS_DIR_AX3 Trigger point of the 3rd measuring axis in positive direction (applicate, Z at G17, Y at G18) GUD =_TPW[x,5]
tem!
54646 MEA_TPW_EDGE_DISK_SIZE Effective edge length or grinding wheel diameter of the tool probe. GUD =_TPW[x,6]
Milling tools are normally measured with wheel-shaped probes while turning tools are measured
with square probes.
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54647 MEA_TPW_AX_DIR_AUTO_CAL Enabling axes and traversing directions for "Automatic calibration" of milling tool probes. GUD=_TPW[x,7]
The default setting refers in X and Y to the plus and minus direction respectively, in Z only to the
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minus direction.
The parameter is divided into three components the functions of which are to be assigned to
calibration data records 1, 2 or 3!
The calibration data records are firmly assigned to tool measuring in the working planes G17 (1),
G18 (2) and G19 (3)!
Meaning of the parameter components
Decimal position:
Value:
= 0: Axis not enabled
54648 MEA_TPW_TYPE Tool probe type GUD =_TPW[x,8]
0: Cube
Page 24
101: Wheel in XY, working plane G17
201: Wheel in ZX, working plane G18
301: Wheel in YZ, working plane G19
54649 MEA_TPW_CAL_MEASURE_DEPTH Distance between the upper tool probe edge and the lower milling tool edge. GUD =_TPW[x,9]
For tool probe calibration this distance defines the calibration depth and for milling tool measur-
ing the measuring depth!
This parameter does not apply to turning tool measuring!
54655 MEA_REPEAT_ACTIVE Measurement repetitions after exceeding of the dimensional difference (parameter _TDIF) and/or GUD =_CBIT[0]
the safety margin (parameter _TSA)
=0: When the dimensional difference and/or safety margin is exceeded, the measurement is not
repeated. A corresponding alarm is displayed that can be acknowledged with "RESET".
=1: When the dimensional difference and/or safety margin is exceeded, the measurement is
repeated 4 times max.
54656 MEA_REPEAT_WITH_M0 This parameter refers to SD54655 $SNS_MEA_REPEAT_ACTIVE, provided that it is set to "1"! GUD =_CBIT[1]
In this case one of the following behaviors can be selected:
=0: No alarm, no M0 in the measurement repetitions
=1: NC command "M0" is generated in all measurement repetitions; the repetition must be
started with NC-START.
The corresponding alarm that can be acknowledged with "NC-START" is displayed for
each measurement repetition, [default = 0]


54657 MEA_TOL_ALARM_SET_M0 M0 with tolerance alarms 62304 Allowance, 62305 Undersize, 62306 Permissible dimensional GUD =_CBIT[2]
difference exceeded
=0: No M0 is generated when alarms 62304 "Allowance", 62305 "Undersize" or 62306
"Permissible dimensional difference exceeded" are output.
These alarms are merely displayed, but do not cause program execution to be interrupted!

=1: NC command "M0" is generated when these alarms are displayed.
54659 MEA_TOOL_MEASURE_RELATE Tool measuring and calibration in the machine workpiece coordinate system. GUD =_CBIT[5]
The function of this parameter only refers to CYCLE982.
=0: Tool probe calibration and tool measuring are performed in the machine coordinate system
(MCS).
Tool probe calibration data are stored in the $SNS_MEA_TP_..... parameter fields.
=1: Tool probe calibration and tool measuring are performed in the active workpiece coordinate
system (WCS).
Calibration and measurement must be performed under the same environmental conditions
(frames). Thus, tools can be measured even at active transformations, e.g. TRAANG.
Notice: the $SNS_MEA_TP_..... parameter fields are used for calibration and measure-
ment here, too.
54660 MEA_PROBE_BALL_RAD_IN_TOA Accept the calibrated workpiece probe radius in the tool data. GUD =_CBIT[15]
Page 25
The function of this parameter only refers to CYCLE976.
0: Calibrated workpiece probe radius is not accepted in the tool data

1: For the calibration type "with probe sphere calculation" the determined "effective probe
sphere diameter" (54600 $SNS_MEA_WP_BALL_DIAM), is converted into a radius value and
entered in the tool radius geometry memory of the active workpiece probe.
54670 MEA_CM_MAX_PERI_SPEED Max. permissible peripheral speed of the tool to be measured when the spindle rotates. GUD =_CM[0]
9759
Monitoring parameter for tool measuring with rotating spindle only effective with
SD54749 $SNS_MEA_FUNCTION_MASK_TOOL, Bit 10 = 0!
54671 MEA_CM_MAX_REVOLUTIONS Max. permissible tool speed for tool measuring with rotating spindle. GUD =_CM[1]
The speed is automatically reduced when this value is exceeded. 9760
54672 MEA_CM_MAX_FEEDRATE Max. permissible feed for contact of the tool to be measured with the probe when the spindle ro- GUD =_CM[4]
tates. 9771
A043
A043
A043
54673 MEA_CM_MIN_FEEDRATE Min. feed for first contact of the tool to be measured with the probe when the spindle rotates. GUD =_CM[4]
Too small feeds for large tool radii are thus avoided! 9761
A043
54674 MEA_CM_SPIND_ROT_DIR Direction of spindle rotation for tool measuring with rotating spindle (default: 4 = M4) GUD =_CM[5]
Notice: If the spindle is already rotating when the measuring cycle is called, the direction of rota-
tion is maintained independently of $SNS_MEA_CM_SPIND_ROT_DIR!
54675 MEA_CM_FEEDFACTOR_1 Feedrate factor 1, for tool measuring with rotating spindle GUD =_CM[6]
=0: Single probing with the feedrate calculated by the cycle (but at least with the value of 9769
$SNS_MEA_CM_MIN_FEEDRATE)
>=1: First probing with calculated feedrate (but at least with the value of
$SNS_MEA_CM_MIN_FEEDRATE).
54676 MEA_CM_FEEDFACTOR_2 Feedrate factor 2, for tool measuring with rotating spindle GUD =_CM[7]
=0:Second probing with the feedrate calculated by the cycle (only effective with 9770
Page 26
MEA_CM_FEEDFACTOR_1 > 0)
>=1: Second probing with calculated feedrate, feedrate factor 2
Third probing with calculated feedrate (tool speed is influenced by SD54749
$SNS_MEA_FUNCTION_MASK_TOOL, Bit 12)
Notice: - Feedrate factor 2 should be smaller than feedrate factor 1!

