En 840D SL Complete Service v45

SINUMERIK 840D sl
Service Documentation
Sinumerik 840D sl
Edition 2014.04
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 4.5

Contents
Start
A060
System
Overview
A002 A021
Service & A061 Access Levels/
Commissioning Menu Structure Time and Date
Tools Settings
A041
Machine and
Setting Data
A035
Program
Handling
A003 A007 A044
Battery and Fan Electronic Licensing of
Exchange Logbook Options
A017
Data
Management
A010
PCU and TCU
Connections
and Diagnostics
A036
A030 A051
NCU
Digital Inputs & Line and Motor
Connections
Outputs Modules
and Diagnostics
A053
Axis and Drive
Diagnostics
A084
Encoder
Adjustments
A008
A026
A033 MCP&PP72/48
Creating a PLC
PLC Functions Connections
Program
and Diagnostic
A037
Alarm Structure
A031
PLC Alarms
and Messages
A058 A103
A011
PLC Onboard Service Used
Run MyScreens
Diagnostics Cases
A016
Additional Axis
Installation
A006
Electrical
Cabinet Design
Appendix C Appendix B Appendix A
Hardware
End PLC
Interface
Technology
Settings Differences
A060 System Overview
Sinumerik
Operate
Module Description:
The 840D sl Sinumerik Operate system is made up of a variety of hardware components.

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

840D sl with PCU50.x
Sinumerik
840D sl with PCU50.x and TCU

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

System Overview A060
System Overview:
START
Sensor
Modules
840D sl with
TCU
Terminal
Modules,
DRIVE CLIQ
Hub
840D sl with
PCU50.x
Operator
Panels
840D sl with
PCU50.x and
TCU
Drive CLiQ
Rules
Component
Overview:
S120 / 840D sl
System Overview:
END
NCU and NX
Modules
S120
Booksize
Components
S120 Line
Modules &
DC link
Components
S120
Booksize
Motor
Modules
Notes
840D sl Sinumerik Operate Page 3 A060

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

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

840D sl with PCU50.5
DVI External monitor

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

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

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

Component Overview: S120 / 840D sl
SINUMERIK and SINAMICS automation system components.
NCU 710.3
NCU 720.3
NCU 730.3
NX 10.3
NX 15.3
Notes

840D sl NCU and NX
840D sl NCU and NX
NCU
SINAMICS S120 Line Module
Motor Module
NX10
NX15
Property NCU 710.3 PN NCU 720.3 PN NCU 730.3 PN
Cooling ribs No Yes Yes
DRIVE-CLiQ Ports 4 6 6
Axes Up to 8 Up to 31 Up to 31
NX10.3 / 15.3 Up to 2 Up to 5 Up to 5
TCU Up to 2 Up to 4 Up to 4
Notes

Key Data for NCU and NX
Notes

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

NCU 730.3
Measuring Sockets Location:

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

Name Function Status Meaning

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

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

NX10.3/NX15.3
Notes

Status LEDs - NX10.3 / 15.3
LED Color Status Description

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

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

NX10 / NX15: Connection DRIVE CLiQ
X105
15
X100
14
NX10/15 (1)
NX10/15 (2)
DRIVE-CLiQ topology
NX components can be connected to the Control Unit via DRIVE-CLiQ. The following rules apply for the
wiring:
 Only one star topology is permitted between the NX and the Control Unit. This means that only one NX
can be operated per DRIVE-CLiQ port on a Control Unit.
 DRIVE-CLiQ ports not assigned to NX can be wired to other DRIVE-CLiQ components.
 Once an NX has been connected and configured, you cannot simply insert it into a different DRIVE-
CLiQ port, as the addresses of the integrated drives are set permanently from the point of view of the
PLC.
The following table illustrates this relation:
DRIVE-CLiQ Port Drive PROFIBUS addresses

X105 15
X104 14
X103 13
X102 12
X101 11
Notes

S120 Booksize Components
840D sl as central control unit
Line Modules for power supply :

 Smart Line Module 400V max. 55kW
 Basic Line Module 400V max. 100kW
 Active Line Modules 400V max. 120kW
One or several motor modules to control the motors

 Single Motor Module, max 200A
 Double Motor Module, max 18A
Optional DC Link Components

 Braking Module
 Braking Resistor
 Capacitor Module
Additional Optional Components:
Sensor Modules: SMC10 (Resolver)

SMC20 (Encoder)
SMC30 (TTL/HTL)
Terminal Modules: TM15, TM31, TM41
Active/ Smart Line Module

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

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

SINAMICS: Component Connection Diagram
Quicker and easier Start-up with SMI

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

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

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

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

S120 Line Modules & DC link components
Smart Line Modules

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

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

 unregulated DC Link Voltage
 No regenerative feedback
 With all BLM: DC-link rails to both sides of line mod-
ule
Active Interface Modules for 16 kW, 36 kW, 55 kW und 80 W/120 kW
Active Interface Modules

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

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

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

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

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

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

Max. connectable cross-section: 6 mm2
Notes

LED Status - 5 kW and 10 kW Smart Line Modules

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

Terminal strip X21 (EP terminals) for 16 kW to 55 kW Smart Line Modules
Terminal Function Technical specifications
1 + TEMP Temperature sensors1): KTY 84-1C130/PTC/bimetallic

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

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

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

SINAMICS Power Components : Line Modules
Properties of Infeed
• Supply voltage 3AC 380-480V, 50/60Hz
• IP20 protection
• cooling: Internal and external air cooling
• Ambient temperature: 0-40 °C without derating, to 55°C with derating
• Height: 380mm
• Depth: 270mm
Smart line modules Supply power (kW) / width (mm)
• 5/50 -> without Drive-CLiQ ports
• 10/50 -> without Drive-CLiQ ports
• 16/100
• 36/150
• 50/200
Active line modules Supply power (kW) / width (mm)
• 16/100
• 36/150
• 55/200
• 80/300
• 120/300
ALM Control Modes
Control Modes The active line module can be operated in one of two different control modes,
depending on the parameterized line supply voltage (p210):
Active Mode DC link voltage is controlled with respect to a settable reference value.
The Line Module acts as a Step-up converter with regulated DC link voltage and
sinusoidal supply voltage.
Smart mode The DC link voltage is not regulated, but results from the rectified supply voltage
Notes

ALM Control Modes
SINAMICS: DC Link Components
Braking
Braking Module
Module und Bremswiderstände
and braking resistors
Two braking resistors are available:
Zwei Bremswiderstände stehen zur Verfügung:
Booksize: 0,3 kW continuous braking power
Booksize: 0,3 kW Dauerbremsleistung
(25 kW peak power)
(25 kW braking
1,5 kW continuous Spitzenleistung)
power
(100 kW peak
1,5 kW power)
Dauerbremsleistung
(100 kW Spitzenleistung)
Capacitor Module
Capacitor modules
IsDient zur
used for Erhöhung
increasing the DCder
linkZwischenkreiskapazität
capacity in order um
tokurzzeitige
deal with shortNetzausfälle
power failures zu überbrücken.
Control Supply Modules

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

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

S120 Booksize Motor Modules
Features Booksize Format

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

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

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

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

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

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

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

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

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

Status LED Description - SMC 10, SMC 20

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

RDY — Off Electronics power supply is missing or outside permissible —
READY tolerance range.
Green Continuous light The component is ready for operation and cyclic DRIVE- —
CLiQ communication is taking place.
Orange Continuous light DRIVE-CLiQ communication is being established. —
Red Continuous light At least one fault is present in this component. Remedy and
corresponding messages have been reconfigured
0.5 Hz
Flashing Firmware download is complete. Wait for POWER ON Carry out a POWER
2 Hz ON
Green/orange Flashing light Component recognition via LED is activated (p0144). —
or Note:
Red/orange Both options depend on the LED status when component
recognition is activated via p0144 = 1.
OUT > 5 V — Off Electronics power supply is missing or outside permissible —

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

Sensor Module External (SME)
Direct encoder systems outside the cabinet can be connected to the Sensor Modules External SME20, SME25, SME120 and
SME125 with protection type (IP67) . The SMEs evaluate these encoder systems and convert the values to DRIVE-CLiQ.
The SME provides the encoder power supply. The power supply for the SME is provided from the connected DRIVE-CLiQ
cable.
SME20/SME25 feature the following interfaces:
SME20 / 25 X500 DRIVE-CLiQ-interface

X100 encoder connector via circular plug
24 V DC electronics power supply via DRIVE-CLiQ link from

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

SME120 / 125 SME120/SME125 have the following interfaces:
X300 hall-effect sensor connection via circular connector

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

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

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

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

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

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

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

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

TM 41
With the TM41 Terminal Module, the number of available digital inputs and outputs and
the number of analog inputs and outputs within a drive system can be expanded. The
encoder interface of the TM41 delivers TTL signals as incremental encoder simulation to
the Control Unit.

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

Status LED Description - Terminal Module TM 15, TM 31:

READY — Off Electronics power supply is missing or outside permissi- —
ble
tolerance range.
Green Continuous The component is ready for operation and cyclic DRIVE- —
light CLiQ communication is taking place.
Orange Continuous DRIVE-CLiQ communication is being established. —
light
Red Continuous At least one fault is present in this component. Remedy and
light Note: acknowledge fault
corresponding messages have been reconfigured.
0.5 Hz
Flashing Firmware download is complete. POWER OFF/ON
2 Hz
Green/ Flashing light Component recognition via LED is activated (p0154). —
orange Note:
or Both options depend on the LED status when component
Red/orange recognition is activated via p0154 = 1.
Status LED Description - Terminal Module TM 41:

READY — Off Electronics power supply is missing or outside permissi- —
ble
tolerance range.
Green Continuous The component is ready for operation and cyclic DRIVE- —
light CLiQ communication is taking place.
Orange Continuous DRIVE-CLiQ communication is being established. —
light
Red Continuous At least one fault is present in this component. Remedy and
light Note: acknowledge fault
corresponding messages have been reconfigured
0.5 Hz
Flashing Firmware download is complete. Wait for POWER ON POWER OFF/ON
2 Hz
Green/ Flashing light Component recognition via LED is activated (p0154). —
orange Note:
or Both options depend on the LED status when component
Red/orange recognition is activated via p0154 = 1.
Z puls- — Off Zero mark found; wait for zero mark output; OR —
es component switched off.
Red Continuous Zero mark not enabled or zero mark search. —
light
Green Continuous Stopped at zero mark.
light
Flashing light Zero mark is output at each virtual revolution. —
Notes

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

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

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

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

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

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

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

Drive CLiQ rules
Obligatory Rules for DRIVE-CliQ
•• Max. 198
Max. 198 DRIVE-CLiQ
DRIVE-CLiQ Teilnehmer
participants per NCU pro NCU
• Max. 14 participants on one connnector
•• Max.
Max 8 14 Teilnehmer
participants in a row an einem Anschluss
• No ring wiring
•• Max 7 Teilnehmer
No Double wiring in Reihe
• Keine Ringverdrahtung
• Keine Doppelverdrahtung
No ring wiring
No Double wiring
Optional Rules for DRIVE-CliQ
Adherence to these rules

• Motorgeber anallows automatic topology
zugehörigem MoModetection.
• For a motor module, the associated motor encoder must also
• Möglichst viele NCU-Ports nutzen
be connected.
• Use as many of the DRIVE-CLiQ connection points on the
NCU as possible as this allows better capacity utilization.
Notes

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

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

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

A060 END System Overview
IP-Adressen NCU
X120 System Network
IP Address Network Station Remarks
192.168.214.1 NCU on X120 Default
192.168.214.2 - 9 Additional NCUs with fixed IP address Unassigned
192.168.214.10 - 239 Fixed Additional TCUs, subsequently for additional PCUs, NCUs, DHCP clients
MCPs & MPPs
192.168.214.241 Fixed IP address for PCU50 (Connected via ETH2 of PCU) Default
192.168.214.242 - 249 Additional PCUs with a fixed IP address Unassigned
192.168.214.250 - 254 For PGs/PCs with a fixed IP address (Service connection) Unassigned
X127 Service Network
IP Address Network Device Remarks
192.168.215.1 NCU on X127 Default
192.168.215.2 - 23 Service use with PG/PC DHCP clients
192.168.215.24 - 30 For fixed IP devices e.g. modem Unassigned
A060: END

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

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

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

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

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

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

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

finalise the installation.
Notes

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

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

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

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

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

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

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

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

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

The PC has been assigned the first available IP address of

192.168.215.2 by the DHCP server of X127.
Online Connection-Access MyMachine Set the privilege level to “Run this program as an administra-
tor“
Administrator Privilege Level
The Toolbox programs should always be run with privileges
set to Administrator.
Setting the Administrator Privilege:

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

A dialogue box appears where the choice of connection is

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

After a short delay the data folders of the controller will appear in the lower half of the Access MyMachine program, this indicates
that a successful connection was made.
Online Connection: StartUp (IBN) Tool Administrator Privilege Level

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

top is not supported.
Notes

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

Setting the PG/PC Interface:

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

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

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

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

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

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

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

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

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

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

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

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

A061 Menu Structure
Sinumerik
Operate
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
Menu Area: Parameter
Menu Area: Program
Menu Area: Program Manager
Menu Area: Diagnostics
Menu Area: Start-up
Short Cut Keys
A061
A061

Menu Structure A061
Menu
Structure:
START
Menu Area:
Program
Manager
Menu Select
Button
Menu Area:
Diagnostics
Mode
Selection
Menu Area:
Start-up
Menu
Selection
Short cut
keys
Menu Area:
Machine (JOG
Mode)
Menu
Structure:
END
Menu Area:
Machine (MDA
Mode)
Menu Area:
Machine
(AUTO Mode)
Menu Area:
Parameter
Menu Area:
Program
Notes

A061 Menu Structure
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

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

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

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

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

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

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

Menu Structure A061
Menu Area: Machine (JOG Mode)
Menu Area: Machine (MDA Mode)
Notes

A061 Menu Structure
Menu Area: Machine (AUTO Mode)
Menu Area: Parameter
Notes

Menu Structure A061
Menu Area: Program
Menu Area: Program Manager
Notes

A061 Menu Structure
Menu Area: Diagnostics
Menu Area: Start-up
Notes

Menu Structure A061
Short cut Key sequences
Keys Function
+ In the program manager and in the program editor from the cursor position,
selects directories or program blocks up to the beginning of the window.
+ Positions the cursor to the topmost line of a window.
+ In the program manager and in the program editor from the cursor position,
selects directories or program blocks up to the end of the window.
+ Positions the cursor to the lowest line of a window.
+ Editing box - Moves the cursor further to the right by one word.
Navigation - Moves the cursor in a table to the next cell to the right.
Keys Function
+ Editing box - Moves the cursor further to the left by one word.
Navigation - Moves the cursor in a table to the next cell to the left.
+ Editing box - Moves the cursor in the table to the beginning of the table.
Navigation - Moves the cursor to the beginning of a window.
+ In the program manager and in the program editor, selects a contiguous

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

selection of directories and program blocks.
Notes

A061 Menu Structure
Keys Function
Moves the cursor to the last entry.

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

+
In the program manager and in the program editor from the cursor position,
+ selects directories or program blocks up to the end of the window.
Deletes a word selected to the left of the cursor.

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

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

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

Menu Structure A061
Keys Function
Reactivates changes that were undone (only in the program editor).

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

+ + S
Backs up the log files on the USB-FlashDrive. If a USB-FlashDrive is not

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

+ M
Feed over ride is increased in Simulation

+
Feed over ride to decreased in Simulation

+
Opens the Editor to enter Asian characters.

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

+ Navigation - Deletes all characters
A061: END
Notes

A061 END Menu Structure

A021 Access Levels / Time and Date settings
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.
It is also important that the system date and time are correct.
This is necessary for checking when an alarm occurred or when a file (Part program, archive etc)
was created or edited.
If at the time of installation, the time and date is not set correctly, the Guarantee period of the con-
troller could be effected.
Before the date and time displays can be edited, the password for the “User” or higher must be en-
tered.
Module Objective:
Upon completion of this module you will be able to set the different access levels using a password
or key switch, and set the time and date for the system.
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
Customising Soft-key Access Levels
Setting the Date and Time
A021
A021
A021 Page 2 840D sl Operate SINUMERIK

Access Levels / Time and date settings A021
Access Levels /
Time & Date:
START
Password
and
key-switch
information
Setting and
Deleting the
Password
Protection of
files
Customising
Soft-key
Access
Levels
Time and
Date
Setting
Access Levels /
Time & Date:
END
Notes
SINUMERIK 840D sl Operate Page 3 A021

A021 Access Levels / Time and date settings
Password and key-switch information
The following table shows the password/key-switch positions

and associated access levels/users. Key switch Colour coded keys
Access
Intended user Protected via
level Access levels of the three keys:
1 Manufacturer Password: SUNRISE
Key colour Switch position Access level
Installation Engineer,
2 Password: EVENING
service
No key required 0 7
3 End User Password: CUSTOMER
Black 0&1 6-7
4 Programmer, Setter Key-switch position 3 Green 0, 1 & 2 5-7
5 Qualified operator Key-switch position 2 Orange 0, 1, 2 & 3 4-7
6 Trained operator Key-switch position 1 It is the responsibility of the OEM to ensure that the key-switch
signals are transferred to the PLC interface.
7 Untrained operator Key-switch position 0
DB10.DBB56 is used for the transfer of the key-switch signals.
The key switch is located on the MCP and has four positions.
Three colour coded keys are available, each of which allow a DB10 Key-switch signals to NC (PLC  NC)
different access level.
This is standard on Siemens machine control panels. It is pos- Bit7 Bit6 Bit5 Bit4 Bit3 Bit2 Bit1 Bit0
sible that a manufacturer may use a different method to set the
interface signal. DBB56 Key- Key- Key- Key-
switch switch switch switch
Pos.3 Pos.2 Pos.1 Pos.0
Setting and Deleting the Password
Setting the password:

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

soft key.
Notes

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

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

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

Module A033 explains how password deletion can be auto-
mated.
Protection of files
The properties of the file are found by paging right and select-
Certain files such as important cycles, programmes etc can be ing the properties Soft-key.
individually protected against accidental editing, deletion or
execution. They can also be hidden from view.
The file to be protected has to be located before the properties
can be edited. In this example, the part programme A dialogue box allows four properties to be changed.
“Example.MPF” is to have it’s properties changed.
In the following example, the program:
The “Part program” directory is located by selecting the
“Program manager” key.  Can only be executed if the “Service” password or
higher is active
 Can only be written to (Edited) if the “Manufacturer”
password or higher is active
 Will only be listed if the key switch position 2 or higher
is active
 Can only be read if the key switch position 3 or higher
is active
Example: TEST.MPF file has been selected in the Part Pro-
grams directory.
Notes

A021 Access Levels / Time and date settings
Customising Soft-key Access Levels
It is possible to set the access levels for each soft-key.

The function must first be activated in the Setup area.
When the correct settings have been entered the “OK” soft
key has to be selected.
When the “OK” key is pressed the function will be activated.

Use the mouse “Left click” to select the
This is confirmed by the message 150100
required access level.
The menu will automatically disappear when the selection is
made.
If an access level is already active the “Original setting” op-
tion will be available.
To set the access levels of the soft-keys it is necessary to con-

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

key to Manufacturer.
Place the mouse pointer over

the soft-key and “Right click”
Notes

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

the “Customize softkeys” area
The “Original setting” soft-key can be used to return the

access levels of all the soft-keys to their default state.
Setting the Date and Time (TCU)
The date/Time screen is reached with the following soft key

sequence:
The time and date can now be checked and corrected if

necessary.
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

Use the cursor keys to move between the data fields. press the “OK” soft key. The current date/time will
The format can be changed by highlighting the required input then be updated with the new values.
field and using the “Select” key.
Notes

A021 END Access Levels / Time and date settings
Setting the Date and Time (PCU50)
On systems with a PCU there are two date/time areas, one for
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.
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

press the “OK” soft key. The current date/time will
then be updated with the new values.
A021: END
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 the machine.
Content:
Sinumerik
Machine & Setting Data Overview
Editing Machine & Setting Data
User Views
A041
A041

Machine and Setting Data A041
Machine and
Setting Data:
START
Machine &
Setting Data
Overview
Editing
Machine &
Setting Data
User Views
Machine and
Setting Data:
END
Notes

Machine & Setting Data Overview Each range contains the individual machine/setting data.
Machine data is often referred to as MD, while setting data is
General assignment referred to as SD.
The Machine/Setting data are divided into the following ranges:

Machine/Setting Data Location:
Range Description The following soft-key selection is used to locate the MD/SD
area.
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
The data is listed in numerical order with the MD/SD number
43000 - 43999 Axis-specific setting data in the left column. The following columns show the descrip-
51000 - 51999 General cycle machine data tion/name, value, units and activation requirement.
52000 - 52999 Channel-specific cycle machine data

53000 - 53999 Axis-specific cycle machine data
54000 - 54999 General cycle setting data
55000 - 55999 Channel-specific cycle setting data
56000 - 56999 Axis-specific cycle setting data
MD/SD identification:
MD/SD name Activation
Number (System language) Value method The MD/SD name contains identifiers so that the system can
identify that particular data.
Units
1st character
$ = System variable (Present on all MD & SD)
2nd character (Defines between MD or SD)

M = Machine data
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
A = Axis Machine Data / Setting Data
4th character
S = Cycle Data (Defines MD/SD as cycle data)
Examples:
Plain text description 9900 $MM_MD_TEXT_SWITCH Display MD
the selected MD/SD.
54600 $SNS_MEA_WP_BALL_DIAM General Cycle SD
55623 $SCS_MEA_EMPERIC_VALUE Channel Cycle SD
30200 $MA_NUM_ENCS Axis MD
Notes

The following data ranges are used for the machine data: Indexes:
$MM_ Display machine data Certain MD/SD have indexes. The function and number of
$MN_ General machine data indexes depends on the data in question.
$MC_ Channel-specific machine data
Example:
$MA_ Axis-specific machine data General MD 10000 $MN_AXCONF_MACHAX_NAME_TAB
$MNS_ General cycle machine data
$MCS_ Channel-specific cycle machine data This MD is used for defining the names of the axes in the
$MAS_ Axis-specific cycle machine data system. Each axis name is assigned to an index the MD.
The following data ranges are used for the setting data:
$SN_ General setting data

$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 Further examples:
30240[0] $MA_ENC_TYPE = The type of encoder connected
to the 1st measuring system input.
30240[1] $MA_ENC_TYPE = The type of encoder connected
to the 2nd measuring system input.
Help Function: Activation of the MD/SD:
The function of each MD/SD is described in detail via the There are four methods available for activating the MD/SD.
“Help” key. The method depends on the MD/SD in question.
The MD/SD first needs to be selected and then the “Help” key The right hand column of the screen displays the required
pressed. The key is found on the NC keyboard method.
Active via “Reset (po)” soft-key or controller

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

key.
A detailed description will be displayed. This will include units,
limits etc as well as the functionality. Active on selection of the appropriate PLC
interface signal, usually via MCP “Reset” key.
Active immediately the “Input” key is selected

to confirm the value.
Notes

Units for MD/SD Unit Description
The function of the MD/SD determines the units in use. mm/rev millimetres/revolution: linear feed-rate deter-
mined by a rotary axis.
The following table shows the abbreviations and descriptions of
the units. m/s³ Meters/second-cubed: linear jerk
rev/s³ revolutions/second-cubed: rotary jerk
Kg Kilogram: Measurement of mass
Unit Description
mm millimetre: Linear measurement.
mm/sec Millimetres/second: Linear velocity/speed
Nm Newton-metre
rpm Revolutions/minute: rotational velocity/speed
mH milli-Henry: Measurement of inductivity
m/s² Meters/second-squared: Linear acceleration
rev/s² revolutions/second-squared: rotary acceleration A Amperes (Amps): Electrical current
kgm² V Volts: Electrical potential

Kilogram/meter-squared: Moment of inertia
s seconds: measurement of time.
Some MD/SD have no units associated with them. In this case
Hz Cycles/second: Frequency. use the “Help” function to determine the data type required.
deg Degrees: Angular measurement.
Editing Machine & Setting Data The machine data which are available for viewing can be re-
stricted via the “Display options” soft-key
To locate the machine data screens first ensure that the rele-
vant access level is active (Module B021 Protection Levels)
then use the following key sequence:-
The default is for the General Machine screen to be displayed
Notes

The Machine & Setting Data is separated into different groups. For further data the “Menu Extension” key must be selected.
This allows access to the Setting Data and also the Display
General MD and general Cycle MD. Machine Data.
Channel-specific MD and channel-specific Cycle MD.
Axis-specific MD and axis-specific Cycle MD.
User Views- Allows the user to create list of specific

machine data.
Control Unit MD.
Supply MD (ALM/SLM-only DriveCLiQ types).
Drive MD (Motor Modules)
General SD and general Cycle SD.
Channel-specific SD and channel-specific Cycle SD.
Axis-specific SD and axis-specific Cycle SD.

When the correct MD has been found, a value can be en-
tered. In this example we are going to change Display MD
Display MD. 9900 from 0 to 1. This will change the MD/SD description
from system language to plain text.
The correct machine data should first be located. This is

done by either using the page/cursor keys or the search
function.
The search function is activated with the “Search” soft key. If
the Machine Data number is known this can be typed into the
dialogue box. It is also possible to enter part or all of the MD
name in text format.
Notes

The correct machine data has to be highlighted. The number Some MD/SD have no units associated with them. In this case
1 is entered and confirmed with the “Input” key. use the “Help” function to determine the data type required.
MD/SD with “Bit patterns”
If the letter “H” appear as the last digit in the “Value” column the
On pressing the “Input” key the text of the machine data MD/SD requires a value in Hexadecimal format. A bit pattern
changes immediately (see below). This will apply to all MD/ can be viewed.
SD. 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.
REMEMBER:- Create a data backup.

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

User Views
The “User views” function allows a customised list of machine

data to be made. MD/SD can be listed that are of importance
to a specific task/function of the machine.
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.
Edit existing machine data list or create new machine data list.
The new entry will be displayed in the View menu.

It is now possible to add the required MD/SD.
In the following example Axis MD for the spindle will be added.
The required MD/SD type is selected from the list and con-
firmed with the “Input” key.
The General machine data will be displayed by default.

A list of all types of data can be viewed on the “Select” list
Notes

Select the data to be added to the 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
bottom of the screen.
Text to be displayed on the list.

Or
(Maximum 30 displayable characters)
The selected MD will appear on the screen.
Detailed text to be displayed at the bottom of

the screen. (Maximum 80 characters)
The position of the text line can be selected when editing is Short text description.
complete.
Or
Example of a list of spindle specific MD complete with descrip-

tive texts:
Detailed text description.
Notes

Modifying a MD/SD entry:
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.
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.
Or
Any unwanted items are removed via the “Delete” Soft-key.

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.
A041: END
Notes

A041 END Machine and Setting Data

A035 Program Handling
Sinumerik
Operate
Module Description:
It is often a requirement to store machining programs off-line on an external computer.
Access MyMachine is a multi-functional software tool which connects via Ethernet (X127 & X130),
one of the functions offers the possibility to connect remotely to controllers in order to transfer ma-
chining programs to and from an external computer.
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 Access MyMachine 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
Access MyMachine connected via X127
Program Handling
External Viewer
Configuring a Network Drive
Network & OP
A035
A035

Program Handling A035
Program
Handling:
START
Access My-
Machine
via X127
Access My-
Machine
via X130
Access My-
Machine
Configuration
of Bookmarks
External
Viewer
Configuring a
Network Drive
Network
&
OP
Program
Handling:
END
Notes

Select the “Internet Protocol Version 4 (TCP/IPv4)” option,

Access MyMachine connected via X127 followed by the “Properties” button:
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.
Select the option “Obtain IP address automatically” Double click the “Access MyMachine ” icon which is found on
the PC desktop
When the program is opened for the first time after the
installation it is necessary to assign a password for encryp-
tion purposes.
Notes

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).
The connection process will now start:
Select the “User” login and enter the password.
Password:-CUSTOMER
When the information box has cleared, the folder structure of the host PC will be seen in the top half of the Access MyMachine
program. The lower half shows the folder structure of the controller.
Notes

Configuring Interface X130
Ethernet interfaceX130 is configurable, the port can be as-

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

connection of certain software tools. It is possible to open
ports to allow connections to be made.
Change the firewall with the following key selection:
Computer Network Settings
When using X130 in a manual set-up, the IP address and

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

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

unique IP address, example 192.168.100.2 with a subnet
mask of 255.255.255.0
Notes

X130 Controller Set-up An overview of the X120 and X130 interfaces is displayed.
X120 is the system network to which is connected hardware
The controller settings for X130 can now be entered. such as Machine Control Panels (MCPs), Operator Panels
(OPs) etc. This interface cannot be configured.
Any existing X130 settings should be recorded before any X130 is the company network and is configurable.
changes are made.
IP address restrictions- IP addresses 192.168.215.xxx &

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

address to X130.
Locate the “TCP/IP diagnostics” screen with the following key

selection:
A more detailed view of the interfaces can be seen. To

configure X130 select “Change”.
Notes

The settings can now be changed. Use the cursor and select The following example shows X130 being manually configured
keys to navigate the screen. with an IP address of 192.168.100.1 and a subnet mask of
255.255.255.0
Address Type: DHCP-To obtain IP address automatically.
Manual-To enter a defined IP address.
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 Allow the boot process to complete.
Check that the settings for X130 are correct
Note the message displayed above the horizontal soft-keys:
Changes will become effective after HW-Reset NC/HMI
Switch the control off/on to activate the settings.
Notes

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
X120: Connection in
use
Access MyMachine Connection
A default connection is available in Access MyMachine for

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

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

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

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

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

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

Access MyMachine -Configuration of Bookmarks
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.
NC data folder containing Standard Bookmarks- selected

MPF, SPF & WKS folders from the drop-down list
Adding Bookmarks A name for the bookmark needs to entered and then saved.
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

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
External Viewer
The external viewer duplicates the controller display on the

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

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

pear which requires acknowledgement, this determined how
long the dialogue box stays on the screen.
When set to “allowed”, then the controller will allow the con-
nection, even when the dialogue box has not been acknowl-
Importen:
edged.
ext. viewer in original colours only with transmission mode LAN!
If set to “Denied” the connection will be blocked if the dialogue
box is not acknowledged.
The settings are saved by selecting the “OK” soft-key.
Connecting the Remote Viewer
To start this function select the following icon from the Access
MyMachine tool bar.
Alternatively select “Start” from the “Remote control” drop
down menu.
When the viewer attempts to connect, providing that the remote viewer has not been blocked, the screen of the controller
will be displayed.
If an acknowledgement is required, a dialogue box will appear. The person at the controller should acknowledge with the
“Yes” soft-key.
This should be done within the time limit specified on the HMI-set-up screen.
When the connection is successful the viewer will display the

same screen as the controller.
Notes

The following keys are used to navigate the

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

changed from the remote computer, archives
can also be created.
Configuring a Network Drive
Create a user account "AUDUSER" with password protection "SUNRISE".
Add or remove user accounts
with accounts selecting and opening.
Notes

Create a new account “AUDUSER“
Entering as a password "SUNRISE"
Show the local User and Groups: start Lusrmgr.msc with
Notes

Setup Network Drive

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

Right click on the folder and select “Properties”. The share permissions for the new folder can be set. The
folder access over the network can be restricted to certain
users. The following example sets the permissions for
Select the “AUDUSER” (Log-in name of the computer).
“Sharing” tab
Select “Share
Select this folder”.
“Advanced The “Share
Sharing” name” will auto-
matically take
the folder name
Notes

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

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

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

shared folder. The type of access is determined next.
The following settings allow the user “AUDUSER” to have full About Shared Folders:
control of the shared folder including editing/creating items.
Start Fmgmt.msc with:
Notes

Displays shared folders, current sessions, and open files.
Logical Drive Set-up
Mapping the Shared Folder
The folder previously set up for sharing now needs to be

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

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

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

untouched. The next available free area is position 2. Use
the cursor and select keys to navigate the screen.
Notes

In the following example, details of the external PC have The new soft-key will now be available in the Program area:
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.
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.
Notes

Network & OP´s
To activate the Network & OP´s settings carry out a reset procedure:
Configuration of port X130 Network
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 company network. When configuring for connection to a company network, certain
information is required from the company 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 Change.
Notes

Configuration of port X120 Network
All operator stations in the system network (TCUs, HT8, PCU 50) are administered on the NCU with "master priority", i.e. this
contains the config.ini files relevant for the runtime and also the .leases file with all the IP addresses assigned in the system.
Adjusting system network on “master priority“
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.
The distribution of the config.ini files

to all the other NCUs/PCUs is per-
formed by the master NCU with the
"Reload" softkey.
With the "Invalidate cache" softkey

and subsequent Power Off/On of the
entire system, the NCUs/PCUs are
assigned their specified IP addresses
and new IP addresses assigned for
TCUs and MCPs and then the .leases
file distributed to all NCUs/PCUs.
Notes

The config.ini files of all operator stations can be edited directly on the master NCU with the page OPs , on each HMI.
The distribution of the data to all NCUs/PCUs is performed automatically with each change.
All settings with regard to network-

ing and TCU configuration can be
made via “Network & OP´s“!
The Config.ini files

card/user/common/tcu/<TCU-
Name>/common/tcu/config.ini and
the basesys.ini are edited via Net-
work & OP´s
Removal of TCUs
TCUs that are not active can be removed on the Avaible operator panels …. .!
Notes

A035 END Program Handling
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:
As a rule, the internal HMI sl should be switched off, because the operation of two HMIs (HMI Advanced and Operate) on one
NCU is only permitted in special cases.
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
entered at VNC connection (config.ini)!
A035 : END
Notes

A044 License and Option Management
Sinumerik
Operate
Module Description:
When a CF card with options is purchased a software License key is issued. The License 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 License and
activate options.
Content:
Sinumerik
Entering and checking Licenses
Assigning Licenses
A044
A044

License and Option Management A044
License and
Option
Management:
START
Entering and
Checking
Licenses &
Options
Assigning
Licenses
License and
Option
Management:
END
Notes

Entering and Checking Licenses & Options
To check the License number, use the following key

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

ber is displayed.
The License 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 License key can be entered on this page. This is activated
by an NCK reset using the “Reset (po)” soft-key.
The control should arrive with documentation regarding the

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

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

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

www.siemens.com/automation/license
Notes

For retrieving a lost key, use the “Show License 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 License screen shown on the controller.
The license key will now be displayed. A license report can

be requested and emailed to an email address.
The license key can be saved as a text file by right clicking on

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

Saving the License number: The new folder now appears. Select “OK” to save the License
key file to this folder.
It is possible to save the License number to a file so that it
can easily be restored.
Choose the destination for the License key.
Create a new directory if required.
A message is displayed momentarily above horizontal soft-

keys.
Notes

Restoring the License number:
Select the “Read in License key” soft-key.
Highlight the License key file and press the “OK” soft-key.
Transferring License key from a text file
The License key will copy from the keys.txt and direct insert
transferred to the key-box!
The License key will now appear in the License key box.
Handling of Options: To select an option use the cursor keys to highlight the de-
sired option and then press the “Select” key to activate or en-
The “All options” soft-key can be selected to view all set and ter a number depending on the type of option being activated.
licensed options. An NC reset (Reset (po) ) is required to complete the proce-
dure.
Non-licensed options:
If a non-licensed option is activated, the controller will issue a
License alarm.
Notes

To see all non-licensed options, select the “Missing Licenses”

soft-key.
Assigning Licenses
If a License key is insufficient for a required option, it is possible

to assign a new License key that includes the missing option.
The assignment of a new License key is done via the internet.
Each option is issued a License Certificate. The certificates are

delivered with the CF card and contains the License and dis-
patch note numbers.
Example: A License certificate
Sequence: Access the “Web License Manager“ on a PC with Internet ac-

cess: http://www.siemens.com/automation/license
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 License manager screen.
Step 1 of 5 - Login:
To login, select “Direct Access“ on the “Web License Manager“
screen.
Notes

Enter the License number and the dispatch note number. Con-
tinue to step 2 with the “Next“ button.
Step 2 of 5 - Identify Product:

Enter the hardware serial number and select the product. Con-
tinue to step 3 with the “Next“ button.
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
with the “Next“ button.
Notes

Step 4 of 5 - Assigning the License:

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

The License Key includes all options assigned for the 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.
You assign the Licenses to the hardware specified by clicking

the “Assign“ button.
Save the file to a suitable place in order that it can be loaded to

the controller.
Change to the licensing screen and enter the License Key by

Saving the License as an ALM file: pressing the “Read in License key“ soft-key.
Select the file to be loaded and continue with the “OK” soft-key.
Download the License Key by double clicking the following link.
Notes

It can be checked whether the License Key has been entered

successfully by pressing the “All options“ soft-key and checking
that the missing option is licensed.
Setting the Options according to the License Key:

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

A044 END License and Option Management

A007 Electronic Logbook
Sinumerik
Operate
Module Description:
The electronic logbook function of the 840D sl controller is used to enter data such as manufactur-
er (OEM), dealer and user information, 1st and 2nd commissioning dates as well as records of ser-
vice 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 previous service visits) and also for quality control measures.
Module Objective:
Upon completion of this module the course participant will be able to do the following:
 Import/Enter Logbook data

 Make logbook entries
 Save and load the log file using the 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
A007
A007

Electronic Logbook A007
Electronic Logbook:
START
Logbook
information
Importing/
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

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

of the machine:
- Manufacturer information at OEM

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

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

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

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

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

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

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

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

Load via “Import” soft-key. until point of sale.
Logbook entries
1st Commissioning
2nd Commissioning
Service visits
If the controller has existing machine identity data, it is necessary to delete the “identity.xml” file.
The location of the file varies between systems operating with a PCU50 or NCU.
The location of the “identity.xml” file:
PCU50: System hard disk\C:\ProgramData\Siemens\MotionControl\user\sinumerik\hmi\data\version\identity.xml
NCU: System CF card\user\sinumerik\hmi\data\version\identity.xml
Notes

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

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

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

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

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

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

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

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

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

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

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

described previously.
Select the “Manufacturer” soft-key to view the “oem subsidi-
ary” data
No data will be displayed until an “Address selection” has been

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

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

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

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

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

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

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

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

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

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

commissioning) the “Machine Installed” soft-key is pressed
This automatically logs the current time and date.
To confirm that 1st Commissioning is complete.
The information will appear on the main logbook page.
To confirm that 2nd Commissioning is complete.
The name and company/department of the engineer should

The information is now added to the main logbook page . be entered followed by a detailed description of the fault and
work carried out.
Recording a Service Visit
Whenever an engineer visits the machine to carry out mainte-

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

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

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

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

data to a file.
The file contains all information about the system (Controller,
drives, software and hardware etc) as well as the information
entered on the logbook pages.
The file is given a default name using details from the machine
information page. This can be changed. A comment can also
be added.
Two files are created by default, Version data and Configura-
tion data.
The “Version data (.TXT)” file is a text file and contains details
regarding the versions of the controller, drives etc.
The “Configuration data (XML)” file is an xml file and contains
more information about the whole system including the log- In this example, the files are saved in the “version” folder.
book entries. It is this file which needs to be uploaded to the
database via the internet. PCU50: System hard disk\C:\ProgramData\Siemens\
MotionControl\user\sinumerik\ hmi\data\version
NCU: System CF card\user\sinumerik\hmi\ data\version
The information will now be saved.
Notes

The file can be opened for viewing in the “System data” area: The information that was entered via the Logbook screen is
now stored in the xml file.
Service visits are found at the end of the file: Uploading to 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

The file is closed with the following soft-key selection. required. Notification emails will be sent to this address if the
“Enable email status notification“ option is selected. To continue
use the “Next” key.
Notes

Language selection
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.
Notes

Use the “Browse” key to locate the file.
The selected file is now ready to upload, select the “Upload”

key.
Notes

After a short delay an information box will indicate a successful The uploaded file will be seen in the “Assigned files list”
upload operation.
The “Action Bar” of the assigned files list is used for various Problems with uploading the XML files
functions.
Refresh the page
Upload an XML file
View the file
In the event of an error during the upload process will be

Delete the file
necessary to email the xml file to:
service.euna.industry@siemens.com
A007: END
Notes

A007 END Electronic Logbook

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, result-
ing in a drop in voltage or that the cooling fans show signs of wear and tear. In either case the bat-
teries 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.
Module Objective:
Upon completion of this module you will be able to locate and change the PCU50 battery and the
NCU battery and fans.
Content:
Sinumerik
Battery Health and Safety Warning
PCU 50.x: Replacing the Battery
840D sl NCU: Replacing the Fan/Battery-Module.

Replacing the Battery
SINUMERIK 840D sl Operate V4.5 Page 1 This document was produced for training purposes.
A003
A003

Battery and Fan Exchange A003
Battery and fan

Exchange:
START
Batteries:
Health and
Safety Warning
PCU 50.x:
Replacing
the battery
840D sl NCU:
Replacing
the battery/
fans
Battery and fan

Exchange:
END
Notes

A003 Battery and Fan Exchange
Batteries: Health and Safety Warning Danger of explosion and release of harmful substances!
Lithium batteries pose a risk to health and safety, please Do NOT:

read the following before commencing the exchange of Throw a lithium battery into a fire
batteries. Solder anything to the casing
Open the casing
The Lithium-batteries must be replaced only by types Short circuit the terminals
recommended by the manufacturer. Failure to do this can Expose to temperatures above 100°C
lead to component damage.
DO:
Dispose of used batteries using the local connection point Dispose of properly
specifically set-up locally so that they are correctly recy- Protect from direct sunlight,
cled or are disposed of as hazardous waste. Avoid excessive humidity and condensation.
Observe the correct polarity.
PCU 50.x: Replacing the battery 5. Open the battery compartment on the left side of the
PCU 50.x
Before disconnecting the battery all present BIOS Settings (Image 1).
must be recorded.
6. Remove the battery holder (Image 2).
This is particularly important if the default values have been
changed and have not been saved in the user profile. 7. Disconnect the cable (Image 3).
8. Re-connect the cable on the new battery.
9. Remove the old battery from the holder.
Note
10. Clip the new battery into the holder.
If the new battery is connected within 1 minute of disconnect-
ing the old battery, all settings (including date / time) will be 11. Close the battery compartment.
maintained. 12. Power on and enter the BIOS page, check the BIOS-
Setup settings or restore user profile.
Procedure: Image 1: Battery location with battery cover open.

The PCU50.x 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
the bottom of the screen, press the 2nd softkey or the F2
key on an external keyboard.
3. Record the BIOS settings.
4. Switch OFF the control unit once more and lock the main
switch to prevent accidental switching on of the power.
Image 1
Notes

Battery and Fan Exchange A003
Image 2: Battery being withdrawn from the PCU50.x. Image 3: Battery fully withdrawn, revealing the connector.
Connector which
allows easy
exchange of the
battery.
Image 2
Image 3
Note:
Batteries are perishable items. They should be replaced
every 5 years (by PCU50.x) as a safeguard against unex-
pected problems.
840D sl NCU: Replacing the Battery/Fans Note:

NCU Batteries are perishable items. They should be replaced
The battery and fans of the 840D sl NCU are contained in the every 3 years (by NCU 7x0.x ) as a safeguard against
same housing which fits to the underside of the NCU box. unexpected problems.
The battery and fans can be replaced separately or the whole
unit.
Battery Information:
Fan Information:
Battery buffered data is stored in the SRAM located on the
NCU board.  Fan warning: If one of the fans no longer rotates.
If the battery voltage falls to a critical level (2.7 to 2.9 Volts)  Fan fault: If both fans are stopped.
alarm number “2100 NCK battery warning threshold reached”
will be triggered. Approximately one minute later the components will be
The battery must then be replaced within 6 weeks of the alarm switched OFF automatically and the status will be indicated by
first appearing. means of the red SF LED.
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 Some battery/fan housings contain two fans.
case if the power is removed the buffered data will likely be
lost/corrupted.
NOTICE:
To avoid loss of data, the dual fan/battery module must be replaced during operation. When doing this, observe that the Con-
trol Unit can only be operated for a maximum of 1 minute without fans. If this time is exceeded, the Control Unit will shut itself
down.
Notes

A003 END Battery and Fan Exchange
Replacement: Location and components of Battery/fan housing:
The fan/battery module is replaced as follows.