- If the value of feedrate factor 2 is 0, a third probing will not be not performed!
54677 MEA_CM_MEASURING_ACCURACY Required measuring accuracy for tool measuring GUD =_CM[3]
The value of this parameter always refers to the last contact of the tool with the probe! 9762
54689 MEA_T_PROBE_MANUFACTURER Tool probe type (manufacturer) GUD =_TP_CF
These indications are required for tool measuring with rotating spindle. 9774
=0: No indication
=1: TT130 (Heidenhain)
=2: TS27R (Renishaw)


54691 MEA_T_PROBE_OFFSET Measurement result offset for tool measuring with rotating spindle. GUD=_MT_COMP
=0: No offset 9775

=1: Cycle-internal offset (only effective with SD54690
$SNS_MEA_T_PROBE_MANUFACTURER<>0)

=2: Offset through user-defined offset table
54695 MEA_RESULT_OFFSET_TAB_RAD1 Parameter for user-defined measurement result offset for tool measuring with rotating spindle,
$SNS_MEA_RESULT_OFFSET_TAB_RAD1[0] ... this element always has value ZERO
$SNS_MEA_RESULT_OFFSET_TAB_RAD1[1] ... 1st tool radius
$SNS_MEA_RESULT_OFFSET_TAB_RAD1[2] ... 2nd tool radius
$SNS_MEA_RESULT_OFFSET_TAB_RAD1[3] ... 3rd tool radius
$SNS_MEA_RESULT_OFFSET_TAB_RAD1[4] ... 4th tool radius
$SNS_MEA_RESULT_OFFSET_TAB_RAD2[0] ... 1st peripheral speed
$SNS_MEA_RESULT_OFFSET_TAB_RAD2[1] ... offset value for radius regarding 1st ra-
dius and 1st peripheral speed
$SNS_MEA_RESULT_OFFSET_TAB_RAD2[2] ... offset value for radius regarding 2nd ra-
Page 27
$SNS_MEA_RESULT_OFFSET_TAB_RAD2[3] ... offset value for radius regarding 3rd ra-
$SNS_MEA_RESULT_OFFSET_TAB_RAD2[4] ... offset value for radius regarding 4th ra-
$SNS_MEA_RESULT_OFFSET_TAB_RAD3[0] ... 2nd peripheral speed
$SNS_MEA_RESULT_OFFSET_TAB_RAD3[1] ... offset value for radius regarding 1st ra-
dius and 2nd peripheral speed
$SNS_MEA_RESULT_OFFSET_TAB_RAD3[2] ... offset value for radius regarding 2nd ra-
$SNS_MEA_RESULT_OFFSET_TAB_RAD3[3] ... offset value for radius regarding 3rd ra-
$SNS_MEA_RESULT_OFFSET_TAB_RAD3[4] ... offset value for radius regarding 4th ra-
A043
A043
A043
$SNS_MEA_RESULT_OFFSET_TAB_RAD4[0] ... 3rd peripheral speed
A043
$SNS_MEA_RESULT_OFFSET_TAB_RAD4[1] ... offset value for radius regarding 1st radius

and 3rd peripheral speed
$SNS_MEA_RESULT_OFFSET_TAB_RAD4[2] ... offset value for radius regarding 2nd radius
$SNS_MEA_RESULT_OFFSET_TAB_RAD4[3] ... offset value for radius regarding 3rd radius
$SNS_MEA_RESULT_OFFSET_TAB_RAD4[4] ... offset value for radius regarding 4th radius
$SNS_MEA_RESULT_OFFSET_TAB_RAD5[0] ... 4th peripheral speed
and 4th peripheral speed
Page 28
$SNS_MEA_RESULT_OFFSET_TAB_RAD6[0] ... 5th peripheral speed
54705 MEA_RESULT_OFFSET_TAB_LEN1 Parameter for user-defined measurement result offset for tool measuring with rotating spindle,
$SNS_MEA_RESULT_OFFSET_TAB_LEN1[0] ... this element always has value ZERO
$SNS_MEA_RESULT_OFFSET_TAB_LEN1[1] ... 1st tool radius
$SNS_MEA_RESULT_OFFSET_TAB_LEN1[2] ... 2nd tool radius
$SNS_MEA_RESULT_OFFSET_TAB_LEN1[3] ... 3rd tool radius
$SNS_MEA_RESULT_OFFSET_TAB_LEN1[4] ... 4th tool radius


$SNS_MEA_RESULT_OFFSET_TAB_LEN2[0] ... 1st peripheral speed
$SNS_MEA_RESULT_OFFSET_TAB_LEN2[1] ... offset value for radius regarding 1st radius
and 1st peripheral speed
$SNS_MEA_RESULT_OFFSET_TAB_LEN2[2] ... offset value for radius regarding 2nd radius

$SNS_MEA_RESULT_OFFSET_TAB_LEN2[3] ... offset value for radius regarding 3rd radius
$SNS_MEA_RESULT_OFFSET_TAB_LEN2[4] ... offset value for radius regarding 4th radius
$SNS_MEA_RESULT_OFFSET_TAB_LEN3[0] ... 2nd peripheral speed
and 2nd peripheral speed
Page 29
$SNS_MEA_RESULT_OFFSET_TAB_LEN4[0] ... 3rd peripheral speed
A043
A043
A043
54709 MEA_RESULT_OFFSET_TAB_LE Parameter for user-defined measurement result offset for tool measuring with rotating spindle,
$SNS_MEA_RESULT_OFFSET_TAB_LEN5[0] ... 4th peripheral speed
A043

$SNS_MEA_RESULT_OFFSET_TAB_LEN6[0] ... 5th peripheral speed
Page 30


54748 MEA_FUNCTION_MASK_PIECE Setting for input screen, measuring cycles in Automatic mode, workpiece measurement
Bit 0 Measuring plane G17 (XY), G18 (ZX), G19 (YZ)
Bit 1 Multiprobe / monoprobe
Bit 2 Log (standard protocol)
Bit 3 Measurement result display

Bit 4 Measuring feedrate input (VMS)
Bit 5 Calibration data (probe number/field)
Bit 6 Calibrate to unknown centre point
Bit 7 Zero offset TZL for calibration
Bit 8 WO compensation coarse / fine
Bit 9 WO compensation basis reference
Bit 10 WO compensation channel-spec. basis
Bit 11 WO compensation global basis
Bit 12 Tool offset geometry / wear
Bit 13 Tool offset not inverted / inverted
Bit 14 Tool offset L1, L2, R
Bit 15 Tool offset zero offset TZL
Bit 16 Tool offset TDIF
Bit 17 Total offset
Bit 18 Offset into tool environment
Page 31
Bit 19 Empirical values
Bit 20 Mean values
54749 MEA_FUNCTION_MASK_TOOL Setting for input screen, measuring cycles in Automatic mode, tool measurement
Bit 1 Measure in WCS, MCS
Bit 2 Log (standard protocol)
Bit 3 Measurement result display
Bit 5 Measure absolute / incremental
Bit 6 Tool offset geometry / wear
Bit 7 Zero offset TZL for calibration
Bit 8 Dimensional difference check TDIF
Bit 9 Number of measurements
Bit 10 Specification of feedrate/spindle speeds
Bit 11 Empirical values
Bit 12 No spindle speed reduction for last touch during tool measurement
54750 MEA_ALARM_MASK Bit 0 - 7 Workpiece measurement
Bit 0 =1 Alarms with cycle-internal states and coding are displayed (expert mode)!
Bit 1 - 7 Reserved
Bit 8 -16 Tool measuring
A043
Bit 0 - 7 Reserved
A043
A043
54798 J_MEA_FUNCTION_MASK_PIECE Setting for input screen, measuring cycles in JOG, workpiece measurement
A043
Bit 1 Reserved
Bit 2 Activation of functionality “Measure with electronic workpiece probe” 9747
Bit 4 Measuring feedrate input (VMS)
Bit 5 Reserved
Bit 6 WO compensation basis reference
Bit 7 WO compensation channel-spec. basis
Bit 8 WO compensation global basis
Bit 9 WO compensation in settable frame
Bit 10 WO compensation in active frame
54799 J_MEA_FUNCTION_MASK_TOOL Setting for input screen, measuring cycles in JOG, tool measurement
Bit 0 Reserved
Bit 1 Reserved
Bit 2 Activate calibration of electronic tool probe
Bit 3 Enable selection of tool probe calibration data field 9749
Page 32
55200 MAX_INP_FEED_PER_REV Feedrate input upper limit for mm/rev 9665

55201 MAX_INP_FEED_PER_TIME Feedrate input upper limit for mm/min 9664
55202 MAX_INP_FEED_PER_TOOTH Feedrate input upper limit for mm/tooth 9666
55212 FUNCTION_MASK_TECH_SET Function mask Cross-technology
Bit 0: Tool pre-selection active 9667
Bit 1: Automatic calculation of thread depth 9640
Bit 2: New


55214 FUNCTION_MASK_MILL_SET Function mask Milling
Bit 0: Default setting - milling cycles with synchronous operation 9827
Bit 1: Angle of rotation in relation to the centre with POCKET3 GUD _ZSD[9]
Bit 1 = 0 When the rectangular pocket is dimensioned over a corner point, the angle of rotation
relates to this reference point