Removal: Fan Rear
Battery locator
1. Gently push the fan/battery module backward. This will
release the retaining clips.
2. The fan/battery module can now be lowered and the rear
locator slid from the NCU box.
Replacing:
Push to
1. Hold the fan/battery module tilted slightly forward. release Battery/fan housing
2. Insert the locator into the guide at the bottom of the NCU
box.
3. Lift the front of fan/battery module upward, until the
retaining clips lock into place.
The fan/battery module and the control unit are interfaced via
two small plug/sockets, these are automatically connected
when the fan/battery module is locked into place.
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

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 configura-
tion 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
TGZ Backup Files
PCU50.5 XP Ghost-Images
PCU50.5 WIN 7 Ghost-Images
Siemens assumes no responsibility for its contents. A017
A017

Data Management A017
Data Management:
START
Archives:
TCU & PCU50
TGZ Backup
Files
PCU50.5 XP:
Ghost-Images
PCU50.5 WIN 7:
Ghost-Images
Data Management:
END
Notes

Archives TCU & PCU50 PLC hardware upgrade archive (SDB’s only) - Creates a
PLC archive for use when starting up series machines.
Series Start-up archives can be used to save NC, PLC, Drive (For testing the PLC periphery components)
and HMI data.
Archives are created for a variety of reasons: Read in series start-up - Archives are read-in with this option.
Create original status archive - Used to create an archive

 Series machine production that will return the machine to its delivery state.
 Exchange of the TCU
Read in original status archive - For reading in the original
 Exchange of the PCU status archive
 Exchange of the NCU/PLC
 Exchange of the system CF card Creating a Series Start-up Archive:
The method for creating archives is the same for both PCU50
To create a Series Start-up Archive locate the relevant area by
& TCU. However, when the data is stored locally it is to differ-
using the following key sequence.
ent destinations.
In the case of the TCU the archives are stored on the system
CF card.
With the PCU50 the data is stored on the hard disk drive.
Ensure that the option “Create series start-up” is selected and

The screen displayed has five choices: select “OK”.
Create series start-up - Archives of the four control compo-

nents (NC, PLC, Drives, HMI) can be created with this option
Compensation data
Cycles
Offsets
R parameters
Part Programs
Workpieces
Option data
Global and Local user data (GUD & LUD)
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.
HMI data: This saves data that is stored on the HMI.

The list comprises of:-
Cycle storage
Texts
Templates
Control Components: Applications
Configurations
The controller data is split into four components Version data
Logs
NC data:- The NC data consists of: User views
All machine and Setting data (except for drive machine data) Dictionaries
Tool & magazine data
Notes

The four control components are available for selection. They Creating an NC archive
can be selected in any combination to create archives contain-
ing different data. The following example will create an NC archive including
compensation data.
The NC data can be selected with or without compensation
data. Use the cursor and select keys to select the necessary check
Compensation data is machine specific data such as lead boxes.
screw error compensation. This would not be included in an The comment area at the bottom of the screen offers the
archive used for series machine production. chance to add information about the archive.
The Drive data can be saved in two formats:
Archives containing drive data should be created using the ACX

format. ASCII format is for expert use only.
If the HMI component is chosen you can include “All” HMI data
or be selective of the data to include via the “Execute” option.
The destination of the archive has to be chosen, this can be

locally on the system CF card/hard disk drive or externally to a
USB device or networked PC.
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
restore.
Notes

A name must be entered for the archive.
An information box indicates that the archive was successfully

created.
The archive will now be created and stored in the destination

specified earlier.
Restoring a Series Start-up Archive: Select the source from which the archive is to read in from.
To restore an archive the option ”Read in start-up archive”

needs to be selected
Notes

Information about the selected archive is displayed. This in- The archive will be read in and a series of status boxes are
cludes any comments entered by the creator. displayed.
The software version of the system that the archive was creat-
ed on is also displayed.
A final status box will be displayed which confirms that the

archive was read in successfully.
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 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
The default selections are shown below. It has to be decided files are to be included.
by the machine builder which components are needed to re-
turn the machine to its original delivery state. All: This option will include all the HMI data
Notes

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.
Allow the archiving process to complete:
The individual components are selected using the cursor/

select keys
Reading in Original Status Archives
To restore an original status archive, the option ”Read in origi-

nal status archive” needs to be selected.
Notes

As only one Original Archive is allowed there isn’t a list select Status boxes will be displayed informing of the progress of the
from. Information about the archive contents is displayed. read-in procedure
If any overwrite questions arise, carefully read the message When the archive has been read in a status box is
before continuing with one of the responses below. displayed to confirm this.
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

to read in.
Cancel the archive read in procedure.
Overwrite the file in question, archive continues to read

in.
Notes

Creating Archives with Shortcut keys
A quick method of making a complete archive to a USB device

is by selecting 3 keys simultaneously.
The keys to be pressed are “CTRL” + “ALT” + “S”
Simultaneously select the following keys to produce the ar-

chive.
+ + The boxes will clear when the archive has been saved
A file with the .arc extension will be created and given a de-
Several dialogue boxes will be shown, these will clear when fault name which includes time and date information.
the archive has been created. It should be checked that the file exists on the USB/CF device
before commencing work.
Example:
TGZ backup files
Another method of creating a backup of the System CF card is

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. Locate the “linuxbase.img” file and select “Open”
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.

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

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

Select the drive letter of the USB stick.
The writing process will begin
Creating a CF card backup (TGZ file)
Starting the Emergency Boot System.
Switch off the controller and insert the bootable USB stick
into X125 of the NCU.
The following screen will be displayed:
The process can be repeated of required.
Insert the USB stick into X125 of the NCU and switch
on the NCU.
After successful boot up the Emergency Boot System will
be displayed. Cursor to the “Backup NCU Software and Data” menu item
and select “Ok”
Notes

A suitable filename should be entered. This should contain

information that helps identify the file to other users. The TGZ
extension is mandatory.
A number of backup choices are available, select the menu

item “Backup Complete CF card to USB memory stick”
The backup procedure will begin.
On completion, press any soft-key.
The original screen will be displayed.

The USB stick should be removed and the system rebooted.
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

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.
Insert the USB service stick
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.
Notes

PCU 50.5 XP: Ghost Images

Hard Disk Partitions:
The PCU50 operates with a Solid State Disk (SSD) which con-
tains the operating system (Windows®), Sinimerik basic In order to enable the separation of the software packages, the
software, Sinumerik 840D sl Operate software, archives, user hard disk of the PCU 50.5 WIN XP is sub-divided into four
files etc. NTFS partitions, each with different functionality.
The (SSD) is divided into four partitions (C, D, E, F)
The method used to back-up the SSD drive is Norton Ghost®.
Norton Ghost is present on all replacement SSD drives to facili- Description of Partitions:
tate creating and restoring a Ghost image.
The procedure produces a “Ghost image”. The size of the Partition C Emergency: Active primary partition
Ghost image will depend on the individual application but is in (Service/tools menu)
excess of 1GB.
The image can be saved externally to a USB device, provided Partition D TMP: Extended partition
that there is sufficient space or via network. (Local images, install, update)
It is also possible to create local Ghost images of partitions C,
E & F to partition D. Partition E System: Primary partition
Prior to creating a Ghost image it is recommended that the (Windows® operating system)
archiving procedure is followed and that the files are saved to
the PCU. Partition F USER: Primary partition
(HMI, Shopmill/turn, Step7, OEM)
PCU50.5 :
Service switch to "E" to boot the PCU 50.5 from the
USB service system.
Creating a USB service stick
PCU 50.5 start up in service mode
Start the PCU.

During the boot up, there is a time interval for pressing key “3“ when the HMI Base Version
information appears on the lower right of the background screen.
Notes

Plug a USB memory with at least 8 GB into a PCU USB port.
Launch Ghost32.exe in directory E:\Tools
Select Ghost: Local → Disk → From Image. As the source, select D:\Eboot\eboot.gho and
as the destination select the USB memory store (recognizable by its storage capacity).
Result:
After successfully transferring eboot.gho to the USB memory store, the service system for
the PCU is ready to use.
Using the same procedure, create a service system on a PG/PC. For this, you need the Fille Ghost32.exe and eboot.gho
on a PG/PC
Booting from the USB service system
Set the service switch to "E", if you wish to boot the PCU 50.5 from the USB service system.
Creating Ghost Images The ServiceCenter will now be started. This runs from
Ram disk and takes a short while to load.
First insert the USB (At least 16GB) device into the rear USB
interface.
The Ghost image is created via the ServiceCenter of the
PCU50.
Power on the controller
Notes

The Ghost image now needs to be given a name. Be sure to A summary will be displayed showing details of the Ghost im-
select “Enter” to confirm the image name. age.
Restoring Ghost Images
Images are also restored using the Service Menu.
The process will begin, this may take some time depending
upon the size of the Ghost image
Notes

Select the Ghost image to be restored. A summary will be displayed showing details of the Ghost
image.
The restore process will begin, details such as time elapsed The computer (PCU50) name can be changed if required.
and time remaining are shown. If the PCU is connected to a factory network a specific name
may have to be entered.
Select “OK” to reboot the system.
Notes

PCU 50.5 WIN 7: Ghost Images
The PCU50 operates with a Solid State Disk (SSD) which con-
tains the operating system (Windows®), Sinimerik basic Partitions
software, Sinumerik 840D sl Operate software, archives, user C: SYSTEM (incl. EMERGENCY)
files etc.
The (SSD) is divided into four partitions D: USER (incl. TMP
C: SYSTEM (incl. EMERGENCY)
D: USER (incl. TMP)
The method used to back-up the SSD drive is Norton Ghost®.
Norton Ghost is present on all replacement SSD drives to facili-
tate creating and restoring a Ghost image. Service-Mode
The procedure produces a “Ghost image”. The size of the Pressing key „3“ on the control panel during PCU boot
Ghost image will depend on the individual application but is in or
excess of 5GB. Service switch to “3“
The image can be saved externally to a USB device, provided USB-Boot
that there is sufficient space or via network. Service switch to “E“
It is also possible to create local Ghost images.
Prior to creating a Ghost image it is recommended that the
archiving procedure is followed and that the files are saved to
the PCU.
Creating a USB service stick for PCU 50.5 WIN 7 Ghost
Service switch to „3“ and turn on the PCU.
„Show desktop“ and

startGhost32 with:
Notes

Select Ghost: Local → Disk → From Image. As source, select D:\Eboot\eboot.gho, as the destination select the USB memory
store (recognizable by its storage capacity).
Result:
After successfully transferring eboot.gho to the USB memory store, the service system for
the PCU is ready to use.
Using the same procedure, create a service system on a PG/PC. For this, you need the file Ghost32.exe and eboot.gho on a PG/
PC.
Creating Ghost Images The ServiceCenter will now be started. This runs from Ram
disk and takes a short while to load.
First insert the USB (At least 16GB) device into the rear USB
interface.
The Ghost image is created via the ServiceCenter of the
PCU50.
Service switch to “E” and Power on the controller.
Select disk backup with mouse or
Notes

Select drive S: (USB Boot stick).
Start restoring Ghost with „Backup“

„File name“ now needs to be given a name.
Notes

Restoring Ghost Images With „Select source“, select a ghost file.

Images are also restored using the Service Menu.
Select Disk Restore with mouse or
Notes

Select drive S: (USB Boot stick), and mark Ghost File (*gho) .
Read Ghost File with „Restore“.
Notes

A017: END
Notes

A017 END Data Management
Notes

A010 PCU, TCU and OP Diagnostics and Interfaces
Sinumerik
Operate
Module Description:
The PCU50.x is an industrial PC on which the operating system (Windows®), the Sinumerik basic
software, the Sinumerik 840D sl Operate software, ShopMill/ShopTurn, archives, user files, etc. are
installed. Two 7-segment displays and two status LEDs are integrated for the diagnostics (e.g. for
operation without a monitor).
The PCU 50.3 is equipped with a hard disk drive.
The PCU 50.5 is equipped with an electronic SSD (Solid State Disk) drive. A Service switch with
power button are also integrated for the diagnostics.
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 (OP) are used for interfacing the PCU/TCU to the controller. The PCU/TCU is easi-
ly mounted on the rear of the OP. The OP has 2 x LEDs for basic diagnostic functionality and a sin-
gle 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
PCU50.5: Interfaces
PCU50.x: Diagnostic Service
TCU: Interfaces
Operator Panel Diagnostics
A010
A010

PCU, TCU and OP Diagnostics and Interfaces A010
PCU/TCU/OP
Diagnostics and
Interfaces:
START
PCU50.5:
Interfaces
PCU50.x:
Diagnostic
Service
TCU:
Interfaces
Operator
Panel
Diagnostics
PCU/TCU/OP
Diagnostics and
Interfaces:
END
Notes

PCU50.5: Interfaces
The interfaces of the PCU50.3 are located on two sides
X70
Digital Video
Interface X4 X60 USB 2.0
(DVI) MPI/DP Port 1 / 2
Port 3 / 4
X1 X0 S0
2 x PCI-
Ethernet 1 +24 VDC ON/OFF
slots
Factory Net supply switch
X2
Ethernet 2
System Net
Service module
Alternative installation location
The Service module can be
remounted on the side panel
for portrait assembly. BIOS battery
location
Notes

X44 I/O interface for con-

nection of the I/O cable of the
operator panel front
X42 Optional connection

for operator panel fronts with
USB 2.0 front interface
X400 1st LVDS interface for

connection of the TFT display
cable
X401 2nd LVDS-interface

for dual LVDS displays (e.g.
OP 19) - is behind X400 (can
be reached by removing the
SSD housing cover)
Service module SSD housing cover (substitute for hard

as delivered disk) Solid State Disks
PCU 50.5 XP
2 x 7-segment displays
Switch setting Function
0 Normal mode (delivery condition)

2 x LEDs: H1 and H2
9 Reset BIOS to factory settings
E Boot from USB-device (Eboot-stick)

Service switch
Power button
This can be used to start and stop the Windows operating sys- PCU 50.5 WIN 7
tem.
Switch setting Function
0 Normal mode (delivery condition)
3 Boot with Service Desktop
9 Reset BIOS to factory settings
E Boot from USB-device (Eboot-stick)
Notes

PCU50.5: Diagnostic LEDs and 7-Segment Displays LED LED H1 H2 Status

H1 H2 Dis- Dis-
play play
The diagnostics displays of the PCU50.x consist of 2 x LEDs
and 2 x 7 segment displays. Orange Orange Output of After switch on
BIOS post
codes
Orange Off After cycling the BIOS
H1 H2
LED and Orange Off After starting Windows
LED and
7-segment 7-segment 1 0 Start Load device
display display Windows drivers needed
for Windows
2 0 PCU PCU hardware
hardware service has
H1: Assigned to the PCU basic software. Displays status service been started
codes for system booting and shutdown. 5 0 Network Wait for net-
work interfac-
H2: Assigned to the application software. es
Status codes during system power up. 8 0 TCU Wait for FTP
support server to start
test step 1
9 0 TCU Wait for TCU
support network boot
test step 2 and TCU
hardware ser-
vice to start
Status codes during system power up, continued. Status codes during operation.
LED LED H1 H2 Status LED LED H1 H2 Status

H1 H2 Dis- Dis- H1 H2 Display Display
play play
Flashing 0 0 OK
A 0 TCU Wait for VNC green
support test server to start
step 3 Flashing Error: See below
red
B 0 HMI Wait for HMI 1 0 Temperature Housing or
manager manager to alarm CPU over
start temperature
E 0 PCU General fault: 2 0 Fan alarm Housing or
Base see Windows CPU fan, low
software “Event viewer” speed or
failure
3 0 Hard disk S.M.A.R.T*
alarm hard disk
error
6 0 VNC server
failure, or
stop VNC
service
Notes

Status codes during shutdown.
LED LED H1 H2 Status

H1 H2 Dis- Dis-
play play
Flashing 5 0 Shutdown active

red/
green
In order to maintain the higher level of system availability, we Fan

recommend the preventive replacement of PC components Fans are components subject to wear. The fan speed is moni-
that are subject to wear in accordance with the replacement tored and an alarm issued at failure.
intervals listed in the following table. The main cause of failure for fans is pollution. The first criterion
for replacement should be a visual inspection. If the fan is very
dirty, it should be replaced. In the field, a replacement interval
Component Replacement interval of 5-7 years has proven itself under average industrial condi-
tions.
Electronic SSD drive > 5 years
Back-up battery
Fan 5-7 years Batteries are components subject to wear. They should be
changed every 5 years in order to guarantee the long-term
CMOS back-up battery 4/5 years functionality of the device. If a plug-in PCI card is also supplied
from the battery (centralized battery concept), the preventive
replacement is reduced to 4 years.
SSD
In industrial environments, it can be assumed that the service
life is longer then conventional mechanical hard disks, and ac-
cording to present knowledge, is > 5 years.
The write load is a factor that has a significant effect on the
total service life.
Notes

A010 END PCU, TCU and OP Diagnostics and Interfaces
TCU: Interfaces On the rear side of the TCU are two ribbon cable connectors
for connecting to the operator panel.
Ribbon cable connectors:

X206
+24 VDC
supply
X201
CF card
(Not enabled)
X202
System
Ethernet
X203 & X204

2 x USB
For the NC keyboard and
USB memory devices.
Operator Panel Diagnostics
There are two LEDs located on the front of the OP (Operator

Panel). The LEDs indicate:
 The supply of power to the PCU/TCU
 Temperature of the PCU outside the permissible
range (5—55º C)
In normal running conditions the Power LED is permanently lit.

The temperature LED illuminates when the PCU50 housing or
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

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 de-
scribed 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

NCU Diagnostic Displays and Switches A036
NCU Diagnostic
Displays and
Switches:
START
Status LED’s
and 7 Segment
Display
NCK & PLC

Rotary Switch-
es
NCK & PLC

general reset
NCU Diagnostic
Displays and
Switches:
END
Notes

A036 NCU Diagnostic Displays and Switches
Status LED’s and 7 Segment Display.
The NCU diagnostic features are found on the lower front face
and consists of a 7-segment display unit and 8 status-LED’s.
LED Location
7 segment display Location
Area of LED’s and 7 segment

display.
The 7 segment display is found
beneath the light blue clip-on
cover.
LED Colour Explanation LED Colour Explanation

There is at least one fault (e.g. RESET, STOP orange PLC in the Stop status (PLC stop)
red Watchdog monitoring etc.), or the control unit
is in process of booting. SU/PF red FORCE activated (PLC force)
red/ flashing 0.5Hz. Error accessing Compact SF red PLC group error
orange Flash Card DP red PROFIBUS group error X126
orange Accessing Compact Flash Card DP/
red PROFIBUS group error X136
MPI
flashing (0.5 Hz). Updating the firmware of
RDY orange
the connected DRIVE-CLiQ components PN red PROFINET IO group error X150
flashing (2 Hz). Firmware update is complete Synchronization status (SY) of the
orange for components. Wait for POWER ON for the onboard PROFINET IO interface (X150)
components in question. SY/MT green
Maintenance status (MT) of the NCU
(presently without function)
green NC operative
The PROFINET system runs correctly;
gn/og Flashing (1 Hz). LED-supported recognition
off data exchange to all configured IO devic-
or of connected DRIVE-CLiQ component is
es runs.
rd/og activated: (p0124[0] = 1).
OPT Bus fault (no physical connection)
RUN green PLC operative (PLC run) red
Incorrect transmission rate
Failure of a connected I/O device.
red
Incorrect or no configuration
Notes

NCU Diagnostic Displays and Switches A036
7-Segment display 7-segment display during power up.
The 7-Segment display is located behind the lower cover of 7-segment Meaning
the control unit. display
The display can output a single numeric value (0 to 9) or a
1 Not applicable.
single letter (A, C, E, F, P). A decimal point is present to the
lower right of the numeric value. 2 Not applicable.
It serves as a status display during commissioning and can 3 Debugger was initialised.
be used to display the following information:
4 NRK operating system was successfully activat-
 IP address of the NCU ed.
5 NRK operating system has booted, init task is
 Test and diagnosis information being processed (The application boots)
 Status during booting 6 Initialisation was successfully performed; the
6. control is in cyclic operation and the cycles are
During normal operation a "6." is displayed with the point active.
flashing. The “RDY” LED will be green and constant. F Internal error.
An "8" indicates that the fan is defective or that the Control 1 or 2 CF card and SRAM data do not match. To re-
Unit is operating without a fan. solve this problem, a general reset is required by
booting with NCK- Switch position 1 or 2.
During the boot phase the display changes to indicate the
different stages of the boot process.
System Errors 7_segement display in relation to “RDY” LED (See above)
System errors are indicated by a combination of the “RDY” 7 segment Meaning

LED and the 7-segment display. display
“RDY” LED fault description: Permanent error

“Crash”: Operating system crash (similar to a
C “Blue screen” in Windows) Further details can be
“RDY” LED Meaning found in the system log-file.
Flashing red Permanent error: System stopped P “Partition”: Error when repartitioning
@ 2Hz (See below for 7-segment display) Temporary error
Flashing red/ Temporary error: System may continue with
orange @ restricted functions. “Error”: A read or write error has occurred on the
Compact Flash Card (an additional point is dis-
2Hz (See below for 7-segment display) E
played to indicate a “write error). It is possible
that the CF card is defective.
“Full”: The Compact Flash Card is full, it is possi-
ble that not all services will have started.
F When booting, the error is displayed for 1 minute;
the system will then continue to boot, however, it
can be assumed that problems will occur.
Notes

A036 END NCU Diagnostic Displays and Switches
NCK and PLC rotary switches NCK switch functionality
Two rotary switches, one for NCK functions and one for PLC Switch
Function
functions are also present. Certain tasks can be achieved Position
depending on the position of the switches.
0 Normal NCK boot up
Some tasks require a restart for activation, the “RESET” but- 1 NCK boot up with default values (Memory reset)
ton is conveniently located for this purpose.
7 Debug mode, NCK is not started.
8 IP address is displayed on 7 segment display
All others Not relevant.
PLC switch functionality.
RESET-button Switch
Function
Position
NCK start-up 0 Run

switch
1 Run (Protected mode)
PLC mode 2 STOP

selector switch.
3 Memory reset on boot up (MRES)
All others Not relevant.
NCK and PLC general reset