Bit 1 = 1 When the rectangular pocket is dimensioned over a corner point, the angle of rotation
relates to the pocket centre point
Bit 2: Depth calculation in milling cycles without parameter SC GUD _ZSD[1]
Bit 2 = 0 Depth calculation in milling cycles is carried out between reference plane + safety clear-
ance and depth
Bit 2 = 1 Depth calculation in milling cycles is carried out without inclusion of the safety clearance
Note: Bit 2 is active with the following milling cycles: CYCLE61, CYCLE71, CYCLE76, CYCLE77,
CYCLE79, CYCLE899, LONGHOLE, SLOT1, SLOT2, POCKET3, POCKET4
55216 FUNCTION_MASK_DRILL_SET Function mask Drilling
Bit 0: Tapping CYCLE84: reverse the direction of spindle rotation in the cycle
Bit 1: -
Bit 2: -
Bit 3: Tapping CYCLE84: monitoring machine data 31050 and 31060 of the spindle
Page 33
Bit 4: Tapping CYCLE840: monitoring machine data 31050 and 31060 of the spindle
Bit 5: Tapping CYCLE84: calculation of the brake point at G33
55218 FUNCTION_MASK_TURN_SET Function mask Turning
Bit 0: New thread table during thread cutting
Bit 1: Reserved (CYCLE93)
Bit 2: Reserved (CYCLE93)
55220 FUNCTION_MASK_MILL_TOL_SET Function mask High Speed Settings CYCLE832
Bit 0: Display input fields technology
Bit 1: Settings as agreed in the following setting data:
$SCS_MILL_TOL_TECHNO_NORM
$SCS_MILL_TOL_TECHNO_ROUGH
$SCS_MILL_TOL_TECHNO_SEMIFIN
$SCS_MILL_TOL_TECHNO_FINISH
$SCS_MILL_TOL_VALUE_NORM
$SCS_MILL_TOL_VALUE_ROUGH
$SCS_MILL_TOL_VALUE_SEMIFIN
$SCS_MILL_TOL_VALUE_FINISH
A043
A043
A043
55221 FUNCTION_MASK_SWIVEL_SET Function mask Swivel CYCLE800
Bit 0: Display input field "No swivel"
A043
Bit 1: =0: Retract Z or retract Z XY

=1: Retract to fixed position 1 or
Bit 2: Allow selection "Deselection" of the swivel data block
Bit 3: Show active swivel plane under Swivel in JOG
The settings of the Swivel function mask affect all swivel data records.
55230 CIRCLE_RAPID_FEED Rapid traverse feedrate in mm/min for positioning on circle path between circumferential grooves 9724
and contour elements
55231 MAX_INP_RANGE_GAMMA Maximum input area alignment angle gamma 9863
55232 SUB_SPINDLE_REL_POS Z retraction position for the counter spindle 9851
55405 MILL_TRAORI_USERCYCLE_NAME Program name of manufacturer cycle, if 5-axis machining (TRAORI) is called by means of the
High Speed Settings cycle. .
55410 MILL_SWIVEL_ALARM_MASK Hide and unhide cycle alarms CYCLE800
Bit 0: Error analysis 62186 - active work offset G%4 and base (base relation) include rotations
Bit 1: Error analysis 62187 - active base and base relation (G500) include rotations
Page 34
55440 MILL_TOL_TECHNO_NORM Settings at deselection of High Speed Settings cycle CYCLE832 of G group 59 GUD TOLT[0]
55441 MILL_TOL_TECHNO_ROUGH Settings for roughing High Speed Settings cycle CYCLE832 of G group 59 GUD _TOLT[1]
55442 MILL_TOL_TECHNO_SEMIFIN Settings for pre-finishing High Speed Settings cycle CYCLE832 of G group 59 GUD _TOLT[2]
55443 MILL_TOL_TECHNO_FINISH Settings for finishing High Speed Settings cycle CYCLE832 of G group 59 GUD _TOLT[3]
55445 MILL_TOL_VALUE_NORM Tolerance value on deselecting High Speed Settings cycle CYCLE832 GUD _TOLV[0]
55446 MILL_TOL_VALUE_ROUGH Tolerance value for roughing High Speed Settings cycle CYCLE832 GUD _TOLV[1]
55447 MILL_TOL_VALUE_SEMIFIN Tolerance value for pre-finishing High Speed Settings cycle CYCLE832 GUD _TOLV[2]
55448 MILL_TOL_VALUE_FINISH Tolerance value for finishing High Speed Settings cycle CYCLE832 GUD _TOLV[3]
55460 MILL_CONT_INITIAL_RAD_FIN This data affects the radius of the approach circle during contour pocket finishing. 9670
-1: The radius is selected to maintain a safety clearance to the finishing allowance in the start-
ing point.
>0: The radius is selected to maintain the value of this setting data to the finishing allowance in
the starting point.


55461 MILL_CONT_DIFF_TOOLRAD_MIN This data is required for contour pocket milling. This data defines the percentage by which the 9657
radius of an operating cutter can be smaller than the radius with which the contour program was
generated.
55462 MILL_CONT_DIFF_TOOLRAD_MAX This setting data is required for contour pocket milling. It defines the amount by which the radius 9658