NCK and PLC = general reset !
NCK and PLC (incl. SDB) general reset

When commissioning the NCU for the first time, in order to
achieve a defined initial state of the whole system, a general
NCK and PLC reset must be performed. NCK general reset
Turn the NCK commissioning switch to position “1“  NCK commissioning switch to position “1“
and the PLC commissioning switch to position “3“.  Initiate a power on reset by switching-off the control and
Initiate a power on reset by switching-off the control and switching-on again – or by pressing the Reset button
switching-on again – or by pressing the Reset button.
Allow the system to run-up and wait for 5 on the 7-Segment  Run-up to wait for 6 on the 7-Segnent display
display  NCK commissioning switch to position “0“
LED "STOP" flashes and the LED "SF" is lit ! Turn the PLC
commissioning switch to "2" → “3“ → “2“ NCK = erased (standard–MD loaded)!
The LED "STOP" first flashes faster and then changes to
steady light.
Turn the PLC and the NCK switch back to position “0“
A036: END
Notes

A030 Digital Inputs and Outputs
Sinumerik
Operate
Module Description:
The 840D sl has interfaces for the connection of Digital inputs and outputs (I/O).
These are located on X122 ,132 & X142.
Connections used within the drive group components are known as BiCo’s.
The connectors X122 &X 132 is for Sinamics and X142 for NCK functionality.
Certain connections can be configured either as an output or an input via machine data.
The digital I/O are used to handle various signals, for example:
 Drive Enables
 Probe Inputs
 Automatic Line Contactor Control
 External Reference Mark (Bero)
This module shows the pin assignment of each connector and shows several examples of how a
BiCo is assigned to a function, including probes and line contactors and how NCK I/O are used in a
machining program.
Module Objective:
Upon completion of this module you will be able to locate the interface connectors and configure
individual connections to perform certain functions.
Content:
Sinumerik
X122, X132 & X142 Terminal Location and Description.
Digital Input/Output Terminal Description
Assignment of the BICO’s
NCK Inputs and Outputs
A030
A030

Digital Inputs and Outputs A030
Digital Inputs and

Outputs:
START
Interface
Description
Assigning
BICO’s
NCK Inputs
and
Outputs
Digital Inputs and

Outputs:
END
Notes

Interface Description The Binary Connectors (BiCo’s) of X122 and X132 are used to
assign Sinamics inputs/outputs to a specific function e.g. Ena-
X122, X132 & X142 digital I/O interfaces are located beneath bling of drives, BERO’s, automatic line contactor control etc
the flip-down cover of the NCU. X142 is used for NC digital inputs and outputs.
Certain terminals are automatically assigned to a function by

default, remaining terminals can be assigned to a function via
X122 X132 X142 machine data.
The status of the terminals is transferred to CU parameter

r0722 which is referred to when assigning a function.
Ext. 24V
+ M
Sinumerik NCU7x0 1* Fast inputs/outputs (Must be shielded).
X124 2* Electrical isolation for digital inputs (DI) if jumper open.
+ 3* Can be parameterised as Inputs or outputs.
+
M
M X122 X132 X142
1 DI 0 1 DI 4
1 Not used
2 DI 1 2 DI 5
2 Not used
3 DI 2 3 DI 6
3 NCK DI1
4 DI 3 4 DI 7
4 NCK DI2
5 DI 16 5 DI 20
5 M
6 DI 17 6 DI 21
6 NCK DI3
7 M1 7 M2
2* 2* 7 NCK DI4
8 M 8 M
8 M
9 DI/DO 8 1* 9 DI/DO 12 1*
9 NCK DO1
10 DI/DO 9 1* 10 DI/DO 13 1*
10 NCK DO2
11 M 11 M
11 M
12 DI/DO 10 1* 12 DI/DO 14 1*
12 NCK DO3
13 DI/DO 11 1* 13 DI/DO 15 1*
13 NCK DO4
14 M 14 M
3* 3* 14 M
Notes

X122 - Default BiCo assignments
BICO connection
X122 Signal Function/Default Setting
Source Destination
ON/OFF1 for DriveCLiQ line mod-

Pin 1 Sinamics DI 0 CU-r0722.0 Infeed p0840
ules (ALM, SLM >=16Kw)
Each drive 2nd OFF3,

Pin 2 Sinamics DI 1 OFF3 drive enable-Fast Stop CU-r0722.1
p0849
SH/SBC 1 – Group 1
p9620 (all drives in the
Pin 3 Sinamics DI 2 SINAMICS Safety Integrated CU-r0722.2
group)
(SH enable = p9601)
group)
(SH enable = p9601)
Pin 5 Sinamics DI 16 Freely available CU-r0722.16
Pin 7 Ground (G1) Ground for pins 1 to 6

Pin 8 Ground (M) Ground for terminals 9, 10, 12, 13
SH/SBC – Group 1 (Input) p9774 bit 1
Sinamics DI/O8
Pin 9 SINAMICS Safety Integrated CU-p0738 BICO from CU after the 1st
(Rapid input)
drive in the group
Sinamics DI/O9 p9774 bit 1
SH/SBC – Group 2 (Input) CU-p0739
Pin 10 (Rapid input) BICO from CU after the 1st
SINAMICS Safety Integrated
drive in the group
Sinamics DI/O10
Pin 12 Bero 1 - external zero mark (Input) CU-r0722.10 Drive p0495=2
(Rapid input)
Sinamics DI/O11 Probe 1: central measuring Each drive p0488, Index
Pin 13 CU p680[0]=3
(Rapid input) (Input) (MD13210=0) encoder 1, 2, 3=0
Notes

X132-Sinamics I/O
Default setting (In bold)/ BICO connection

X132 Signal
suggested setting Source Destination
Pin 4 Sinamics DI 7 Line contactor feedback signal CU-r0722.7 LM p0860

Sinamics DI/O Infeed operation (Output)
Pin 9 LM-r0863.0 CU-p0742
12 (Line Module with DRIVE CliQ)
Sinamics DI/O Infeed ready to start (Output)
Pin 10 LM-r0899.0 CU-p0743
13 (If L M with DriveCliQ)
Line contactor control (Output) LM-r0863.1 CU-p0744
Sinamics DI/O
14
2nd OFF 2 (Input) CU-r0722.14 Drive p0845
Sinamics DI/O Probe 2: central measuring (Input) CU-p680[1]=6 Each drive p0489,
Pin 13
15 (MD13210=0) CU-p728 bit 15=0 Index 1, 2, 3=0
Notes

X142-NCK I/O

Pin 1 Reserved Reserved
Pin 3 NCK DI 0 Digital Input $A_IN[1]
Pin 5 GND Ground
Pin 8 GND Ground
Pin 9 NCK DO 0 Digital Output $A_OUT[1]
Pin 11 GND Ground
Pin 14 GND Ground
Notes

Assigning BiCo’s Use the “Select” key to give a more detailed view.
Assigning a BiCo to a function requires changing machine

data.
The default setting for OFF3 can be checked as an example.
The OFF3 signal is input on X122.2, the status of this signal The information regarding the source of the OFF3 signal
is displayed via CU r0722.1. (X122.2) can be viewed.
In order for the signal to have any effect on the operation of
the drives It has to be referenced to each drive.
This is achieved through p0849 for each drive.
Parameter p849 Source of OFF3 signal:
Example: How the OFF3 signal is assigned to X axis p0849 CU parameter r722.1
Physical connection of the OFF3 signal:

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

to CU X122.2/r722.1.
Assignment of probe inputs: Assigning probe 2 to X132.13

From the list highlight the required input
Probe 1 is assigned to X122.13 by default. i.e. [6]DI/DO 15 (X132.13).
Press “Input” to enter the value.
In the following example, probe 2 will be assigned to BICO con-
nector X132.13.
The standard probing function of the 840D sl is “Centralised

measuring”.
The probes are assigned with CU parameter p680.
Notes

Assigning the probe inputs
Checking the functionality of the Bico terminals:
X132.9, 10, 12 & 13 can be used as either inputs or outputs.

This can be changed by the setting of CU parameter p728.
The default setting is for inputs which is correct for probing

operations. P728 Bits 12, 13 14 &
15 set as inputs by
default
Note:
- Workpiece probe at measurement input 1 by default

(MD52740 Bit 0=0)
- Tool probe at measurement input 2 by default

(MD52740 Bit 16=1)
Activation of Probe Soft-keys:
The soft-keys for the probing operation are not displayed as

standard. To display the soft-keys it is necessary to set
General Setting Data 54780 bit 2 and 54782 bit 2.
Notes

Setting the Probe Dimensions.

The probe radius has to be has to be entered into General
Machine Data 51780.
The following example shows probe 1 with a diameter of 5mm Or
5mm.
Select the input terminal to which the BERO switch is

Assigning the Spindle BERO Connector: connected (X122.10).
The training equipment has a proximity switch connected to
X122.10, this is for the spindle BERO (External zero mark)
signal.
To make this active the relevant Drive Machine Data (p495)
has to be set.
Ensure that the correct drive is selected, i.e. Spindle.
The status of the save process is displayed directly above the

horizontal soft-keys:
The assignment of the Drive Machine Data p495 and the

BERO switch input is now complete.
When the process is complete another message will be briefly

displayed:
Saving the Changes:
The changed data needs to be saved, use the following soft-

key sequence to save the drive data:
Checking the status of X122 and X132 via CU parameter
r722
The training equipment has two red buttons on the left off the
MCP, these are connected to X122.11 (Left button) and
X132.11 (Right button).
The status of the probe inputs and any other input can be
checked via CU parameter r722: CU digital inputs status.
The Hexadecimal value is displayed:
Notes

The status of the r722 bit editor is displayed when the “Select”
key is pressed. A change in status is not automatically updat-
ed, the page needs to be refreshed to view any changes.
By pressing the red buttons the status of the probe inputs will
go high. (Bits 11 & 15)
Configuring the automatic line contactor.

The automatic line contactor function is used to ensure correct
switching of the line supply to the line modules (DriveCLiQ
versions only)
The following example shows how to configure the line con-

tactor coil and line contactor feedback signals.
The feedback (Input) signal will be assigned to X132 pin 4
(Sinamics digital input 7).
The coil signal (Output) will be assigned to X132 pin 12
(Sinamics digital input 14).
Configuring the feedback signal:
The table of X132 shows information about the source and

destination. For the feedback signal, the source is CU param-
eter r0722.7. The destination of this signal is LM parameter
p0860.
Use the following soft-key selection to locate the set-up pag-
es.
Notes

For identification purposes, the LED of

the module can be made to flash.
The supply voltage can be manually entered or detected auto-

matically.
Select the check box for SINAMICS-internal line contactor.
A summary of the line supply data is displayed, this can be

saved to a text file if required.
The BICO connectors for line contactor operation are pre-

assigned.
X132.12 Output to line contactor coil.
X132.4 Input from line contactor.
Notes

The new BiCo settings need to be saved, select the “Yes” soft-
key.
The following dialogue box indicates the state of save Checking the Line Contactor Signals
process, the box clears when the process is complete.
The status of the line contactor feedback signal can be checked
via CU parameter r722.7
The status of the line contactor coil digital output can be
checked using CU parameter r747.14
The example below shows bit 14 is high.
Notes

NCK Digital Inputs and Outputs Example: Setting an NCK output via a part program.
NCK digital I/O can be addressed directly from machining The NCK outputs can be set directly from a part program. The
programs. following example will show how NCK digital input 2 is set and
unset.
To address Inputs, for example Digital NCK input 2, the fol-
lowing has to be entered in the part program: $A_IN[2] Select “MDA” mode.
Inputs cannot be written to (Read only) but their status can be

checked and used to influence the machining operation.
Type in the following text:
Addressing outputs is done in a similar manner, example ad-
dress for digital output 2: $A_OUT[2]
$A_OUT[2] = 1 Set NCK output 2 to 1 Optional program
stop, program will
The digital outputs are not active by default. General machine M00 halt until Cycle
data 10360 $MN_FASTIO_DIG_NUM_OUTPUTS is used to Start is pressed.
activate the outputs.. $A_OUT[2] = 0 Set NCK output 2 to 0
The value entered determines how many output bytes will be M30 Program end
available.
Press Cycle Start.
The program will stop at the “M00” command, a message will The status of the PLC variable can now be checked.
be displayed.
Optional stop active.
Note:
Interface X142 on training equipment has been wired so that

X142 pin 4 ($A_IN[2]) and X142 pin 10 ($A_OUT[2]) are
linked.
This allows demonstration of the use of an NCK input in MDA

mode ands also shows that X142 pin 10, does actually out-
put a physical voltage.
Notes

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

Setting NCK output 2 to 1 will
$A_OUT[2] = 1 also set NCK input 2.
If NCK input 2 = 1
IF $A_IN[2] == 1 GOTOF LABEL1
jump forward to LABEL1.
MSG (“NCK INPUT 2 IS LOW”) Message line showing that Start the program via the “Cycle Start” button.
the input is low.
M00 M00 Program stops until cycle start is pressed.
M30 M30 Program end.
LABEL1: LABEL1 used for the jump command (GOTOF).
Message line for showing

MSG (“NCK INPUT 2 IS HIGH”) that the input is high.
M00 M00 Program stops until

cycle start is pressed.
M30 M30 Program end.
When “IF $A_IN[2] == 1 GOTOF LABEL1” is reached, the sys- When the cycle start is pressed again the program will see the
tem will check the status of digital input $A_IN[2] for a value of 1. M30 instruction and the program will be reset, the message
If this is true the program will jump to LABEL1 and continue from will clear.
there.
The program message will be displayed and the cycle will pause
because of the M00 instruction.
The program now needs to be edited so that NCK output 2 is

set to 0.
Notes

A030 END Digital Inputs and Outputs
Start the program via the “Cycle Start” button.
The program will not process the GOTOF command because

of the status of Input 2.
Instead it will process the next block which is the message
“NCK Input 2 is LOW” the program will halt due to the M00
command.
When the cycle start is pressed again the program will see the
M30 instruction and the program will be reset, the message
will clear.
The status of the input can be checked in the same way as

the output:
A030: 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
Drive-CLiQ 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
integrated 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

Line and Motor Modules A051
Line and Motor

Modules:
START
Topology
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

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 Drive-CLiQ.

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

Topology
Example- 7 axis system with NX ...“fast commissioning“
Equipment connected to X101 is assigned to the CU, the numbering is continued complete-
ly.
For those involved in NX... (CU) the connected drives/motors uses the same numbering
Drive system
rules as the CU.
Drive device 1: NCU

NCU 1 ALM 2 MoMo 3 MoMo 4 5 MoMo 6 7
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 END Line and Motor Modules
SINAMICS Communication CU
STEP7 (HW-Config) DP Slave
SINAMICS S120
properties
Numeric Control
Numeric Control
Extension Drive-
Extension
Parameter Parameter Telegram type-
Component Parameter I/O adress
p978[0-9] p922 Length
p922
drive objects Telegram type
Telegram type
list
MoMo 3 3 136 136. PZD-15/19 4100
MoMo 4 4 136 136. PZD-15/19 4140
MoMo 5 5 136 136. PZD-15/19 4180
MoMo 6 6 136 136. PZD-15/19 4220
MoMo 7 7 136 136. PZD-15/19 4260
not available 255 not available 136. PZD-15/19 4300
CU 1 391 391. PZD-3/7 6500

end of cyclical
0
data
ALM 2 9 999. BICO 6514
1. NX 60
SINAMICS Communication NX 15
STEP7 (HW-Config) DP Slave
SINAMICS S120
properties
Numeric Control
Numeric Control
Extension Drive-
Extension
Parameter Parameter Telegram type-
Component Parameter I/O adress
p978[0-9] p922 Length
p922
drive objects Telegram type
Telegram type
list
MoMo 2 2 136 136. PZD-15/19 4340
MoMo 3 3 136 136. PZD-15/19 4380
NX 1 391 391. PZD-3/7 6530
not available 255

end of cyclical
0
data
Notes

Communication NC- CU/NX
NC CU/NX
Achs-MD NC- MD PLC HW - Config
NCU PLC- E/A-

Slot Adr.
IDX MD 13050 1=DRV1 4100
[0] 4100 2=DRV2 4140
AX MD 30110 [1] 4140 3=DRV3 4180
MD 30220 [2] 4180 4=DRV4 4220
1:X1 2 [3] 4200 5=DRV5 4260
2:Y1 1 [4] 4260 6=DRV6 4300
3:Z2 3 [5] 4300 7=CU 6500
4:SP1 4 [6] 4340 8 =Alm] 6514
5:A1 5 [7] 4380
6:C1 7 [8] 4420 NX15 PLC- E/A-
7:TC1 8 Slot Adr.
[9] 4460
1=DRV1 4340
[10] 4500
2=DRV2 4380
[11] 4540
3=DRV3 4420
4=DRV4 4460
passive
IDX MD 13120 5=DRV5 4500
[0] 6500 6=DRV6 4540

[1] 6530 7=CU 6530
[2] 0 8=Alm 6534
Notes

General Information
Example, S120 Line module with two motor modules:
Line and Motor Modules
Line and motor modules are responsible for supplying power to

the motors.
The Sinumerik 840D sl works with the Sinamics S120 range of
drive products.
All Motor Modules have to be connected to the Drive-CLiQ bus
system.
All Line Modules with the exception of 5 & 10Kw SLM modules
have to be connected to the Drive-CLiQ bus system.
Line modules require a 3 phase AC supply, this is rectified into

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

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

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

plied by the user to the line module and then distributed to the
motor modules via a bus system. Line Module Motor Modules
(LM) (MM)
Bridging device for

Drive Module power Supply 24V DC Electronics supply (X24) continuity of the
+24V DC bus
Power Requirements between drive
modules.
The drive modules require two power supplies in order to op-
erate.
A 3 phase AC supply (380V to 480V +10% (-15% < 1 min) to

the bottom of the line module is used to produce the 600V DC +24V DC Bus-bar
link. The DC link is distributed to the motor modules via a bus
bar system on the front of the drive modules beneath a flip 0V DC Bus-bar
down cover.
+ DC Link Bus-bar
An electronics supply (+24V DC) is required and must be sup- - DC Link Bus-bar
plied to the Line Module via connector X24. This is then dis-
tributed by a bus bar system to the remaining drive modules.
The electronic supply is used internally by the drive modules
LM MM1 MM2
for powering of the electronic circuitry etc. Externally it is used
for supplying the Drive-CLiQ encoders and fault, ready and
enable signals. X24– Electronic Supply 24V DC
X24 “M” Terminal: Electronics ground

Location of the electronics supply and DC link bus bars:
“+” Terminal: +24V DC (20.4V to 28.8V)
Notes

Smart Line Modules (SLM) X21: X22:

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

terminal locations etc.
X1: Mains supply

Protective earth (3-Phase AC)
connections
Connector locations X21, X22 & X24 X22 Terminal description and functionality
Terminal Function Description

+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-
X21: X22: (SLM 5 & 10Kw
generation function to be disabled.
Enable, ready only)
and fault sig- Regeneration and In some cases it may be necessary to
nals fault stop the regeneration of current
Disable
reset signals caused by braking motors. Example:-
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-
X24: setting of any drive faults.
24V DC Elec- Fault Reset A fault occurring on the drives system
3
tronics sup- (Input) will be latched, this can be reset with
this function providing the cause of
the original fault is no longer present.
0V DC Must be connected to the same 0V of
4
(Ground) the electronics supply (X24).
SLM
Notes

X21 Terminal description and functionality
Switches high (+24V DC) when the following conditions are true:
 Electronics supply present (X24).
 DC Link is pre-charged.
Ready Signal
 Pulses enabled (X21.3)
1  No over-temperature
(Output)
 No over-current
It is recommended that the signal is connected directly to the 840D sl controller via con-
nector X122 pin 1. This is the OFF1 enable signal.
Switches low when any of the following conditions arise:

 Over-temperature threshold reached.
 I²t threshold reached.
Pre-warning  Mains fault making regenerative feedback impossible. If feedback is intentionally
2
(Output) deactivated (X22.2 is high) this warning is disabled.
This signal is for use by the manufacturer to set a user alarm and alert the operator to a
problem.
X21 Terminal description and functionality
Applying +24V DC will cause the pulses to be enabled. (Current consumption:10mA)
This signal must be removed at least 10ms prior to the 3-phase mains supply being re-
moved.
Failure to do this can lead to damaged drive modules. This is especially important when
the axes/spindles are decelerating and causing regenerative currents. if the mains circuit
Enable Pulses is opened these regenerative currents remain within the drive system causing damage to
3
(Input) the modules.
It is recommended that this terminal is connected via an early break contact on the ma-
chine isolator switch and the line contactor (If used).
If the terminal is used by the manufacturer it must be ensured that it is controlled in the
suggested manner.
When used in this way the transistors will be switched off and mains regeneration halted,
the motors will then coast to a halt. This is not suitable for an emergency stop situation.
Enable Pulses
4 Must be connected to the 0V of the enable pulses supply.
(Ground)
Notes

LED Status Display X200/X201/

X21:Pulse ena- X202:
ble Drive-CLiQ
LED Colour Status Explanation connectors
Green On Module is healthy and operational.
X24:Electronic
Pre charging of DC link active; By- s supply
Yellow On
pass relay dropped out.
Electronics/DC
READY Over temperature/current fault or link bus bars
(Top) Red On electronics power supply outside (below flip
permitted range. down cover)
Electronics power supply outside
Off
permitted range.
DC LINK
Yellow On DC link voltage within tolerance.
(Bottom)
Red On DC link voltage outside tolerance.
LED status
Indicators
Smart Line Modules- 16Kw and above
These models are always required to be connected to the

Drive-CLiQ drive bus network.
The functionality of certain terminals is therefore different from
the non-Drive-CLiQ SLM modules.
Regeneration can be deactivated by parameter P3533-Inhibit
regenerative operation.
Protective X1: Mains sup-
Terminal locations of an internally cooled 36Kw SLM: earth ply
terminals
Connector locations X21, X24, X200, X201 & X202 X21 Terminal description and functionality
X21: Terminal Function Description

Pulse enable (PE) 1 Not used Not used
2 Not used Not used
X202:
Drive-CLiQ
X201:
Drive-CLiQ
X200:
Drive-CLiQ
X24:
24V DC Electronics
Supply
Notes

Terminal Function Description LED Status Display

Applying +24V DC enables the pulses. LED Colour Status Explanation
(Current consumption:10mA)
Electronics power supply out-
This signal must be removed at least Off
side permitted range.
10ms prior to the 3-phase mains supply
being removed. Module configured and ready,
Failure to do this can lead to damaged Green On Drive-CLiQ communication is
drive modules. This is especially im- active.
portant when the axes/spindles are re- Drive-CLiQ communication is
generating. If the mains circuit is opened Orange On being established/module not
in this state, regenerative currents remain READY configured.
Enable (Top)
within the drive system causing damage Red On At least one fault is present.
Pulses
to the modules. Green/ Flashing Firmware download procedure
3 Input
It is recommended that this terminal is Red 2Hz is running.
(EP)
connected via an early break contact on
the machine isolator switch and the line Green/
contactor (If used). Orange Flashing Component recognition is active
If the terminal is used by the manufactur- or Red/ 2 Hz (p0124 = 1)
er it must be ensured that it is controlled Orange
in the suggested manner. Electronics power supply out-
Off
When used in this way the transistors will side permitted range.
be switched off and mains regeneration DC link voltage within tolerance-
halted, the motors will then coast to a DC LINK Orange On Only if unit is configured and
halt. This is not suitable for an emergency (Bottom) ready.
stop situation. DC link voltage outside toler-
EP Must be connected to the 0V of the ena- Red On ance-Only if unit is configured
4
(Ground) ble pulses supply. and ready.
Active Line Modules (ALM) X21: X200/X201/

Pulse enable, X202:
The ALM is responsible for the rectification of the AC mains temperature Drive-CLiQ
supply into the DC link voltage which is then utilised by the sensor
Motor Modules.
This DC link voltage is also stabilised unlike the SLM mod- X24: Electronics/DC
ules Electronics link bus bars
The ALM is also responsible for handling regenerative current supply. (below flip
caused by the braking of motors. down cover)
The regenerative current is fed back into the mains network.
This eliminates the need for braking resistors and complex LED status
Indicators
measures for heat dissipation.
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.
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- X1:
namic machinery where the acceleration and positioning of 3-Phase AC
Protective Mains supply
axes/spindles is critical. earth
connections.
Terminal locations of ALM modules:-
Notes

Location of ALM connectors X21, X24, X200, X201 & X202 X21 Terminal description and functionality
X21:
Enable and
Temperature sensor. Terminal Function Description
+ Temp Temperature sensor input from Active
1
(Input) Interface Module (Observe the polarity)
X203: Drive-CLiQ. - Temp Temperature sensor input from Active
2
(Input) Interface Module (Observe the polarity)
X202: Drive-CLiQ.
X201: Drive-CLiQ.
X200: Drive-CLiQ.
X24: 24V DC
Electronics supply
Terminal Function Description ALM LED Status Display.

Applying +24V DC enables the pulses. LED Colour Status Explanation
(Current consumption:10mA)
Electronics power supply
This signal must be removed at least Off
outside permitted range.
10ms prior to the 3-phase mains supply
being removed. Module configured and ready,
Failure to do this can lead to damaged Green On Drive-CLiQ communication is
drive modules. This is especially im- active.
portant when the axes/spindles are DriveCLiQ communication is
regenerating. If the mains circuit is Orange On being established/module
opened in this state, regenerative cur- not configured.
rents remain within the drive system Red On At least one fault is present.
Enable causing damage to the modules.
READY Green/ Flashing Firmware download procedure
3 Pulses It is recommended that this terminal is
(Top) Red 2Hz is running.
(Input) connected via an early break contact
on the machine isolator switch/line con- Green/
tactor. Orange Flashing Component recognition is active
If the terminal is used by the manufac- or Red/ 2 Hz (p0124 = 1)
turer it must be ensured that it is con- Orange
trolled in the suggested manner. Electronics power supply outside
Off
When used in this way the transistors permitted range.
will be switched off and mains regener- DC link voltage within tolerance-
ation halted, the motors will then coast DC LINK Orange On Only if unit is configured and
to a halt. This is not suitable for an (Bottom) ready.
emergency stop DC link voltage outside tolerance-
situation. Red On Only if unit is configured and
EP Must be connected to the 0V of the ready.
4
(Ground) enable pulses supply.
Notes

Motor Modules (MM) X200/X201/X202:

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

These units will have two identical Motor/Brake connectors X200/X201/ Electronics/DC
(X1 & X2) and two identical enable connectors (X21 & X22). X202/X203: link bus bars
Drive-CLiQ (below flip down
connectors cover)
LED Status
Indicators
X1 & X2 Output
to Motor,
including the
brake output for
Protective MM less than
earth 45A
connections
X11: Brake out-

put for MM of 45A
Notes

Terminal descriptions
Positive temperature sensor input from
+ Temp
X21: Pulse 1 non-Drive-CLiQ temperature sensor.
(Input)
Enable etc. Type:- KTY84-1C130/PTC
Negative temperature sensor input from
X22: Pulse - Temp
2 non Drive-CLiQ temperature sensor.
X21: Pulse Enable etc. (Input)
Enable etc. Type:- KTY84-1C130/PTC
X203: Applying +24V DC will cause the pulses
Drive-CLiQ of the individual axis to be enabled.
X202:
Drive-CLiQ (Current consumption:10mA)
X202: When the signal is low, “Safe pulse
X201: Drive-CLiQ suppression” is activated.
Drive-CLiQ Note:-No electrical isolation occurs
X201: Enable between the Motor module and the motor.
X200: Drive-CLiQ Pulses This enable signal is only operational if the
3
Drive-CLiQ (EP) Safety Integrated function “Safe Standstill
X200: Input (SH)” is enabled.
Drive-CLiQ 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
Single axis Double match.
EP Must be connected to the 0V of the enable
4
Connector X21 & X22 (X22 only for double axis (Ground) pulses supply.
modules)
LED Status Display Motor connector (MM less than 45A)

LED Colour Status Explanation
Screw terminals. Not
Electronics power supply out- on Crimped cable
Fixing Metal connector
Off side types housing, also
permitted range.
Module configured and ready,
Green On Drive-CLiQ communication is Brake: Posi-
Brake: Nega-
active. tive tive Connec-
Drive-CLiQ communication is tion
READY Orange On being established/module not
(Top) configured.
Locating key- Locating key
Red On At least one fault is present. -
Green/ Flashing Firmware download procedure
Red 2Hz is running.
Green/
Orange Flashing Component recognition is active Motor: Phase Motor: Motor:
U Phase V Phase W
or Red/ 2 Hz (p0124 = 1)
Orange
Electronics power supply
Off
outside permitted range.
For MM modules of 45A and above, the brake is supplied by a
DC link voltage within tolerance-
separate connector (X11).
DC LINK Orange On (Only if unit is configured and
(Bottom) Ready)
The brake control circuit is isolated therefore it is not permissi-
DC link voltage outside toler- ble to connect the VE brake connector to the 0 V common of
Red On ance (Only if unit is configured the machine.
and ready)
Notes

Minimum 10ms-
Supply and Enabling Examples if supply disconnected
while drive is operational
For trouble free operation it is essential that the drives are
powered on/off and enabled correctly.
If the mains supply switch/contactor is opened while the drive Mains supply
pulses are enabled and the drive is in regeneration mode, the E Stop active
regenerative current which is normally fed back into the mains DB56.DBX0.1
will have no where to go, except that is into the motor and line Input to ALM/SLM via line switch
modules, this can result in damage to these modules. Enable Pulses
ALM/SLM
The solution is to use an auxiliary contact fitted to the mains X21.3
switch and drive line contactor.
Output/Input from/to 840D
This auxiliary contact must open at least 10ms before the In-feed ready.
From/to 840D sl
main contacts open. Link X132.10 to
The contact is wired to the Pulse Enable terminal of the SLM/ X122.1 (OFF1)
ALM module.
Energise line Output from 840D
If the Main switch or contactor is operated while the drive is in contactor–
operation the pulses will be disabled and the motors will free 840D sl X132.12
wheel to a standstill. (Except when the Safety Integrated func- Output
tion “Safe Stop” is enabled) Input from N/O contact
Line contactor
Any potentially harmful current will be unable to enter the drive energised-
modules as the transistors are now switched off. 840D sl X132.4
Input
Below is the timing diagram for the enabling of drives via the Input to ALM/SLM
OFF3 Enable
controller using a line Contactor. from user to
840D sl
X122.2
Notes

Notes

A051 END Line and Motor Modules
A051: END
Notes

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

Axis and Drive Diagnostics A053
Axis and Drive

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

Diagnostics:
END
Notes

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

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

ature problem on Axis 1. In this case the encoder cable was
not connected to the drive.
The displayed axes can be changed to suit personal prefer-

ences.
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 “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.
Notes

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

This detailed information can be very useful when a problem is done with the “Axis +” and “Axis -” soft keys.
occurs on the machine.
OR
An alternative method of selecting the required axis is via the

“Axis selection” soft key.
This the quickest method on a machine with many axes.
Useful information about the axis in question ranging from

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

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

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

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

The following screen shows a healthy system, indicated by the

green tick symbols.
Drives not ready or in a fault condition will display yellow or

red symbols.
The following example shows MSP1 exhibiting a problem. Example: The “Status indicator” information indicates that axis
To see more information about the cause, cursor to the failed is in commissioning mode.
axis and select the “Details” soft-key. The lower half of the screen offers further information.
The screen will display information regarding the cause of

the problem.
Use the “Drive object +” & “Drive object -” soft-keys to check

the status of other axes.
OR
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).
Notes

Two further soft-keys are also available for displaying further

information. Selecting the “Faults” soft-key also displays more
information which indicates a problem with encoder
1, drive component 18.
Selecting the “Warning” soft-key displays more infor-
mation which indicates a problem with encoder 1.
The “Help” key, found to the lower right of the vertical soft-
keys can be used to get more information about Warnings/
Faults. The alarms and warnings can also be seen on the alarm
screen.
Notes

The alarms displayed can be filtered via machine data 13150

“SINAMICS_ALARM_MASK”.
Many alarms are generated when the system detects a com-

CU (Drive object 1) is connected
ponent error. The machine data is used to filter out alarms via X100 to a motor module
which may be confusing. The default value is 0909 this sets (Drive object 2) socket X200.
bits 0, 3, 8 & 9. For service and commissioning work it maybe
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 Drive-CLiQ interconnections of the drive
objects and components.
Notes

The topology display can also be used to help identify faults. Drive component renaming
The component names can be changed to a more suitable

name if desired:
When a drive object has a fault, the text

will be displayed in red or grey.
Example: Renaming of Motor_Module_2 to Spindle.
Press the “OK” soft-key to confirm the changes, wait for the
dialogue box to clear.
Notes

Display options Automatic Firmware Update:

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

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

When the process is running the top LED of the drives will
flash red. Other Drive-CLiQ components will also indicate the
process in a similar way.
When the update has finished a complete power off/on of the
controller/drives is required.
The configuration area has several further functions:
The Drive Object and Component names can be changed via

the “Change” soft-key.
The system assigns default names to the objects/components.
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.
Example: Details of MX1 Servo Motor:
Electronic Rating Plates
Useful information is displayed when the “Details” soft-key is

selected.
These are known as the ”Electronic Rating Plates”.
Example: Details of MX1 axis Motor Module:
Notes

The “Sort” soft-key is used to view the components in a partic-

ular order according to Drive Object, Wiring, Component num-
ber or Axis number:
Comparison Levels:
Some of the information on the screen can only be viewed by

using the cursor left/right keys.
Display Settings
The level of displayed information about the components can

be controlled with the “Display options” function.
To the right of the screen, a column named “C.level” can be To change the level of comparison select the “Change” soft-
seen. key and then the “Insert” key.
This is used to set the comparison level for the Drive-CLiQ
components.
The system compares the stored details of the electronic rat-
ing plate of each object with the actual components connect-
ed to the Drive-CLiQ bus.
Once the drive system is configured it is continually moni-
tored. Alarms will be displayed if a fault occurs or an unknown
object is detected.
Notes

A053 END Axis and Drive Diagnostics
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.
Service case 2: If two existing components are to be inter-

changed to prove a fault e.g. Motor Module 1 & Motor Module
2, the system will detect this and issue alarms depending on
the setting of the comparison level.
In this case setting the comparison level to low would allow
the modules to be interchanged without alarms occurring.
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 im-
portant machine data.
Module Objective:
Upon completion of this module you will be able to synchronise/adjust the measuring system for
the Sinumerik 840D sl controller.
Content:
Sinumerik
Referencing Incremental Encoders
Referencing Absolute Encoders
Machine Data Information
Automatic Referencing
A084
A084

Encoder Adjustment A084
Encoder
Adjustment:
START
Referencing
Incremental
Encoders
Referencing
Absolute
Encoders
Machine Data
Information
Automatic
Referencing
Encoder
Adjustment:
END
Notes

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.
Look for the “Measuring system 1 active” and “Measuring sys- If it is uncertain whether an axis has an incremental or abso-
tem 2 active”. A green tick symbol indicates which measuring lute encoder fitted, this can be checked via axis machine data
system is active for each axis., typically the motor encoder. A 30240.
2nd measuring circuit is typically a linear scale on an axis or an To check the machine data use the following soft key se-
encoder for a spindle. quence.
Some manufacturers may also switch between measuring sys-
tems. If there is uncertainty about this please contact the manu-
facturer for information.
Machine data 30240[0] & [1] can also be checked.
If the active measuring circuit is 1, machine data 30240[0]

should be used to identify the encoder type.
Ensure that the correct axis is selected.
Or should be used to identify the encoder type.
Incremental encoder = 1
Absolute encoder =4
To reference an axis fitted with an incremental encoder, an

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

ence point approach interface bit.
Notes

Before referencing can be initiated the controller needs to be

placed into Reference Mode by selecting the “REF.POINT”
button on the machine control panel. The LED should Illumi-
nate, the “JOG” mode LED remains illuminated.
Interface signal DB3x.DBX12.7 “Delay Ref. Pt approach” Confirmation that the correct mode is selected can be seen
needs to be set to high to initiate the referencing procedure. at the top of the screen.
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

2nd axis - DB32.DBX12.7
3rd axis - DB33.DBX12.7
etc.
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
Each axis can be referenced individually. It is also possible more common to find that the axis will continue to move
to reference the axes automatically. This usually set up by even when the jog direction button is released.
the machine builder and will be explained in more detail later
in the module.
To reference an individual axis select the correct axis via the

machine control panel.
Notes

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

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

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

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

When an axis is referenced the controller issues interface Referencing Absolute Encoders
signals:
General information
1st axis DB31.DBX60.4 1st measuring circuit is referenced Absolute encoders need referencing on first commissioning
1st axis DB31.DBX60.5 2nd measuring circuit is referenced and remain referenced until a problem occurs with encoder or
2nd axis DB32.DBX60.4 1st measuring circuit is referenced the NCK. Re loading of an archive will also necessitate the
2nd axis DB32.DBX60.5 2nd measuring circuit is referenced referencing of the encoder.
etc. Procedure:
First it must be ascertained that the encoder is of the absolute
type. This can be done by checking the motor data rating plate
The position display will indicate the axis is referenced and dis- (In the case of an integrated motor encoder)
play any values stored in machine data: Checking with the supplier of the encoder is another method
34100 $MA_REFP_SET_POS of determining the correct type.
Machine data 30240[0] & [1] can also be checked.

Symbol indicating the axis is referenced.
If the active measuring circuit is number 1, then the value of
machine data 30240[0] should be used to identify the encoder
type.

should be used to identify the encoder type.
Value from Axis MD 34100 The following values determine the encoder type:
Incremental encoder =1
Absolute encoder =4
Check that machine data 34200 ENC_REFP_MODE is set to 0

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

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

The axis to be referenced should be moved to the known

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.
Confirmation that the correct mode is selected can be seen at

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

Machine Data Information

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

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

A084 END Encoder Adjustment
Automatic Referencing
Automatic referencing cycle

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.
The order is set by axis machine data
$MA_REFP_CYCLE_NR (Default 1)
Possible entries:-
0 = no referencing cycle participation.
1 to 15 = allowable range for setting the sequence.
-1 = no reference required for Cycle start.
Up to eight axes can be referenced at the same time.
To initiate the automatic cycle the necessary interface bit

(DB21.DBX1.0 ) has to be set.
Example of how the automatic referencing cycle can be initi-

ated:
Ref Mode active NC start request Activate

(Mode group 1) (Channel 1) referencing
(Channel 1)
Interface signal DB21.DBX33.0 changes to 1 while the

referencing cycle is active.
A084: END
Notes

A008 MCP & PP72/48 PN Connections and
Diagnostics
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, how the parameterisation of the function block is
made and the Profinet configuration of PP72/48 I/O modules.
Module Objective:
Upon completion of this module the course participant will know how to configure and install a
Siemens machine control panel (MCP) and PP72/48 periphery I/O modules.
Content:
Sinumerik
Machine Control Panel Types
MCP483 PN Front and rear Layout
MCP310 PN Front and rear Layout
Machine Control Panel Addressing
Machine Control Panel Interface Signals
Machine Control Panel Signal Test
PP72/48 PN Description and Interface Signals
Profinet Configuration PP72/48
A008
A008

MCP & PP72/48 PN Connections and Diagnostics A008
MCP & PP72/48 PN

Connections and
Diagnostics:
START
Machine
Control Pan-
el Types
MCP483
Front and
Rear layout
MCP310
Front and
Rear layout
MCP
Configuration
and
Addressing
Machine Control
Panel Interface
Signals
MCP Signal
Test
PP72/48 PN De-
scription and
Interface Signals
Profinet Con-
figuration
MCP &
PP72/48
MCP & PP72/48 PN

Connections and
Diagnostics:
END
Notes

A008 MCP & PP72/48 PN Connections and Diagnostics
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
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.
MCP483 Rear Layout
X10
X53
X54 X60 X61
X3 X51
X52
X55
X20
H3
H2
X30 H1 X21
X5
S2
Interface Description:- X51 Digital inputs X60 Hand-wheel

S2 Addressing switch. X52 Digital inputs X61 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
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.
MCP310 Rear Layout
X1
X5
X5 X60
X3 X5
X5
X5
X2
H3
H2
X3 H1
X2
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 LED Indicators:
X20 Port 1 Ethernet connection in.
X55 Digital inputs H1 Power OK (Green)
X21 Port 2 Ethernet connection out.
H2 BUSSYNC
X30 Feedrate override interface.
H3 BUSFAULT
X31 Spindle override interface
Notes

Machine Control Panel Configuration and Addressing Parameter description:
Determining the MCP start address MCPNum Number of MCPs on the system.
Function Block FB1 is used for configuring the I/O assignment MCP1In Pointer-The start address of the MCP inputs.
of the MCPs.
Module “A033 PLC Functions” describes the full configuration MCP1Out Pointer-The start address of the MCP outputs.
procedure for the MCPs.
FB1 is called from within Organisation Block OB100. There are MCP1BusAdr Addressing of MCP, set by dip-switch
many parameters associated with FB1.
MCP1BusType Bus type; 55 = Ethernet
The following is an example of FB1, the parameters for setting
the I/O start addresses for a single MCP.
The MCP is connected to X120 system network.
X120 is a DHCP server with a default IP address of
CALL FB 1 , DB 7(
192.168.214.1 and a subnet mask of 255.255.255.0.
MCPNum := 1,
MCP1In := P#I 0.0,
MCP1Out := P#Q 0.0,
MCP1StatSend := P#Q 8.0,
MCP1StatRec := P#Q 12.0,
MCP1BusAdr := 192,
MCPBusType := B#16#55,
NCKomm := TRUE,
ExtendAlMsg := FALSE);
Each hardware item connected to the network needs a unique The following table shows examples of S2 switch positions and
address. the resulting addresses, including the default address of 192.
This is determined by the setting of S2 on the MCP.
Meaning/
Each switch position from 1 to 8 represents a value which is Switch S2
address
active when the switch position is set to “On”.
All switches in the “On” position have their values added to- 10 9 8 7 6 5 4 3 2 1
gether to give the address of the MCP. Off Off - - - - - - - - Reserved
Switch positions 9 & 10 must always set to “Off” to enable

Ethernet operation. - - Off Off Off Off Off Off Off Off 0
- - Off Off Off Off Off Off Off On 1
Switch S2: Positions and relevant values.
- - Off Off Off Off Off Off On Off 2
Switch S2 Value when in
Position “On” state - - Off Off Off Off Off Off On On 3
1 1 - - : : : : : : : : :
2 2 192 (Delivery
- - On On Off Off Off Off Off Off
setting)
3 4
- - : : : : : : : : :
4 8
- - On On On On On On On Off 254
5 16
- - On On On On On On On On 255
6 32
7 64
8 128
9 Always OFF
10 Always OFF
Switch S2
Notes

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
IBn+2 Key-switch Key-switch Feed *Feed

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
IBn+4 Rapid Key switch
+ - position 3 X 4th axis 7th axis
traverse 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
QBn+1 Feed *Feed

NC Start *NC Stop REPOS REF INC var. INC 10000
start stop
Direction Minus X 4th axis 7th axis Single block

QBn+2 Spindle start *Spindle stop
R13 R1 R4 R7 R10
QBn+3 Z 5th axis 8th axis 6th axis Direction Plus

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
QBn+7 KT-OUT6 KT-OUT5 KT-OUT4 KT-OUT3 KT-OUT2 KT-OUT1

(X54.3) (X54.2) (X54.1) (X53.3) (X53.2) (X53.1)
Signals marked with * are inverse signals.
Notes

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)
position 2 position 1
Direction keys
IBn+4 Rapid KT-IN5 KT-IN4 KT-IN3 KT-IN2 KT-IN
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)

QBn *NC Stop Spindle Dec. Spindle 100% Spindle Inc. Single Block JOG MDA AUTO
NC RESET REF REPOS Teach In

QBn+1 start
Spindle right *Spindle Stop Spindle left
QBn+2 Feed Start *Feed Stop INC var. INC 1000 INC 100 INC 10 INC 1
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

(X54.3)
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


KT-IN7
1
User I/O pin assignment KT-IN8
2
The 9 inputs and 6 outputs available on plugs X51 to X55 are KT-IN9
3
designed for use with switches/buttons and indicator lamps
which can be installed in the blanked holes of the MCP. M (0 volts)
4
Below shows the I/O assignment of each individual plug.
X55
The input terminals in the normally open state measure 5 V DC
(Supplied by the MCP) Output Assignment (X53 & X54):
The inputs work by sinking the 5 V DC signals to 0 V (M).
The outputs terminals are supplied with +24 V DC from the