of an operating cutter can be larger than the radius with which the program was generated.
55480 DRILLING_AXIS_IS_Z Drilling axis depends on plane (G17, G18, G19) or always Z
55481 DRILL_TAPPING_SET_GG12 Settings for tapping G group 12 cycle CYCLE84 and CYCLE840: 9855 - Index [0]
G group 12: Block change behavior at exact stop (G60) 9856 - Index [1]
0 = Exact stop behavior, same as before the cycle call
1 = G601
2 = G602
3 = G603
Index[0]: for tool spindle
Index[1]: for main spindle - for drilling in centre
55482 MILL_TOL_TECHNO_FINISH Settings for tapping G group 21 cycle CYCLE84: 9855 - Index [0]
G group 21: Acceleration profile (SOFT, BRISK, ..) 9856 - Index [1]
0 = Acceleration behavior, same as before the cycle call
1 = SOFT
Page 35
2 = BRISK
3 = DRIVE
55483 DRILL_TAPPING_SET_GG24 Settings for tapping G group 24 cycle CYCLE84 and CYCLE840: 9855 - Index [0]
G group 24: Feedforward control (FFWON, FFWOF ) 9856 - Index [1]
0 = Feedforward control, same as before the cycle call
1 = FFWON
2 = FFWOF
55484 DRILL_TAPPING_SET_MC Setting for tapping cycle CYCLE84 spindle operation at MCALL 9855 - Index [0]
0= Reactivate spindle operation at MCALL 9856 - Index [1]
1= Maintain position-controlled spindle operation at MCALL
55489 DRILL_MID_MAX_ECCENT Maximum centre offset for centre drilling 9862
55490 DRILL_SPOT_DIST Rough drilling depth for drill and thread milling 9682
A043
A043
A043
55500 TURN_FIN_FEED_PERCENT When selecting Complete machining (roughing and finishing), the percentage of the entered 9630
feedrate F as specified in this setting data is used for finishing.
A043
55505 TURN_ROUGH_O_RELEASE_DIST This setting data defines the distance by which the tool is returned from the contour during stock 9648
removal of an outer corner. This does not apply to stock removal of a contour.
-1: The distance is specified internally.
55506 TURN_ROUGH_I_RELEASE_DIST This setting data defines the distance by which the tool is returned from the contour during stock 9649
removal of an inner corner. This does not apply to stock removal of a contour.
-1: The distance is specified internally.
55510 TURN_GROOVE_DWELL_TIME If a tool clearance time occurs in a cycle, e.g. deep hole drilling, grooving, the value of this setting 9621
data is used
- Negative value in spindle revolutions
- Positive value in seconds
55515 TURN_THREAD_RELEASE_DIST In this setting data you specify the distance to the workpiece, by which the tool is retracted be- 9850
tween the infeed motions during thread cutting.
55540 TURN_PART_OFF_CTRL_DIST Path for cut-off check 9859
55541 TURN_PART_OFF_CTRL_FEED Feedrate for cut-off check 9860
Page 36
55542 TURN_PART_OFF_CTRL_FORCE Force in percent for cut-off check 9861
55543 TURN_PART_OFF_RETRACTION Retraction path prior to cut-off with counter spindle 9858
55550 TURN_FIXED_STOP_DIST In this setting data you specify the distance to the programmed target position, after which the 9852
counter spindle travels with a special feedrate during travel to fixed stop (see 55551
$SCS_TURN_FIXED_STOP_FEED).
55551 TURN_FIXED_STOP_FEED In this setting data you specify the feedrate with which the counter spindle travels to a fixed stop. 9853
In setting data 55550 $SCS_TURN_FIXED_STOP_DIST you specify the distance after which the
tool travels in this feedrate.
55552 TURN_FIXED_STOP_FORCE In this setting data you specify at which percentage of the driving force the counter spindle is to 9854
stop during travel to fixed stop.
55553 TURN_FIXED_STOP_RETRACTION Retraction path prior to chucking after travel to fixed stop 9857
55580 TURN_CONT_RELEASE_ANGLE This setting data defines the angle by which the tool is retracted from the contour during contour
turning roughing.
55581 TURN_CONT_RELEASE_DIST This setting data defines the value by which the tool is retracted in both axes during contour turn- 9550
ing roughing. This applies to cutting, plunge-cutting and plunge turning.
55582 TURN_CONT_TRACE_ANGLE This setting data specifies the angle between the cutting edge and the contour, at which the con- 9553
tour is rounded in order to remove residual material.


55583 TURN_CONT_VARIABLE_DEPTH Percentage for variable cutting depth during contour turning 9556
55584 TURN_CONT_BLANK_OFFSET This setting data specifies the distance to the blank, after which contour turning is switched from 9552
G0 to G1 in order to adjust any possible blank allowances. This applies to cutting, plunge cutting
and plunge turning.

55585 TURN_CONT_INTERRUPT_TIME Feed interrupt time during contour turning, contour grooving and plunge turning 9557
- Negative value in spindle revolutions
- Positive value in seconds
This setting data is effective only if setting data 55586 is 55586
$SCS_TURN_CONT_INTER_RETRACTION = 0.
55586 TURN_CONT_INTER_RETRACTION Retraction path feed interrupt during contour turning, contour grooving and plunge turning: 9558
>0: Retraction path after feed interrupt (setting data 55585
$SCS_TURN_CONT_INTERRUPT_TIME is ineffective!)
=0: No retraction path
55587 TURN_CONT_MIN_REST_MAT_AX1 This MD defines the limit value for stock removal of residual material in the direction of the 1st 9554
axis.
Example:
If this MD is set to 50% and if the finishing allowance is 0.5 mm, the residual material which is thin-
ner than 0.25 mm is not removed in a separate machining step, but during finishing.
Page 37
55588 TURN_CONT_MIN_REST_MAT_AX2 This MD defines the limit value for stock removal of residual material in the direction of the 2nd 9555
axis.
Example:
If this MD is set to 50% and if the finishing allowance is 0.5 mm, the residual material which is thin-
ner than 0.25 mm is not removed in a separate machining step, but during finishing.
55595 TURN_CONT_TOOL_BEND_RETR Retraction due to tool bending during plunge turning. In this setting data you specify the lateral 9560
distance to the last cut, by which each next cut will be shortened.
55596 TURN_CONT_TURN_RETRACTION Retraction depth prior to plunge turning 9561
55600 MEA_COLLISION_MONITORING Collision detection with tool probe for intermediate positioning GUD =_CHBIT
[2]
=0: no collision detection
=1: the movement of positioning operations calculated by the measuring cycles and performed
between the measuring points is stopped as soon as the probe provides a switching signal. A cor-
responding alarm message is displayed.
A043
A043
A043
55602 MEA_COLLISION_MONITORING Coupling of spindle orientation and coordinate rotation in the active plane, in the case of work- GUD =_CHBIT
piece measurement with multiprobe in Automatic mode [13]
A043
=0: No coupling of spindle orientation and coordinate rotation in the plane.