MCP. KT-OUT1 KT-OUT4
1 1
No external voltages should be applied to the input and output KT-OUT2 KT-OUT5
2 2
terminals.
KT-OUT3 KT-OUT6
3 3
Input Assignment (X51, X52 & X55): M (0 volts) M (0 volts)
4 4
KT-IN1 KT-IN4
1 1 X53 X54
KT-IN2 KT-IN5
2 2 The outputs are capable of supplying 1.2 Watts per output, it is
KT-IN3 KT-IN6 not permissible to connect relays, valves or other inductive
3 3
devices.
M (0 volts) M (0 volts)
4 4
X51 X52
MCP signal test
The signals to and from the MCP can be checked using the on-
board diagnostic feature of the controller.
To locate the diagnostic screens use the following soft-key
selection:
On the screen it is possible to enter the inputs and outputs of

the MCP and check the functionality of each button/key.
Notes

To ensure that the correct signal is selected, first check the FB1 parameterisation for the “Pointer” value (Page 9).
Secondly, refer to the relevant Machine Control Panel Interface Signal tables.
Example::
To test the NC start button input signal on an MCP310 with a “Pointer” of 0, the input I1.7 needs to be monitored.
Cycle Start button not pressed:
Cycle Start button pressed:
PP72/48 PN Description and Interface Signals

S1
PP72/48 PN modules are a compact component which con-
nect to the Profinet network (Ports PN1 or PN2 of the PPU).
There are two variants, one of which is all digital while the X111
second offers both digital and analogue functionality.
A 24 V DC supply is required.
In total 72 digital inputs and 48 digital outputs are available on
each of the two variants.
The analogue module has an additional two analogue inputs
and two analogue outputs.
X222
Part number:- 6FC5311-0AA00-0AA0 Digital only
(PP72/48D PN)
6FC5311-0AA00-1AA0 Digital/analogue
(PP72/48 2/2A PN)
X2 X2
X333
X1
Notes

Pin assignment X111

Ribbon cable connections.
Pin Signal Pin Signal Pin Signal
The following tables show the pins and I/O addresses for
ribbon connectors X111, X222, X333. This is assuming 1 0V DC 19 I2.0 37 Q0.6
the PP72/48 PN is configured with a start address of 0 2 +24VDC O/P 20 I2.1 38 Q0.7
(Input bytes 0, 1, & 2 and output bytes 0 & 1).
3 I0.0 21 I2.2 39 Q1.0
Note: The first input byte of X222 has FAST gating hard-
ware. 4 I0.1 22 I2.3 40 Q1.1
5 I0.2 23 I2.4 41 Q1.2
6 I0.3 24 I2.5 42 Q1.3
7 I0.4 25 I2.6 43 Q1.4
8 I0.5 26 I2.7 44 Q1.5
9 I0.6 27 Not used 45 Q1.6
10 I0.7 28 Not used 46 Q1.7
11 I1.0 29 Not used 47 +24V DC I/P
12 I1.1 30 Not used 48 +24V DC I/P
13 I1.2 31 Q0.0 49 +24V DC I/P
14 I1.3 32 Q0.1 50 +24V DC I/P
15 I1.4 33 Q0.2
16 I1.5 34 Q0.3
17 I1.6 35 Q0.4
18 I1.7 36 Q0.5
Pin assignment X222 Pin assignment X333
Pin Signal Pin Signal Pin Signal Pin Signal Pin Signal Pin Signal
1 0V DC 19 I5.0 37 Q2.6 1 0V DC 19 I8.0 37 Q4.6
2 +24V DC O/P 20 I5.1 38 Q2.7 2 +24V DC O/P 20 I8.1 38 Q4.7
3 I3.0 21 I5.2 39 Q3.0 3 I6.0 21 I8.2 39 Q5.0
4 I3.1 22 I5.3 40 Q3.1 4 I6.1 22 I8.3 40 Q5.1
5 I3.2 23 I5.4 41 Q3.2 5 I6.2 23 I8.4 41 Q5.2
6 I3.3 24 I5.5 42 Q3.3 6 I6.3 24 I8.5 42 Q5.3
7 I3.4 25 I5.6 43 Q3.4 7 I6.4 25 I8.6 43 Q5.4
8 I3.5 26 I5.7 44 Q3.5 8 I6.5 26 I8.7 44 Q5.5
9 I3.6 27 Not used 45 Q3.6 9 I6.6 27 Not used 45 Q5.6
10 I3.7 28 Not used 46 Q3.7 10 I6.7 28 Not used 46 Q5.7
11 I4.0 29 Not used 47 +24V DC I/P 11 I7.0 29 Not used 47 +24V DC I/P
12 I4.1 30 Not used 48 +24V DC I/P 12 I7.1 30 Not used 48 +24V DC I/P
13 I4.2 31 Q2.0 49 +24V DC I/P 13 I7.2 31 Q4.0 49 +24V DC I/P
14 I4.3 32 Q2.1 50 +24V DC I/P 14 I7.3 32 Q4.1 50 +24V DC I/P
15 I4.4 33 Q2.2 15 I7.4 33 Q4.2
16 I4.5 34 Q2.3 16 I7.5 34 Q4.3
17 I4.6 35 Q2.4 17 I7.6 35 Q4.4
18 I4.7 36 Q2.5 18 I7.7 36 Q4.5
Notes

Profinet Configuration - MCP & PP72/48
Each hardware item connected to the Profinet network needs a unique IP address.
This is determined by the setting of S2 on the MCP and S1 on the PP72/48.
Each Profinet device has an IP address in the range 192.168.214.xxx . The switch setting determines the last part of the IP
address xxx.
Switch S1/S2
The selected IP address will determine the I/O that will be assigned. This is seen in the following tables:
For all Profinet applications switch positions 9 and 10 need to be set to on.
Switch S1 - PP72/48 Default device name

Switch S1/S2 Binary Value Switch S2 - MCP483/MCP310
Position pp72x48pn xxx
1 1
The switch positions 1 to 8 define the default device name of
2 2
the I/O module. There are up to 128 default device names. If
3 4 these default device names are used, there is no need for
initialization.
4 8
binary value 9 = pp72x48pn9
5 16
6 32 DCP-Mode
Switch S1 to S8 be switched "on".
7 64 In this mode, there is no default device name.
8 128 The device name must be set using initialization and remains
saved on the I/O module. It is first deleted when the factory
9 Profinet=ON setting is restored, e.g. using STEP7.
10 Profinet=ON
A008: END
Notes

A008 END MCP & PP72/48 PN Connections and Diagnostics

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

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

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

Step7 300 PLC: PLC

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

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

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

PLC
Operating system
Notes

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

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

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

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

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

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

menu when not activated when inserting the NCU.
Notes

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

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

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

Reserved Data Blocks
Overview of data blocks

DB no. Name Function Package
1 Reserved for Siemens BP

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

19 HMI interface
Overview of data blocks

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

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

Example: Base Program Integration

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

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

now be extended with additional mo-
dules from the Profinet branch of the
Hardware catalogue.
Notes

The Profinet periphery PP72/48 will be

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

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

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

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

The Topology editor con-

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

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

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

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

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

Dip switches and Device names

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

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

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

At this point the "PROFIBUS DP

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

A026 END Creating a PLC program
Profibus populated with ET200S
Notes

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

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

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

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

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

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

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

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

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

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

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

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 V4.5 Page 1 This document was produced for training purposes.
A033
A033

PLC Functions A033
PLC
Functions:
START
PLC Start-up
Parameteri-
sation
MCP
Transfer
Reading and
Writing of
NC Variables
PI Services
Reading Glob-
al User data´s
Starting ASUP
Axis / Spindle
control
PLC
Functions:
END
Notes

A033 PLC Functions
PLC Start-up parameterisation ORGANIZATION_BLOCK OB 100

TITLE =
{ S7_language := '9(1) English (United States)
13.10.2010 16:56:20' }
The PLC interface is made up of a series of Step 7 Data VERSION : 1.0
Blocks, the number and length of the data blocks is deter-
mined by the system on startup. VAR_TEMP
OB100_EV_CLASS : BYTE ;
The machine tool builder can also influence this process and OB100_STRTUP : BYTE ;
others using the parameterisation possibilities of the PLC Ba- OB100_PRIORITY : BYTE ;
OB100_OB_NUMBR : BYTE ;
sic program in OB100. OB100_RESERVED_1 : BYTE ;
OB100_RESERVED_2 : BYTE ;
The parameterisation is carried out with the direct parameteri- OB100_STOP : WORD ;
sation of the Function Block 1 in the OB100 start-up routine, OB100_RESERVED_4 : WORD ;
these values are made available to the PLC Basic program OB100_DATE_TIME : DATE_AND_TIME ;
through the use of an Instance DB (DB7) of the FB1. END_VAR
BEGIN
NETWORK
Example:- TITLE =
CALL FB 1 , DB 7 (
MCPNum := 1,
MCP1In := P#I 0.0,
MCP1Out := P#Q 0.0,
MCP1BusAdr := 192,
NCKomm := TRUE);
END_ORGANIZATION_BLOCK
In addition to the Interface being configured, various other

functions are implemented,
including:-
 Define the number of MCPs
 Define the address range of MCPs
 Defining the type of MCP
 Hand held unit configuration
 PLC Communication to NCK option
 Alarm configuration
The parameters of FB1 and their meaning can be found on

the following pages.
Notes

PLC Functions 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 ma-
MCP2In or chine 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 relevant ma-
MCP2Out or chine 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 con-
MCP2Timeout trol 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 panel

MCP2Stop 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 signals
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 PLC Functions
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
B#16#6 (6 Byte)
BHGOutLen I BYTE HHU default: Available owing to compatibility
B#16#14 (20 Byte)
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

PLC Functions 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 PLC Functions

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

PLC Functions 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 PLC Functions
Traversing keys
MCP (Machine Control Panel) Transfer
Overrides
Function Description: Key-operated switch
With the following Step 7 Functions, the Machine Control Pa-

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

FC24 MCP small None
FC26 HT6
NCK Requirement:
The following group signals are transferred: None
Mode Groups
PLC Requirement:
Axis selections
Parameterisation of the corresponding Step 7 Function.
WCS/MCS switchover commands
Steps to achieve running function: Axis sequence for FC19,FC25 etc
Parameterisation of the corresponding Function.

The axis sequence for the FC19 can be found in the inter-
face DB10 beginning at DBB8 for the first axis, a maximum
Parameter description of FC19 of 9 axis can be configured.
The Machine axis number has to be entered into the Inter-
Signal Type Format Range of Remark face byte.
values Axis numbers 1 - 9 are entered sequentially as default.
BAGNo I BYTE 0 - b#16#0A No. of mode group to
and which the mode sig-
b#16#10 - nals are transferred. Parameter BAGNo
b#16#1A BAGNo >= b#16#10
means access to the
second machine con- The BAG NO is a parameter with size BYTE.
trol panel. This Byte can be considered as Left and Right nibble(4
ChanNo I BYTE 0 - B#16#0A Channel no. for the bits).
channel signals The left nibble is the BAG No for the 2nd MCP if available,
the right nibble being the BAG no for the 1st MCP.
SpindleIFNo I BYTE 0 - 31 Number of the axis
(B#16#1F) interface declared as a
spindle
FeedHold Q BOOL Feed stop from MCP, MCP 2 MCP 1
modal
Bit 4 - 7 Bit 0 - 3
SpindleHold Q BOOL Spindle stop from
MCP, modal BAGNo BAGNo
Notes

PLC Functions A033
Reading and Writing of NC Variables

The NC Var selector is part of the PLC Toolbox.
Function Description:
During the manufacturing process it may be necessary to have Prerequisites for the Function:
data available to the NC program from the automation system
in order to optimize the NC machining process. The prerequisite for the function, is the parameter:
This could take the form of a numerical value being transferred
to an R Parameter or a machine setting data receiving from NCKomm := True
the automation system an optimised value.
In the opposite direction it may be necessary to influence the The parameter belongs to FB1 which is parameteri-
automation system dependent upon the current NC machining sed in OB100.
process, positional data available in the automation system is
an example of this.
HMI Requirement:
Two function blocks are available for the function of :
None
Reading NC data - FB2
Writing NC data - FB3 Drive requirement (Sinamics):
In addition to the FBs, a tool is available for the engineering None

PC, this tool is required for generating the necessary parame- NCK Requirement:
ter values for the two function blocks.
None
The tool is called (NC Var selector).
The parameter values which are obtained from the NC Var PLC Requirement:
selector point to the storage location within the NC which are
required as destination or as source, determined by a READ Parameterisation of FB2 or FB3 in the PLC
or WRITE function.
Steps to achieve function:
Before parameterising FB2 or FB3 the address of the varia-

ble has to be known, and stored in a user Data Block.
This is carried out with the NC Var selector tool.
In order to create the address data the following steps should
be followed:
Start the NC Var Selector
The correct variable database has to be selected with

each new project, in the case of Sinumerik Operate.
Start a new Project
Notes

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

ables are displayed.
The name and the address of the required variable can now
be selected from the list of available variables.
In order to make the selection of the variable easier, a com-
prehensive help file is available.
Notes

PLC Functions A033
It can be seen in the following screenshot that the possibility

The variables can be inserted into the users project using the exists also to parameterise a variable with the value zero (0).
right mouse button, in some cases an input window will ap- In this case the user structure which is generated by the NC
pear, further parameterisation can be carried out at this point. Var selector can be further parameterised in the PLC user
E.g. Channel / axis number etc... program, thus offering an even higher degree of flexibility to
the user.
In the following screenshot, two R parameters are used as an When the user has completed the selection of the necessary
example. variables, the user variable table can be saved.
The first with fixed parameterisation, not parameterising with The file can be saved to a project directory, this directory is
zero, and the second using parameterised value zero. free for the user.
It is therefore possible to manipulate the number of the R The format of the file is „Step 7 source code“ with the data
parameter in the user PLC program. type STRUCT. The STRUCT is contained in a Data Block
container, this Data Block can be configured in the Code se-
lections menu.
Notes

A033 PLC Functions
Configuration of user DB Saving of var file (variable file)
The following describes how the STRUCT information is The AWL file can be inserted directly into the Step 7 project
transferred into the Step 7 project. with the marked icon green.
In the following screenshot, the marked area indicates the link A window allows the project and path to be defined, and with
where the user can select the AWL file name and generate OK you will find your AWL information in the source file folder
the foresaid file. of your Step 7 project.
Notes

PLC Functions A033
It is recommended that the option „transfer DB and Symbol“

be set.
The following screenshot shows the DB number and symbol
name in the Step 7 Symbol table.
This AWL can now be opened in the Step 7 editor, and can
be compiled into S7 DB Format for usage as a parameter
value to the FB2 or FB3.
After successful compilation in Step 7 The call and parameterisation of the FB2 and FB3 can now
take place according to the following parameter description:
Notes

A033 PLC Functions
GET FB2 PUT FB3

Signal Type Format Range of Remark
values
values
Req I BOOL Job start with positive
signal edge Req I BOOL Job start with positive
signal edge
NumVar I INT 1 ... 8 Number of variables to
NumVar I INT 1 to 8 Number of variables to
(corresponds be read
(corresponds to be written
to use of Addr1
use of Addr1 to
to Addr8)
Addr8)
Addr1 to I ANY [DBName]. Variable identifiers from
Addr8 [VarName] NC Var selector Addr1 to Addr8 I ANY [DBName]. Variable identifiers from
[VarName] NC Var selector
Unit1 to Unit8 I BYTE Area address, optional
Unit 1 to Unit 8 I BYTE Area address, optional
for variable addressing
Column1 to I WORD Column address, op-
Column8 tional for variable ad- Column 1 to I WORD Column address, op-
Column 8 tional for variable ad-
dressing
dressing
Line1 to I WORD Line address, optional
Line 1 to Line 8 I WORD Line address, optional
Line8 for variable addressing
Error Q BOOL Negative acknowledg-
Error Q BOOL Negative acknowledg-
ment of job or execution
ment of job or execu-
of job impossible
tion of job impossible
NDR Q BOOL Job successfully exe-
cuted Data are available Done Q BOOL Job successfully exe-
cuted
State Q WORD See error identifiers
SD1 to SD8 I/Q ANY P#Mm.n BYTE Data to be written
RD1 to RD8 I/Q ANY P#Mm.n BYTE Target area for read
x...
x... data
P#DBnr.dbxm.
P#DBnr.dbxm.
n BYTE x
n BYTE x
Notes

PLC Functions A033
Reading and writing of NC variables is only possible with the

FB1,DB7 variable: NCKomm:= true Example: Reading and writing R parameter.
FUNCTION "Read-Write NC" : VOID

TITLE =
VERSION : 0.1
ORGANIZATION_BLOCK OB 100 BEGIN
TITLE = NETWORK
{ S7_language := '9(1) English (United States) 13.10.2010 TITLE =Read R parameter
16:56:20' }
VERSION : 1.0 A I 80.7;
FP M 110.0; // Transition Marker
BEGIN S M 110.1;
NETWORK A M 110.3;
TITLE = FP M 110.4; // Transition Marker
R M 110.1;
CALL FB 1 , DB 7 ( CALL "GET" , DB 110 (
MCPNum := 1, Req := M 110.1,
MCP1In := P#I 0.0, NumVar := 1,
MCP1Out := P#Q 0.0, Addr1 := "ncvar".C1_RP_rpa1_1,
MCP1StatSend := P#Q 8.0, Error := M 110.2,
MCP1StatRec := P#Q 12.0, NDR := M 110.3,
MCP1BusAdr := 192, State := MW 111,
MCPBusType := B#16#55, RD1 := MD 113);
NCKomm := TRUE); Option
Symbol table showing the Symbol name and Absolute name

NETWORK of the VAR Data Block
TITLE =Write R parameter
A I 81.0;
S M 117.1;
A M 117.3;
R M 117.1;
CALL "PUT" , DB 111 (
Req := M 117.1,
NumVar := 1,
Addr1 := "ncvar".C1_RP_rpa0_1,
Line1 := W#16#2,
Error := M 117.2,
Done := M 117.3,
State := MW 118,
SD1 := MD 113);
END_FUNCTION
Notes

A033 PLC Functions
Content of VAR DB with symbol name.

C1_RP_rpa0_1:
STRUCT
SYNTAX_ID : BYTE := B#16#82;
Area_Unit : BYTE := B#16#41;
Column : WORD := W#16#1;
Line : WORD := W#16#0;
BlockType : BYTE := B#16#15;
// ------------------------------------------------------- NumOfLine : BYTE := B#16#1;
// File : E:\NCVar Projects\DBData.awl DataType : BYTE := B#16#F;
// Length : BYTE := B#16#8;
// Source File : E:\NCVar Projects\DBData.var END_STRUCT ;
// Generation Date: 16/12/2010 Time: 16:02:55
// ------------------------------------------------------- END_STRUCT ;
DATA_BLOCK DB 120 Ncvar = Symbol name BEGIN

VERSION : 0.0 END_DATA_BLOCK
STRUCT
C1_RP_rpa1_1:
STRUCT
SYNTAX_ID : BYTE := B#16#82;
Area_Unit : BYTE := B#16#41;
Column : WORD := W#16#1;
Line : WORD := W#16#1;
BlockType : BYTE := B#16#15;
NumOfLine : BYTE := B#16#1;
DataType : BYTE := B#16#F;
Length : BYTE := B#16#8;
END_STRUCT ;
PI Services PI service Function
CRCEDN Create new cutting edge

Function description: Automate an Operator function
CREACE Create cutting edge
The following PI services are available:
CREATO Generate tool
PI service Function DELECE Delete a cutting edge
ASUP Assign interrupt DELETO Delete tool
CANCEL Execute cancel MMCSEM Semaphores for various PI services
CONFIG Reconfiguration of tagged machine data TMCRTO Create tool
DIGION Digitizing on TMFDPL Empty location search for loading
DIGIOF Digitizing off TMFPBP Empty location search
FINDBL Activate block search TMGETT T-number for the specified tool identifier
with duplo number
LOGIN Activate password TMMVTL Prepare magazine location for loading,
unload tool
LOGOUT Reset password
TMPOSM Position magazine location or tool
NCRES Trigger NC-RESET
TMPCIT Set increment value for workpiece counter
SELECT Select program for processing for one
channel TMRASS Reset active status
SETUDT Sets the current user data to active TRESMO Reset monitoring values
SETUFR Activate user frame TSEARC Complex search using search screen
forms
Notes

PLC Functions A033
Function Description: cont. HMI Requirement:

None
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- None
word, this is an action which is often carried out by the oper-
ator but can also be automated using the PLC program.
It is therefore possible to automate the deactivation of the PLC Requirement:

password at system start-up, Parameterisation of FB4 or FB7 in the PLC
Prerequisites for the Function: NCK Requirement:

Dependant upon function
NCK prerequisite is dependant upon the function.
PLC Prerequisite:
The prerequisite for the function is the parameter:
NCKomm := True
The parameter belongs to FB1 which is

parameterised in OB100.
Steps to achieve running function:
ORGANIZATION_BLOCK OB 100
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
Notes

A033 PLC Functions
Parameter description of FB4 Error codes

Signal Type Format Range of values Remark
State Significance Note
Req I BOOL Job request
PIService I ANY [DBName]. PI service 3 Negative acknowledg- Internal error, try:
[VarName] description1) ment, job not NC RESET
Standard is: "PI". executable
[VarName] 6 FIFO full Job must be repeat-
Unit I INT 1... Area number ed since queue is full
Addr1 to I ANY [DBName]. Reference to strings 7 Option not set BP parameter
Addr4 [VarName] specification accord- "NCKomm" is not set
ing to selected PI 9 Transmission occupied Job must be repeat-
service ed
WVar1 to I WORD 1... INTEGER or WORD 13 (0x0d) ANY data reference String data required
WVar10 variables. Specifica- incorrect has not been param-
tion according to eterized
selected PI service, 14 (0x0e) PIService parameter No valid PI descrip-
Error Q BOOL Negative acknowl- reference incorrect tion
edgment of job or 15 (0x0f) String too long Addr1.. Check Addr4
execution of job im- strings
possible
Done Q BOOL Job successfully
executed
In order to use the LOGIN PI service, a string variable has to Example of Password Login and Logout
be available as parameter source.
The string variable is the name of the Password, it is con- FUNCTION "PIServices" : VOID
tained in a user DB using data type STRING.
A I 81.1;
STRING[8] := `SUNRISE ` NOTE 8 Characters - use SPACES S M 122.1;
A M 122.3;
R M 122.1;
CALL "PI_SERV" , DB 132 (
Req := M 122.1,
The DB121 is created and used for the examples, The GUD PIService := "PI".LOGOUT,
string is not required in this module. Unit := 1,
Error := M 122.2,
Done := M 122.3,
State := MW 123);
A I 81.2;
S M 125.1;
A M 125.3;
R M 125.1;
CALL "PI_SERV" , DB 133 (
Req := M 125.1,
PIService := "PI".LOGIN,
Unit := 1,
Addr1 := DB121.L_IN,
Error := M 125.2,
Done := M 125.3,
State := MW 126);
END_FUNCTION
Notes

PLC Functions A033
Reading Global User data´s

Parameter part for Addr1 -- PI Login
Global User Data's can be both read and written to by the au-
tomation system (PLC).
Global User Data's are often referred to as GUD's . The OEM

is able to define his own user variables in this way.
Dependant upon the OEM functionality of the relevant GUD it
may be necessary in process to read the current value to the
PLC or to write the value from the PLC.
With the Function Block FB5 you are able to read the value of
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.
By reading the content of the variable with FB5 and with addi-
tional parameterisation of the FB5 the internal address can be
obtained as a result parameter of the FB5, this result / output
parameter can be used as a destination parameter with the
FB2 PUT allowing an indirect way to write the GUD's.
Prerequisites for the Function: HMI Requirement:

None
GUD Data's available in the NC
None
Plus the parameter:
NCKomm := True NCK Requirement:

GUD Data available
The parameter belongs to FB1 which is
PLC Requirement:
Parameterisation of FB5 in the PLC
Steps to achieve running function:
Notes

A033 PLC Functions
ORGANIZATION_BLOCK OB 100 Signal Type Format Value Comment

TITLE =
range
13.10.2010 16:56:20' } Req I BOOL Job start with positive
VERSION : 1.0
signal edge
BEGIN Addr I ANY [DBName]. GUD variable name in
NETWORK
TITLE =
[VarName] a variable of data type
STRING
CALL FB 1 , DB 7 ( Area I BYTE Area address:
MCPNum := 1,
MCP1In := P#I 0.0, 0: NCK variables
MCP1Out := P#Q 0.0,
MCP1StatSend := P#Q 8.0, 2: Channel variables
MCP1StatRec := P#Q 12.0, Unit I BYTE NCK area: Unit:=1
MCP1BusAdr := 192,
MCPBusType := B#16#55, Channel area: Chan-
NCKomm := TRUE); Option nel no.
//Insert User program from here Index1 I INT Field index 1 of varia-
ble
Variable has the value
0 if no field index is
used.
Parameter description of FB5
Index2 I INT Field index 2 of varia-
ble
Variable has the value
0 if no field index is
used.
Signal Type Format Value Comment Error codes

range
CnvtToken I BOOL Activate generation of a State Meaning Note
10 byte variable token
VarToken I ANY [DBName]. Address to a 10-byte WORD H WORD L
[VarName] token (see example)
Error Q BOOL Negative acknowledg- 0 1 Access error
ment of job or execution
of job impossible
0 2 Error in job Incorrect compilation
Done Q BOOL Job successfully execut- of Var. in a job
ed
0 3 Negative ac- Internal error, try:
State Q WORD See error identifiers knowledgment, NC RESET
RD I/Q ANY P#Mm.n data to be read job not executa-
BYTE x... ble
P#DBnr.db 0 4 Data areas or Check data to be
xm.n data types do not read in RD
BYTE x tally
1 4 Insufficient local read variable is long-
user memory er than specified in
available RD
0 6 FIFO full Job must be repeat-
ed,
since queue is full
Notes

PLC Functions A033
State Meaning Note

In order to read a GUD value, the OEM must first generate
WORD H WORD L and activate the GUD file using the HMI function available in
the System explorer.
0 7 Option not set BP parameter
"NCKomm" is not set The name of the GUD name has to be parameterised as a
STRING variable to the function block, at parameter; Addr.
0 8 Incorrect target RD may not be local
If the GUD variable is an array, then the array index can be
area (SD) data
parameterised also.
0 9 Transmission Job must be repeated
occupied According to the description , field index refers to array index.
0 10 Error in address- Unit contains value 0
ing You can additionally use the parameters, to obtain the ad-
0 11 Address of varia-Address check (or vari- dress of the GUD for parameterisation with FB3 PUT
ble invalid able name), area, unit
CnvtToken Activate generation of a 10 byte variable token
1 ... 8 13 (0x0d) ANY data refer- String/NcVar data re- VarToken [DBName].[VarName] Address to a 10-byte token
ence incorrect quired has not been
parameterized
0 15 (0x0f) String more than GUD variable name
32 characters too long
Create and activate GUD file and variables Example reading GUD PLC Parameterisation
FUNCTION "Read_a_GUD" : VOID

TITLE =
A I 81.3;
S M 128.1;
A M 128.3;
R M 128.1;
CALL "GETGUD" , DB 134 (

Req := M 128.1,
Addr := DB121.GUD_GJ,
Area := B#16#0,
Unit := B#16#1,
Index1 := 2,
Syntax in order to generate an NCK GUD Array variable with Index2 := 0,
Error := M 128.2,
the name __GJ Done := M 128.3,
State := MW 129,
RD := MD 131);
END_FUNCTION
Notes

A033 PLC Functions
The variable in the NC viewed on HMI in settings. Starting ASUP
An ASUP (Asynchronous Subroutine) is an NC Subroutine

written normally by the OEM, this subroutine is started from
the automation system (PLC). If a user NC Program is cur-
rently active, it will be interrupted according to the parameter-
isation of the PLC user program.
The ASUP function is carried out in two steps:
1) ASUP Preparation
PI Service ASUP FB4
Only possible in NCK Reset State
2) ASUP Start
Parameterisation and call of FC9
Prerequisites for the Function: Steps to achieve running function:
ASUP available in the NC
Plus the parameter:

ORGANIZATION_BLOCK OB 100
NCKomm := True TITLE =
13.10.2010 16:56:20' }
The parameter belongs to FB1 which is VERSION : 1.0
BEGIN
NETWORK
HMI Requirement: TITLE =
None CALL FB 1 , DB 7 (
MCPNum := 1,
MCP1In := P#I 0.0,
Drive requirement (Sinamics): MCP1Out := P#Q 0.0,
None MCP1StatSend := P#Q 8.0,
MCP1BusAdr := 192,
NCK Requirement: NCKomm := TRUE); Option
ASUP available
PLC Requirement:
Parameterisation of FB4 and FC9 in the PLC
Notes

PLC Functions A033
Parameter description of FC9

Example of initialisation and call of ASUP
Signal Type Format Value Remark
range FUNCTION "ASUP_TEST" : VOID
TITLE =
VERSION : 0.1
Start I BOOL
ChanNo I INT 1 ... 10 No. of the NC channel BEGIN
NETWORK
IntNo I INT 1 ... 8 Interrupt No. TITLE =
Active Q BOOL 1 = Active
Done Q BOOL 1 = ASUP completed A I 81.4;
Error Q BOOL 1 = Interrupt switched FP M 135.0; // Transition Marker
S M 135.1;
off A M 135.3;
StartErr Q BOOL 1 = Interrupt number FP M 135.4; // Transition Marker
R M 135.1;
not assigned or delet- CALL "PI_SERV" , DB 135 (
ed Req := M 135.1,
Ref I/Q WORD Global 1 word per FC 9 (for PIService := "PI".ASUP,
Unit := 1,
variable internal use) Addr1 := DB121.Path,
(MW, Addr2 := DB121.PName,
DBW,..) WVar1 := W#16#1,
WVar2 := W#16#1,
Prior to calling FC9, the ASUP has to be initialised with the WVar3 := W#16#0,
WVar4 := W#16#0,
PI service ASUP. Error := M 135.2,
The following example shows the initialisation and the call of Done := M 135.3,
the ASUP with FC9. State := MW 136);
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.
Content of PLC ASUP

Example of initialisation and call of ASUP
A I 81.5;
FP M 135.4;
S M 135.5;
A M 135.7;
FP M 135.6;
R M 135.5; The following NC Program block will be interrupted:
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); The Interruption can now be seen:
END_FUNCTION
Create ASUP in the Manufacturer directory.
Notes

A033 PLC Functions
Currently running program to be interrupted

Data Block used for STRING Data on various Function Block
calls.
ASUP Interruption Axis / Spindle control
With axis / spindle control it is possible to move an axis or a

spindle from the automation system.
The following is an example of what can be carried out with

the block:
Position spindle
Rotate spindle
Oscillate spindle
Indexing axes
Positioning axes
Notes

PLC Functions A033
Prerequisites for the Function: FUNCTION FC 114 : VOID

TITLE =
VERSION : 0.1
The axis has to be defined as a concurrent positioning axis in BEGIN
the NC machine data. MD30450 NETWORK
TITLE =
HMI Requirement: A I 81.6;
FP M 141.0;
None S M 141.1;
A M 141.3;
Drive requirement (Sinamics): FP M 141.4;
R M 141.1;
None R M 141.7;
A I 81.7;
NCK Requirement: FP M 141.6;
S M 141.7;
Concurrent positioning axis CALL "SpinCtrl" (
Start := M 141.1,
PLC Requirement: Stop := M 141.7,
Parameterisation of the FC18 in the PLC Funct := B#16#5,
Mode := B#16#1,
AxisNo := 1,
Steps to achieve running function: Pos := 5.000000e+003,
Parameterisation of FC18 FRate := 1.000000e+005,
InPos := M 141.3,
Error := M 141.5,
State := MB 142);
END_FUNCTION

Parameter description of FC18 values
Mode I BYTE 0 to 5 0: Pos to absolute pos
Signal Type Format Range of Remark 1: Pos incrementally
values 2: Pos shortest path
Start I BOOL Start spindle control from PLC 3: Pos absolute, positive ap-
Stop I BOOL Stop spindle control from PLC proach direction
4: Pos absolute, negative
Funct I BYTE 1 to B#16#0B 1: Position spindle approach direction
2: Rotate spindle 5: Rotational direction as for
3: Oscillate spindle M4
4: Indexing axis
AxisNo I INT 1 - 31 No. of axis/spindle to be trav-
5: Positioning axis metric ersed
6: Positioning axis inch
7: PosAxis metric with hand- Pos I REAL 0,1469368 I -38 Rotary axis: Degrees
wheel override to Indexing axis: Indexing posi-
8: PosAxis inch with hand- 0,1701412 I tion
wheel override +39 Linear axis: mm or inches
9: Rotate spindle with FRate I REAL 0,1469368 I -38 Rotary axis and spindle: rev/
automatic gear stage selec- to min
tion 0,1701412 I See under table containing
A: Rotate spindle with con- +39 info about FRate
stant cutting rate (m/min) InPos Q BOOL 1 = Position reached,
B: Rotate spindle with con- or function executed
stant cutting rate (feet/min)
Error Q BOOL 1 = error
State Q BYTE 0 to 255 Error code
Notes

A033 END PLC Functions
Reference material
Data Block content for examples: DB121
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 stop-
pages.
Alarms/messages are sub-divided into the following ranges:

 NCK
 HMI
 SINAMICS
 PLC
Module Objective:
Upon completion of this module you will understand the alarm and message structure of the 840D sl
system.
Content:
Sinumerik
NCK Alarms and Messages Structure
Alarm Display Description
Alarm Acknowledgement
Alarm Log
Suppress Alarm Function
A037
A037

Alarm Structure A037
NCK Alarms and

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

Messages:
END
Notes

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

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

of the controller display.
More than Brief alarm description.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Write mode file: Time controlled:

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

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

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

A037: END
Notes

A037 END Alarm Structure

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

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

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

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

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

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

ed offline.
Alarm/message details.
Notes

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

alarms .
Indication that Alarm/

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

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

Alarm/ The file name is:

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

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

NCU: SystemCF card\oem\sinumerik\hmi\lng
PCU50: C:\ProgramData\Siemens\MotionControl\
oem\sinumerik\hmi\lng
NCU: Location of the alarm text file. PCU: Location of the alarm text file.
Notes

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

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

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

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

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

Following is an Example assuming the parameter

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

Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
Byte
510231 510230 510229 510228 510227 510226 510225 510224
9
DB2 Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 Read-in disable-Operator message (OM)
510307 510306 510305 510304 510303 510302 510301 510300

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

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

183 700031 700030 700029 700028 700027 700026 700025 700024
147 600215 600214 600213 600212 600211 600210 600209 600208

184 700039 700038 700037 700036 700035 700034 700033 700032
148 600307 600306 600305 600304 600303 600302 600301 600300
Feed stop/spindle stop for axis/spindle 3 185 700047 700046 700045 700044 700043 700042 700041 700040
149 600315 600314 600313 600312 600311 600310 600309 600308 186 700055 700054 700053 700052 700051 700050 700049 700048
150 600407 600406 600405 600404 600403 600402 600401 600400

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

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

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

and FC10 parameter ToUserIF True and False
cancel alarm display

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

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

and FC910 parameter ToUserIF True and False
Without Alarm no
display
CALL FC10
ToUserIF := True
Quit : = I 3.7
FC35 - Alarm Block
A I 88.4
= DB2.DBX0.0 Feed hold effect
without alarm
A I 88.5 Interface signal to
= DB2.DBX1.0 Feed hold effect NCK
ToUserIF := True
without alarm
Group Signal Trans-
fer
Feed Hold
ToUserIF := False
No Signal Transfer Controlled directly from
CALL FC10 customer PLC when
ToUserIF := False ToUserIF:= False
Quit : = I 3.7
With alarm no dis-
play
CALL FC10
ToUserIF := True
Quit : = I 3.7
FC35 - Alarm Block
A I 88.6
= DB2.DBX310.0 Error Message
A I 88.7
= DB2.DBX311.0 Operator Message Interface signal to
ToUserIF := True NCK
Group Signal Trans-
fer
Feed Hold
ToUserIF := False
No Signal Transfer Controlled directly from
CALL FC10 customer PLC when
ToUserIF := False ToUserIF:= False
Quit : = I 3.7
Notes

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

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

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

User Help Files
To further enhance the fault finding procedure it is possible to create a “Help” file.
When the HELP key is pressed the details of the selected alarm will be displayed on the screen.
Help file information and Rules:

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

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

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

Information/more tags entered here etc.
</html> Closing the “html” tag
Table of Common HTML Tags:
TAG Description
html Root element-Main tag for the help file, contains all other tags, first to be opened and
last to be closed.
head Contains document information, opened immediately after the HTML tag, closed
directly before the BODY tag is opened.
body The main body of the HTML document, determines what will be displayed on the
screen. Opened immediately after the closing the HEAD tag. Closed immediately
before the HTML tag.
table Creates a table for the help file information.
tr Table row, creates a row within the table.
td Table data cell. Used within the tr tag, contains the text that is to be displayed on the
help screen. The tag is used with the width attribute to determine the width of the cell
and the valign attribute to align the text within a cell.
p Used to begin a new paragraph.
b Text will be written in bold type.
i Text will be written in italic type.
br Starts a new line.
Notes

Example help file

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

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

The system is able to cross reference the highlighted alarm with the entry within the “a” tag.
<td width="15%"><a name="700000">700000</a></td>
When an alarm is selected and the help key is pressed the system uses the anchor to locate and display the correct table contents
for the selected alarm.
Adding further alarms to the HTML file is simply a case of copying/pasting the existing “table” tag and its contents and editing to suit
the individual alarm.
The contents of the “head” tag should not be changed. This determines the content type and text format.
Notes

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

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

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

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

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

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

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

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

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

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

A031 END PLC Alarms and Messages
A031: END

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

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

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

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

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

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

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

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

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

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

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

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

System Variables The types of variable available for selection are:

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

A103 Service Used Cases
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 equip-
ment with the tools already integrated in the system. In certain cases, a PG with STEP 7 software
and a suitable connecting cable 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 rectifica-
tion.
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

Service Used Cases A103
Service Used Cases:

START Diagnostics
and replace-
ment of an
SMC module
Diagnostics
of the opera-
ting panel
Replacement
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
exchange of
two SMC
modules
Diagnostics
of the line
module
Replacement of
a motor module
with greater
power
Diagnostics
of the PLC
module
Service Used Cases:
END
Diagnostics
of the safety
modules
Diagnostics
and replace-
ment of an
NX module
Notes

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

connector
Off Off On OK Screen defective
On Off On OK
Notes

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
PCU50.3/.5: Diagnostic LEDs and 7-Segment Displays LED LED H1 H2 Status

H1 H2 Dis- Dis-
play play
The diagnostics displays of the PCU50.x consist of 2 x LEDs
and 2 x 7 segment displays. Orange Orange Output of After switch on
BIOS post
codes
Orange Off After cycling the BIOS
H1 H2
LED and Orange Off After starting Windows
LED and
7-segment 7-segment 1 0 Start Load device
display display Windows drivers needed
for Windows
2 0 PCU PCU hardware
hardware service has
H1: Assigned to the PCU basic software. Displays status service been started
codes for system booting and shutdown. 5 0 Network Wait for net-
work interfac-
H2: Assigned to the application software. es
Status codes during system power up. 8 0 TCU Wait for FTP
support server to start
test step 1
9 0 TCU Wait for TCU
support network boot
test step 2 and TCU
hardware ser-
vice to start
Notes

Status codes during system power up, continued. Status codes during operation.
LED LED H1 H2 Status LED LED H1 H2 Status

H1 H2 Dis- Dis- H1 H2 Display Display
play play
Flashing 0 0 OK
A 0 TCU Wait for VNC green
support test server to start
step 3 Flashing Error: See below
red
B 0 HMI Wait for HMI 1 0 Temperature Housing or
manager manager to alarm CPU over
start temperature
E 0 PCU General fault: 2 0 Fan alarm Housing or
Base see Windows CPU fan, low
software “Event viewer” speed or
failure
Status codes during shutdown. 3 0 Hard disk S.M.A.R.T*
alarm hard disk
LED LED H1 H2 Status error
H1 H2 Dis- Dis-
play play 6 0 VNC server
failure, or
Flashing 5 0 Shutdown active stop VNC
red/ service
green
In order to maintain the higher level of system availability, we Fan

recommend the preventive replacement of PC components Fans are components subject to wear. The fan speed is moni-
that are subject to wear in accordance with the replacement tored and an alarm issued at failure.
intervals listed in the following table. The main cause of failure for fans is pollution. The first criterion
for replacement should be a visual inspection. If the fan is very
dirty, it should be replaced. In the field, a replacement interval
Component Replacement interval of 5-7 years has proven itself under average industrial condi-
tions.
Electronic SSD drive > 5 years
Back-up battery
Fan 5-7 years Batteries are components subject to wear. They should be
changed every 5 years in order to guarantee the long-term
CMOS back-up battery 4/5 years functionality of the device. If a plug-in PCI card is also supplied
from the battery (centralized battery concept), the preventive
replacement is reduced to 4 years.
SSD
In industrial environments, it can be assumed that the service
life is longer then conventional mechanical hard disks, and ac-
cording to present knowledge, is > 5 years.
The write load is a factor that has a significant effect on the
total service life.
Notes

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 correct-

ly and is the 7-segment dis-
play at 6
 Check the Ethernet connec-

tion
 Is the HMI on the NCU

switched on
Diagnostics of the machine control panel
Machine control panel (Ethernet) flashes or is dark
Notes

Select about the following key sequence the TCP/IP diagnostics.
Putting the cursor on the disturbed X machine control panel
This shows green joists the act. OP, the red

joists the cursor position.
Additional nodes about selecting.
All additional nodes of the system network

NCU X120 are reported!
Notes

DIP switch on machine control panel
The Aliasname (for the DNS-Server)that is set can be read at DIP switch S2.
The alias (number) must be adjusted here, with the DHCP servers allocates the IP- address.
Example: Aliasname = 192
1 1 = off
2 2 = off
4 3 = off
8 4 = off
16 5 = off
32 6 = off
64 7 = on
128 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

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

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

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

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 X122.14 to the probe connected correctly?
 Is the power supply from X122.13 to the probe connected correctly?
If there should be a signal change here, check the hardware configuration in STEP 7.
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 system.
Notes

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

Check of the defective module in the topology overview
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

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

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 PB/PN diagnostics.
Notes

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)
Replacement of the hard-

ware
Only a hardware replace-

ment is required. After
switching on, the controller
boots without error messag-
es and you can continue
working with the machine.
Note: Modules displayed in gray are modules that are missing in the actual topology.
The module is connected to the NCU DRIVE-CLiQ connection X105.
Notes

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
Note: Modules displayed in grey are modules that are missing in the actual topology.
In this example, this means that the SMC module of the C axis connected to the motor module of the C4 axis has failed.
The module is connected to the motor module DRIVE-CLiQ connection X202.
Notes

Replacement of the hardware
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

Confirm with “OK”.
Then confirm again with “OK” and switch the machine OFF/ON.
Notes

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

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

Details in drive system
Alarms and faults in drive system
Notes

Notes

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

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

Replacement of the hardware
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 ac-
ceptance report. The replacement of the components must also be documented in this report.
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:
Notes

Now press the “Confirm SI HW” softkey.
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.
Notes

Replacement of a motor module with greater power
After replacement of the motor module, following error message (201420) appears, but only if the comparison stage is set „High“.
Notes

Performing acceptance of the new motor module is only possible manually in the relevant Control Unit and drive
parameters.
Prerequisites:
● Replaced Power Module has different power.
● Vector: Power of Motor Modules / Power Modules not greater than four times of motor current.
Action Reaction Comment
 Switch off power supply

 Replacement of defective components and
correct reconnection.
 Switch on power supply. Alarm 201420
 Drive Object CU: With p9906 = 2: Attention, for all topology

– p0009 = 1 Device configuration components monitoring is strongly reduced.
– p9906 = 2 Component comparison An inadvertent reconnection of DriveCLiQ
– p0009 = 0 Finish configuration connections might be overlooked.
– p0977 = 1 Data backup
 Drive-Object Component: The new code number is in the main memory

– p0201 = r0200 Accept code number of the Control Unit . It has to be written to
– p0010 = 0 Completion of commissioning the permanent memory with p0977 = 1 and
– p0971 = 1 Data backup p0971 = 1 .
Set p0009 = 1
Notes

Set p9906 = 2
Data backup with p0977 = 1
Notes

Comparison of code numbers,

r200 und p201 should be identi-
cal.
Save drive data with p0971 = 1.
A103: END
Notes

A103 END Service Used Cases

A011 Run MyScreens
Sinumerik
Operate
Module Description:
Run MyScreens is a function of the Sinumerik 840D sl which allows the manufacturer to write cus-
tom screens.
The screens are intended as an interface to the specific functions offered by the OEM.
Module Objective:
Upon completion of this module the course participant will be able to create Run MyScreens dis-
play screens.
Content:
Sinumerik
General Information
Basic Configuration Information
Creating Run MyScreens User Files
Language Dependent Texts
Parameters and Variable Description
A011
A011

Run MyScreens A011
Run MyScreens:
START
General
Information
Basic
Configuration
Information
Creating
Run MyScreens
User Files
Language
Dependant
Texts
Parameters
and
Variable
Descriptions
Run MyScreens:
END
Notes

A011 Run MyScreens
General Information
The Run MyScreens function is configured using ASCII files. These files contain the descriptions of the user interface.
As standard, up to 5 screens can be configured. Further screens are available via a licensed option Sinumerik Integrate Run
MyScreens, order No: 6FC5800-0AP64-0YB0.
In order to create images for the screens, a graphic programme is required, e.g. Paint Shop Pro® and Paint® are programmes
which are compatible with the 840D sl controller.
Run MyScreens can be used for the following functions:

1. Display of dialogs and provision of:
 Soft-keys
 Variables tables (this function will be available with a later level of implementation)
 Text and help text
 Graphic displays and help displays
2. Calling up dialogs by means of:

 The (entry) soft-keys
 PLC selection
3. Dynamic re-structuring of dialogs:

 Changing or deleting soft-keys
 Defining and designing variable fields
 Showing, replacing and deleting (language-dependent/independent) display texts
 Showing, replacing and deleting display texts (language dependent/individual)
4. Initiating actions when:

 Showing dialogs
 Entering values (variables)
 Pressing soft-keys
 Closing dialogues
5.. Exchange of data between dialogs.
6. Variables
 Reading (NC, PLC, user variables)
 Writing (NC, PLC, user variables)
 Linking with mathematical, comparative or logic
operators
7. Executing functions:
 Subroutines
 File functions
 PI Services
8. Taking into account levels of protection defined for use groups.
Notes

Run MyScreens A011
Basic Configuration Information
Configuration files are used to create the screens.

These configuration files are automatically interpreted by the
controller.
The files are not available as standard and have to be creat-
ed by the user using an ASCII editor (e.g. Notepad® or di-
rectly on the controller).
The “easyscreen.ini“ file is a master file which is required to

specify which other files are to be used to create a user
screen.
These files contain the information which determine what is
displayed on a particular screen.
The screen is split into different areas:
1 Main dialog area

2 Title bar containing screen name (Left) and
“Long text” description of the selected
variable (Right)
3 Variable input/output field
4 Variable name “Short text”
5 Graphics related text
6 Unit text
Operating areas overview To enable custom screens in other area of the controller, the
“easyscreen.ini” file has to be modified.
Operating area Permissible position for start soft-keys
There are eight areas in total:-
Machine JOG HSK6
Machine Area-Sub divided into:-
Machine MDA HSK6 Jog
MDA
Machine AUTO HSK6 Auto
Parameter HSK7
Parameter Area
Program HSK6
Program Edit Area
Program-Manager HSK2-8, 12-16, if not used for networked
drives Program Manager Area
Diagnostics HSK7 Diagnosis Area

Commissioning HSK7 Start-up Area
Notes

A011 Run MyScreens
Example of how all the areas are specified within the “easyscreen.ini” file:-
The three Machine Areas are specified by the “Menu” entry.

SlMaJogMillMenuHU, SlMaJogTurnMenuHU = Jog screen
SlMaAutoMenuHU = Auto screen
SlMaMdaMenuHU = MDA screen
Each area should have a “com” file specified.
[STARTFILES]
StartFile01 = area := AreaMachine, dialog := SlMachine, menu := SlMaJogMillMenuHU, startfile := ma_jog.com
StartFile02 = area := AreaMachine, dialog := SlMachine, menu := SlMaAutoMenuHU, startfile := ma_auto.com
StartFile03 = area := AreaMachine, dialog := SlMachine, menu := SlMaMdaMenuHU, startfile := ma_mda.com
StartFile04 = area := AreaParameter, dialog := SlParameter, startfile := param.com
StartFile05 = area := AreaProgramEdit, dialog := SlProgramEdit, startfile := aeditor.com
StartFile06 = area := AreaProgramManager, dialog := SlPmDialog, startfile := progman.com
StartFile07 = area := AreaDiagnosis, dialog :=SlDgDialog, startfile := diag.com
StartFile08 = area := AreaStartup, dialog :=SlSuDialog, startfile := startup.com
Creating Run MyScreens User Files Creating the “easyscreen.ini” file on the controller
The files required for the Run MyScreens function need to be This file sets up the links to the files which are to be used to
created. This can be done directly on the controller by navi- create the user screens, it also determine which operating
gating to the relevant folders. Use the following key sequence areas these files are available in. The file has to be located in
to locate the “System data” area. any of the following paths/directories:-
“System CF card\oem\sinumerik\hmi\cfg”
“System CF card\user\sinumerik\hmi\cfg”
Use the cursor keys to locate and open this directory.
Notes

Run MyScreens A011
To create the file select the “New” soft-key and ensure that the “Any” soft-key is selected.
The “Any” soft-key allows the file type to be determined by the user. In the dialogue box type in the name of the file and confirm
with the “OK” soft-key.
The file name must be in lowercase due to the LINUX operating system.
The newly created file will be automatically opened in preparation for editing.
Example: easyscreen.ini file

The following example will show how the “easyscreen.ini” file is used to specify the “Parameter” area of the controller as the area
from where the “Run MyScreens” are to be accessed.
(area := Area Parameter)
The “com” file, the content of which will determine what appears on the Run MyScreens screens, is also declared here.
(startfile := param.com)
The first step is to enter the header ([STARTFILES])

The code for specifying the controller area and “com” file is then entered on a new line as shown below.
[STARTFILES]
StartFile01 = area := AreaParameter, dialog := SlParameter, startfile := param.com
Creating the User Files on an external PC
As mentioned previously it is possible to create the Run MyScreens files directly on the controller or offline using an ASCII editor
(e.g. Notepad®).
These files have to be transferred to the controller and placed in the correct folders using the USB/CF Interfaces or with Ac-
cess MyMachine software.
Below: The easyscreen.ini file located in the cfg directory
Notes

A011 Run MyScreens
Creating the “param.com” file Below: The param.com file located in the proj directory.
The param.com file has been declared in the “easyscreen.ini”

file and now needs to be created.
Code contained within the param.com file is used to create

soft keys and display texts and graphics etc.
The file needs to be created and placed in one of the following

folders:
“System CF card\oem\sinumerik\hmi\proj”
“System CF card\user\sinumerik\hmi\proj”
Example: param.com file Storage path for the image files:

“System CF card\oem\sinumerik\hmi\ico\ico640”
It is necessary to specify a soft-key to be used as the entry “System CF card\user\sinumerik\hmi\ico\ico640”
point to the Run MyScreens.
Further soft-keys can be assigned within the Run MyScreens if To see the results of the example we have to locate the
required. “parameter” area of the control.
The example defines the 7th horizontal soft-key as the entry

point, the soft-key will have the text “Run MyScreens” (on 2
lines).
HS7=("Run %nMyScreens")
When the soft-key is pressed a Mask (mask1) will be loaded: The 7th horizontal soft-key contains the text specified in the
PRESS(HS7) “param.com” file: HS7=("Run %nMyScreens").
LM("mask1")
END_PRESS
//END
The Mask contains the code which determines the content of

the Run MyScreens.
The first line of the mask (Mask header) contains the mask
name, text and graphic information.
The following example shows mask1 with the title of Picture

Test. An image named tiger.bmp, will be displayed when HS7 is
pressed. The image will be positioned 110 pixels from the left
and 25 pixels from the top of the screen.
//M(mask1/ "Picture Test" / "tiger.bmp" / / / 110, 25)
Notes

Run MyScreens A011
Screen title/name tiger.bmp image
Mask header information: Parameter Description
The various parameters are separated by the “Forward slash” Graphic The position of the graphic in pixels. Distances
character (/). Position Position are from the left and top of the dialogue
screen and are separated by a comma.
//M(Identifier/header/Graphic/Dimension/Variable/Graphic Attributes CM (Column Mode) Column alignment.
position/Attributes)
CM0: Default, the column distribution is carried
Parameter descriptions: out separately for each line.
CM1: The column distribution is of the ling with

the most columns applies to all lines.
Parameter Description
CB: (Change Block) Response when the dialogue
Identifier Label of dialogue/mask.
is opened. The CB attribute can also be used on
Header Name of the screen. individual variables, in this case the individual
setting has priority over the CB setting in the
Graphics Name of image to be displayed. Mask Header.
Dimension Position and size of the dialogue. (Distance from CB0: All change blocks associated with the dia-
the left hand side, right hand side, width, height) logue are processed when it is opened.
Values in pixels and separated by commas
Variable The cursor can be assigned to a variable. The CB1: Change blocks are only processed if the
first variable has an index of 1, the remaining relevant value changes.
variables are indexed in the order that they were
configured.
Notes

A011 Run MyScreens
Adding Dialogue Elements: //S(START)
Dialogue Elements refer to long and short texts, graphics texts, HS7=("Run %nMyScreens")
unit texts and I/O fields. Additional soft-keys can also be added. PRESS(HS7)
LM("mask1")
The dialogue elements are added below the mask header. END_PRESS
//END
In the following example (Shown in red text) a soft-key with the
label “Variable Test” is added. When the soft-key is pressed the //M(mask1/"Picture Test"/"tiger.bmp"///110,25)
screen will display a list of four variables. The four variables are
defined under a new mask (mask2-Workpiece Dimensions). HS1=("Variable %nTest")
PRESS(HS1)
The parameters of the variables defined in mask2 are separated LM("mask2")
by the forward slash character (/). END_PRESS
//END
A detailed description of the Dialogue Element parameters can
be found in chapter ”Parameters and Variable Descriptions”. //M(mask2/"Workpiece Dimensions"/)
Def Var1=(R2///"Length of component","R0 X Length"///"$R[0]")
Def Var2=(R2///"Width of component","R1 Y Width"///"$R[1]")
Def Var3=(R3///"Height of component","R2 Z Height"///"$R[2]")
Def Var4=(I///"Main spindle speed","R3 Spindle speed"///"$R[3]")
VS8=("EXIT")
PRESS(VS8)
EXIT
END_PRESS
//END
The additional soft-key can now be seen. Screen title/name Long text of the selected variable.
Short text Input field
Values entered in the input field will be transferred to relevant

When the soft-key is pressed the defined variable will be dis-
variable.
played.
Notes

Run MyScreens A011
Detailed Analysis: Def Var1=(R2///"Length of component","R0 X Length"///"$R[0]")

R parameter 0 as a real number to 2 decimal places, sets the
//M(Mask1/"Workpiece Dimensions") Name of Mask1: component length:
HS1=("Variable %nTest") Determines the text for horizontal

soft-key 1 as “Variable Test”:
Def Var2=(R2///"Width of component","R1 Y Width"///"$R[1]")

R parameter 1 as a real number to 2 decimal places, sets the
When the soft-key is pressed mask2 will be loaded. component width:
PRESS(HS1)
LM("mask2")
END_PRESS
Def Var3=(R3///"Height of component","R2 Z Height"///"$R[2]") VS8=("EXIT") Determines the text for vertical soft-key 8 as
R parameter 2 as a real number to 3 decimal places, sets the “EXIT”:
component height:
Checking the entered values
Values can be entered directly on the custom screen. These

values are transferred directly to the variables.
They can be checked by viewing the variables on the standard
screen by pressing the “User variable” soft-key.
Def Var4=(I///"Main spindle speed","R3 Spindle speed"///"$R[3]")
R parameter 3 as an integer, sets the spindle speed:
Notes

A011 Run MyScreens
Language Dependant Texts Example Text File:

It is possible to configure the Run MyScreens configuration ;VERSION:SLP.02.05.QJM Otc 16, 2010
files so that the Run MyScreens language matches that of ;CHANGE :SLP.02.04.QJM Jun 30, 2010
the system.
In order to do this it is necessary to create one text file for 85100 0 0 "English%nMyScreens"
each required language. 85101 0 0 "English Mask Header"
The text that is to be displayed is contained within the text 85102 0 0 "English Long Text"
files. 85103 0 0 "English Short Text"
The Run MyScreens configuration files use identifiers to en-
sure that the correct text is displayed.
The files containing the text can be placed in the following

locations: Identifier Not used Required text
“System CF card\oem\sinumerik\hmi\lng” Allowable range of identifiers 85000 to 89899

“System CF card\user\sinumerik\hmi\lng”
“System CF card\addon\sinumerik\hmi\lng” Part of the file name can be assigned by the user but must
also contain the correct 3 letter language coding. This is so
that the system can display the contents of the correct file.
Filename Examples: The files for English and German can be seen located in the
OEM area.
easyscr_eng.txt English filename example
easyscr_deu.txt German filename example
User part File

of extension
filename
Language
coding
Example of a second text file for the German language
85100 0 0 "Deutsch%nMyScreens" The identifier is used in place of the text in the param.com file.
85101 0 0 "Deutsch Mask Header" The identifier has to be prefixed by the $ symbol.
85102 0 0 "Deutsch Long Text" The text associated with the identifier will be displayed.
85103 0 0 "Deutsch Short Text"
Notes

Run MyScreens A011
Example param.com file for language dependent text. The language file needs to be declared in the “easyscreen.ini”
file. No language coding is required.
//S(START) Declarations of other text files may also be present.
HS7=($85100)
PRESS(HS7) ;VERSION:SLP.02.01.H56 Nov 10, 2009

LM("mask1") ;CHANGE :
END_PRESS
//END [STARTFILES]
//M(mask1/$85101/"tiger.bmp"///110,25) StartFile04 = area := AreaParameter, dialog := SlParameter,

HS1=("Variable %nTest") startfile := param.com
PRESS(HS1)
LM("mask2") [LANGUAGEFILES]
END_PRESS LngFile01 = almc.txt
//END LngFile02 = alsc.txt
LngFile03 = aluc.txt
//M(mask2/"Workpiece Dimensions"/) LngFile04 = easyscr.txt
Def Var1=(R2///$85102, $85103///"$R[0]") [SYSTEM]

System = 0
VS8=("EXIT")
PRESS(VS8)
EXIT
END_PRESS
//END
Setting the controller language: When using the examples shown earlier it can be seen that the
text displays change with the selected language.
The controller language is selected via the “Start-up” menu.
Or
English long and short texts:
German long and short texts:
Notes

A011 Run MyScreens
Parameters and Variables Descriptions Detailed description:
When a variable is assigned certain properties can be set. 1. Variable type

These properties are contained rounded brackets, each proper- R[x] Real number, “x” indicates the number of decimal
ty is separated by a forward slash (/) places displayed
If a property is not used, the slash still needs to be present. I Integer.
S[x] String,”x” indicates the string length.
Basic description: C Character (Individual character)
B Boolean number
DEF Var1=(1/2/3/4/5/6/7/8/9/10) V Variant type
1. Variable type 2a. Limit values-

2. Limit values, toggle field or table identifier A minimum and a maximum value can be specified. The values
3. Default are separated by a comma, the minimum value is specified first.
4. Texts Values can be in I, C and R decimal formats or as characters in
5. Attributes the format “A” , “F”
6. Help display The limit value also works in conjunction with the limit attrib-
7. System or user variable ute, see the attribute property for more information.
8. Position of short text
9. Position of I/O field (Left, top, width, height) 2b. Toggle field-
10. Colours Creates a list of predefined entries in the I/O field. The list is
initiated by the “*” character.
The entries can be assigned a value.
The Limit value is interpreted as a list for the Toggle field.
If only a “*” is used, a variable Toggle field is generated.
2c. Table Identifiers- 5. Attributes-

Identifiers can be assigned to tables containing NCK/PLC val- The following properties can be influenced by the attributes
ues of the same type. The “%” character is used to differentiate  Input mode
an identifier from a toggle field or limit value.
 Access level
A comma is required after the identifier, the file name containing
the table information is then typed.  Alignment of short text
 Font size
3. Default setting-  Handling limit values
The value in the assigned variable can take on various states.  Response when screen is opened (Change block)
This depends on whether a default value, system or user varia-
ble (Or both) has been assigned to the variable field (I/O or tog- The attributes are separated by commas, and are not valid for
gle field) toggle fields.
Toggling is not possible until a valid value is assigned to the
variable. Input mode:-
Attribute Effect
4. Texts- wr0 I/O field invisible, short text visible.
Text possibilities are- wr1 Read only, no inputting of data, short text visible.
 Long text = text displayed when each element is high- (Default setting)
lighted. wr2 Read & write possible, long and short text visible.
 Short text = name of the element wr3 As with wr1 but with I/O field visible, long and short
 Graphics text = text relating to the graphics, if used. text visible.
wr4 All elements invisible.
 Unit text = unit of the variable e.g. mm, rpm etc
wr5 As wr2 except entries are immediately active.
with wr2 the entry becomes active exiting the field
The texts types are separated by commas and need enclosing
or pressing enter/input/return.
in speech marks:- /”Long”, “Short”, “Graphics”, “Unit”/
Notes

Run MyScreens A011
Access level:- Limits:

Attribute Level Password/Key position Checking whether the value of the variable is within the limits
ac7 7 Not released specified by the limit values.
ac6 6 SUNRISE Attribute Effect
ac5 5 EVENING li0 No check.
ac4 4 CUSTOMER li1 Check with respect to minimum
ac3 3 Key switch pos 3 li2 Check with respect to maximum.
ac2 2 Key switch pos 2 li3 Check with respect to minimum and maximum.
ac1 1 Key switch pos 1
ac0 0 Key switch pos 0
Behaviour when opening (Change block):
Alignment of short text:-
Attribute Effect
Attribute Effect
cb0 The change block defined for this variable is
al0 Left justified (Default)
processed when the screen opens (Default).
al1 Right justified
cb1 The change block defined for this variable is
al2 Centred
processed if there is a change in the value of the
variables.
Font size:
Attribute Effect
The “cb” attributes, specified in the variables definition, take
fs1 8pt. font size (Default)
precedence over the globally specified attributes in the “screen
fs2 16pt font size
form” definition.
The clearance between lines is defined. The default font size
allows 16 lines. The graphics and unit text can only be 6. Help Display-
configured in the default font size.
The name of the HTML file containing the help text needs to be
typed in speech marks. The display appears automatically if the
cursor is positioned on the variable.
Notes

A011 Run MyScreens
7. System or user variables- PLC Data Syntax
The variable to be viewed is entered here, these have to be Byte y of bit z of data block x DBx.DBXy.z
contained within speech marks. The variable must be
addressed in the correct way. Byte y of data block x DBx.DBBy
Word y of data block x DBx.DBWy

Addressing Variables:
Double word y v. of data block x DBx.DBDy
Machine Data Syntax String y with length z from data block x DBx.DBSy.z
Global machine data $MN_... Real y of data block x DBx.DBRy
Axis specific machine data $MA_... Flag byte x bit y Mx.y
Channel specific machine data $MC_... Flag byte x MBx
Flag word x MWx

Setting Data Syntax
Flag double word x MDx
Global setting data $SN_...
Input byte x bit y IBx.y
Axis specific setting data $SA_...
Channel specific setting data $SC_...
System variable Syntax
R parameter 1 $R[1]
PLC Data Syntax 8. Position of short text
Input byte x IBx The Short Text defined in attribute No.4 is positioned using
parameter No.8.
Input word x IWx The measurements are in pixels and relate to the top left
corner of the main dialogue body.
Input double word x IDx
Three values can be entered to define the position from the left,
Output byte x bit y QBx.y
the position from the top and the width of the short text.
Output byte x QBx Each entry has to be separated by a comma.
Output word x QWx The following example would position the text “Short text” 200
pixels from the left and 100 pixels from the top with a width of
Output double word QDx 250 pixels:
Def Var1=(R2///" ","Short text"///"$R[0]"/200, 100, 250//)

Soft-key Status Syntax
Visible (Default) Se1
Disabled (Grey text) Se2
Displayed(Last soft-key used) Se3
Notes

Run MyScreens A011
9. Position of I/O field 1. Colours
The I/O field can be positioned and sized using parameter The foreground and background colours of the I/O field can be
No.9. chosen by using parameter No.10.
The measurements are in pixels and relate to the top left The default colours are foreground: Black, background: White.
corner of the main dialogue body. These are determined by the “Write mode” (See parameter 5)
The following table shows index numbers to be used to achieve

Four values can be entered to define the position from the left, the required colour.
the position from the top and the width and height of the I/O The foreground colour is defined first, followed by a comma then
field. the background colour:
Each entry has to be separated by a comma.
The following example would position the I/O field for the Index Colour
defined variable, 600 pixels from the left and 100 pixels from
the top with a width of 100 pixels and a height of 150 pixels: 1 Black
2 Red/brown
Def Var1=(R2///" "," "///"$R[0]"//600, 400, 100, 150/) 3 Dark green
4 Light grey
5 Dark grey
6 Blue
7 Red
8 Brown
9 Yellow
10 White
A011: END
Notes

A011 END Run MyScreens

A016 Additional Axis Installation
Sinumerik
Operate
Module Description:
A common requirement is for a standard machine to be fitted with an additional axis.

This requirement usually arises after the machine has left the factory.
This module describes the procedure for adding an additional axis to a 3 axis + spindle milling ma-
chine while keeping the original settings intact and takes the form of a running example.
Module Objective:
Upon completion of this module you will be able to retrofit an axis to a running system.
Content:
Sinumerik
Options and Licensing
Adding the Additional Axis
A016
A016

Additional Axis Installation A016
Additional Axis
Installation:
START
Options and
Licensing
Adding the
Additional
Axis
Additional Axis
Installation:
END
Notes

Options and licensing
Any additional axes may need to be licensed to check whether

the licence already exists go to the licence screen:
The new axis can also be named accordingly.
It may be necessary to obtain a new licence if the current one

does not allow further axis expansion.
To activate the machine data a “Reset (po)” procedure is re-

quired.
The new axis also needs to be added in the channel machine

data area.
Configuring the Additional Axis The axes have been assigned to the drives in the following
way:
To replicate a standard 3 axes + spindle milling machine, the
drive configuration has been changed so that the only the X axis Double motor module 1, 1st drive.
double axis modules are used. Y axis Double motor