=1: When multiprobes are used, the spindle is oriented depending on the active coordinate rota-
tion in the plane (rotations around the infeed axis (applicate)).
Thus, the axis-parallel orientation of the probe sphere contact points (calibrated trigger points) is
maintained with regard to the geometry axis.
The direction of spindle rotation is defined by SD55604 $SCS_MEA_SPIND_MOVE_DIR!
Note:
Coordinate rotation in the active plane means: - Rotation around the Z axis at G17,
- Rotation around the Y axis at G18
- Rotation around the X axis at G19.
Notice:
The coupling is annulled by the measuring cycle, if :
- Rotations around the 1st or 2nd measuring axis (abscissa or ordinate at G17) between calibra-
tion and actual measuring are not identical!!!
- The working spindle is not position-controlled (no SPOS possible)
- A monoprobe is used (_PRNUM=x1xx)!
- When the coupling is annulled by the measuring cycle, no alarm or message is displayed!
Page 38
55604 MEA_SPIND_MOVE_DIR Direction of rotation of spindle positioning with regard to active coupling of spindle orientation and GUD =_CHBIT
coordinate rotation in the active plane. [14]
=0: The spindle is positioned as specified by the default.
- Coordinate rotation angle in the plane 0°: spindle positioning 0°
=1: The spindle is positioned in the opposite direction (adjusted angle values).
55606 MEA_NUM_OF_MEASURE Number of measurement repetitions, if the probe does not switch GUD =_CHBIT
=0: Max. 5 measuring attempts are performed before measuring cycle alarm "Probe does not [15]
switch" is output.
=1: After the first unsuccessful measuring attempt measuring cycle alarm "Probe does not switch"
is generated.
55608 MEA_RETRACTION_FEED Retraction velocity from the measuring point
=0: Retraction of the measuring point is performed with the same velocity as in intermediate posi-
tioning (SD55631 $SCS_MEA_FEED_PLANE_VALUE.
=1: The retraction velocity depends on the rapid traverse velocity in percent as specified in
SD55630 $SCS_MEA_FEED_RAPID_IN_PERCENT and is only effective with active collision
detection (SD55600 $SCS_MEA_COLLISION_MONITORING=1).

55610 MEA_FEED_TYP Measuring feed GUD =_CHBIT[17]

=0: For the measuring travel the feedrate generated in the cycle or the feedrate programmed in
parameter _VMS is used.
=1: Travel is first performed with "rapid measuring feed" SD55633
$SCS_MEA_FEED_FAST_MEASURE; after contact of the probe with the measuring object a

retraction of 2 mm from the measuring point is performed. Now the measuring travel itself
with the feedrate from _VMS is performed.
The function "Rapid measuring feed" is realized only if the value in parameter is _FA >=1!
55613 MEA_RESULT_DISPLAY Measurement result display GUD =_CHBIT[10]
=0: No measurement result display GUD =_CHBIT[11]
=1: The measurement result is displayed until cycle end GUD =_CHBIT[18]
=2: The measurement result is displayed until the start/call of the next cycle
=3: With the measurement result display, the cycle is stopped by an internal M0,
with NC start, the measuring cycle is continued and the measurement result display is
deselected
=4: The measurement result display is only shown for cycle alarms 61303, 61304, 61305,
61306. Same behavior as with setting 3!
55618 MEA_SIM_ENABLE Selection of measuring cycle response in an environment simulated in HMI Advanced or in Shop-
Mill / ShopTurn
Page 39
= 0: Measuring cycles are not executed (measuring cycle is skipped internally)
= 1: Measuring cycles are executed; real axes are required!
During calibration no values are entered in the probe data fields,
no measurement result is displayed,
the measuring cycle is not logged,
the travel is performed without collision detection.
555619 MEA_SIM_MEASURE_DIFF With this parameter simulated measurement errors can be specified on the measuring points. GUD=_MC_SIMDI
FF
Provided that SD55618 $SCS_MEA_SIM_ENABLE=1 is used and that the measuring cycles are
executed in a simulated environment of HMI Advanced or ShopMill / ShopTurn, a measurement
difference can be entered in this parameter. The value of the measurement difference must be
smaller than the measuring path in parameter _FA!
Otherwise cycle alarm 61301 "Probe does not switch" is output during active simulation.
55622 MEA_EMPIRIC_VALUE_NUM Number of empirical values GUD=_EVMVNU
M[0]
A043
A043
A043
55623 MEA_EMPIRIC_VALUE In its default setting the empirical value memory consists of 20 memory elements. GUD=_EV[n
A043
Using parameter $SCS_MEA_EMPIRIC_VALUE_NUM the number of memory elements can be

defined! Currently, however, these 20 memory elements can-not be changed!
In the empirical value memory, empirical values can be stored which are cleared with the cur-
rently calculated difference between the setpoint and the actual value.
Using parameter _EVNUM the empirical value element to be cleared is addressed!
55624 MEA_AVERAGE_VALUE_NUM Number of mean values GUD=_EVMVNUM[1]
555625 MEA_AVERAGE_VALUE In its default setting the mean value memory consists of 20 memory elements. GUD=_MV[n
Using parameter $SCS_MEA_AVERAGE_VALUE_NUM the number of memory elements can be
defined! Currently, however, these 20 memory elements can-not be changed!
In the mean value memory, the mean values calculated in connection with functionality
"Automatic tool offset with mean value creation" are stored.
Using parameter _EVNUM the mean value element to be used is addressed!
55630 MEA_FEED_RAPID_IN_PERCENT Traverse velocities for positioning in the measuring cycle between the measuring positions, GUD =_SPEED[0]
with rapid traverse velocity in per cent, with collision detection not active
Note:
Page 40
If necessary, adapt the value of the rapid traverse velocity in per cent to the probe type used and
to the machine characteristics! This means that the maximum deflection of the actual probe type
must be considered!!
Explanations:
In the measuring cycles any intermediate positions are calculated prior to the actual set of meas-
urements. These positions can be approached
- with collision detection (SD55600 $SCS_MEA_COLLISION_MONITORING=1 or
- without collision detection (SD55600 $SCS_MEA_COLLISION_MONITORING=0).
Depending on this setting different velocities are used for the approach:
- with collision detection (SD55600 $SCS_MEA_COLLISION_MONITORING=1):
With SD55631 $SCS_MEA_FEED_PLAN_VALUE the traversing feed is performed in the
plane and
with SD55632 $SCS_MEA_FEED_FEEDAX_VALUE during traversing in the feed axis
(applicate).
If the probe switches when these intermediate positions are approached, the movement
is stopped and the alarm "Probe collision" is output.
- without collision detection (SD55600 $SCS_MEA_COLLISION_MONITORING=0):
The intermediate positions are approached with the maximum axis velocity (rapid trav-
erse) in percent as specified in SD55630 $SCS_MEA_FEED_RAPID_IN_PERCENT.
With SD55630 $SCS_MEA_FEED_RAPID_IN_PERCENT=0 and SD55630
$SCS_MEA_FEED_RAPID_IN_PERCENT=100 the maximum axis velocity is effective.


55631 MEA_FEED_PLANE_VALUE Traverse velocities for intermediate positioning in the measuring cycle in the plane, with and with- GUD =_SPEED[1]
out collision detection
Note:
If necessary, adapt the value of the velocity for the plane to the probe type used and to the ma-

chine characteristics! This means that the maximum deflection of the actual probe type must be
considered!!
Explanations:
With SD55631 $SCS_MEA_FEED_PLAN_VALUE the traversing feed is performed in the
plane.
If the probe switches when these intermediate positions are approached, the movement is
stopped and the alarm "Probe collision" is output.
Page 41
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55632 MEA_FEED_FEEDAX_VALUE Traverse velocities for intermediate positioning in the measuring cycle in the infeed axis, with and GUD =_SPEED
without collision detection [2]
A043
Note:
If necessary, adapt the value of the velocity in the infeed axis to the probe type used and to the
machine characteristics! This means that the maximum deflection of the actual probe type must be
considered!!
Explanations:
With SD55632 $SCS_MEA_FEED_FEEDAX_VALUE the traversing feed is performed in
the infeed axis (applicate).
If the probe switches when these intermediate positions are approached, the movement is
stopped and the alarm "Probe collision" is output.
Page 42
55633 MEA_FEED_FAST_MEASURE Rapid measuring feed GUD =_SPEED
Note: [3]
If necessary, adjust the value of the velocity to the probe type used and to the machine character-
istics!
This means that the maximum deflection of the actual probe type must be considered!!
The use of "Rapid measuring feed" depends of SD55610 $SCS_MEA_FEED_TYP!
55760 J_MEA_SET_TOOL_OFFSET_MODE Selection of the offset target during tool measurement, in “Measure in JOG” GUD =_JM_B[0]
=0: Offset into the geometry of the tool component to be corrected
=1: Offset into the wear of the tool component to be corrected
55761 J_MEA_SET_NUM_OF_ATTEMPTS Number of measuring attempts, if the probe does not switch, in "Measure in JOG" GUD =_JM_B[1]
=0: 5 measuring attempts, then alarm "Probe does not switch" is output
=1: 1 measuring attempt, then alarm "Probe does not switch" is output
55762 J_MEA_SET_RETRAC_MODE Selection of the velocity of retraction from the measuring point, in "Measure in JOG" GUD =_JM_B[2]
=0: Retraction is performed at the same velocity as that of intermediate positioning
=1: Retraction is performed with rapid traverse

55763 J_MEA_SET_FEED_MODE Measuring with rapid or normal measuring feed, in "Measure in JOG" GUD =_JM_B[3]
=0: Measuring with measuring feed
=1: First probing is performed with "Rapid measuring feed" from SD55633
$SCS_MEA_FEED_FAST_MEASURE; the second probing represents the measurement itself
performed with measuring feed.

55764 J_MEA_SELECT_CORR_FRAME Selection of the channel frame to be corrected, in “Measure in JOG” GUD =_JM_B[4]
=0: If basic frame is selected as offset target in the parameterization mask, the offset is carried out
into the last channel-specific basic frame
=1: If basic frame is selected as offset target in the parameterization mask, the offset is carried out
into the system frame "Set zero point" ($P_SETFRAME)
55770 J_MEA_SET_COUPL_SP_COORD Coupling of spindle orientation and coordinate rotation around the active plane, in the case of GUD
workpiece measurement with multiprobe in "Measure in JOG" mode =E_MESS_SET
=0: When multiprobes are used, the spindle is oriented as a function of the active coordinate rota- T[0]
tion in the plane (rotation around the infeed axis (applicate)).
Thus, the axis-parallel orientation of the probe sphere contact points (calibrated trigger
points) is maintained in relation to the geometry axis.
The direction of spindle rotation is defined by SD55604 $SCS_MEA_SPIND_MOVE_DIR!
=1: The current spindle orientation with NC-START of the measuring task for "Measure in JOG"
Page 43
is used as the starting position for the following procedure!
Note:
Coordinate rotation in the active plane means: - Rotation around the Z axis at G17,
- Rotation around the Y axis at G18
- Rotation around the X axis at G19.
Notice:
The coupling is annulled by the measuring cycle, if
- Rotations around the 1st or 2nd measuring axis (abscissa or ordinate at G17) between calibra-
tion and actual measuring are not identical !!!
- The working spindle is not position-controlled (SPOS is not possible)
- A monoprobe is used.
- When the coupling is annulled by the measuring cycle, no alarm or message is displayed.
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55771 J_MEA_SET_CAL_MODE Calibration in the hole with known or unknown centre point, in "Measure in JOG" GUD=E_MESS_
SETT[1]
=0: Calibration in a hole with unknown centre point
=1: Calibration in a hole with known centre point
A043 END
55772 J_MEA_SET_PROBE_MONO Selection of the probe type, in "Measure in JOG" GUD=E_MESS_

MS_MONO
=0 probe type is multiprobe
=1 probe type is monoprobe 9779
55800 ISO_M_DRILLING_AXIS_IS_Z Selection of the drilling axis
0: Drilling axis is vertical to the active plane
1: Drilling axis is always "Z", independently of the active plane
55802 ISO_M_DRILLING_TYPE Tapping type
0: Tapping without compensating chuck
1: Tapping with compensating chuck
2: Deep hole tapping with chip breakage
3: Deep hole tapping with stock removal
55804 ISO_M_RETRACTION_FACTOR Factor for retraction speed (0...200%)
Page 44
55806 ISO_M_RETRACTION_DIR Retraction direction for precision drilling and reverse counter-sinking G76/G87
0: G17(-X) G18(-Z) G19(-Y)
1: G17(+X) G18(+Z) G19(+Y)
2: G17(-X) G18(-Z) G19(-Y)
3: G17(+Y) G18(+X) G19(+Z)
4: G17(-Y) G18(-X) G19(-Z)
55808 ISO_T_RETRACTION_FACTOR Factor (1-200%) for retraction speed at tapping G84/G88
55810 ISO_T_DWELL_TIME_UNIT Dwell time evaluation for deep hole drilling G83/G87
0: Seconds
1: Revolutions
Axis Setting Data

A043: END

En 840D SL Complete Service v26

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SINUMERIK 840D sl

This document was produced for training purposes.

Service Manual for

Sinumerik 840D sl Software 2.6

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.

System Overview: TCU

System Overview: PCU50.3

System Overview: PCU50.3 & TCU

A060 Page 2 840D sl Sinumerik Operate

System overview: Description

This module gives a graphical overview of those components System

840D sl Sinumerik Operate Page 3 A060

X120 system network

A060 Page 4 840D sl Sinumerik Operate

DVI External monitor

X120 system network

840D sl Sinumerik Operate Page 5 A060

X120 system network

A060 Page 6 840D sl Sinumerik Operate

RCS Commander - System card back-up, Remote control (Viewer)

 Install the software tools from the PLC toolbox DVD.

Theory and Objective.

PLC Toolbox Installation.

HMI Advanced Installation

RCS Commander Installation.

Online Connection-RCS Commander

Online Connection-HMI Advanced

Online Connection-Simatic Manager

A002 Page 2 840D sl SINUMERIK Operate

PLC Toolbox Installation: PLC Toolbox

 HMI Advanced - Configuration of drives during the

 RCS Commander - Service, commissioning and re-

840D sl SINUMERIK Operate Page 3 A002

PLC Basic Program for 840D sl

The toolbox is a compressed file and requires extracting to a

Select “Extract all”

Allow the extraction process to complete.

A002 Page 4 840D sl SINUMERIK Operate

A series of dialogue boxes relating to language selection,

Continue until the following dialogue box appears. It is neces-

The following dialogue box indicates that the installation was

The toolbox components will now be installed in turn.

840D sl SINUMERIK Operate Page 5 A002

The HMI Advanced software is used for drive configuration and

Installation DVD for Commissioning/Service Tools:

A002 Page 6 840D sl SINUMERIK Operate

A summary of the selections made, the components to be

The HMI Advanced is used on several types of controllers

840D sl SINUMERIK Operate Page 7 A002

Installation DVD for RCS Commander:

RCS Commander allows a remote operation between the

The software can also be used to write images to compact

Double click the Setup.exe” file

The installation should be allowed to finish. The connection

A002 Page 8 840D sl SINUMERIK Operate

Checking the network adapter type: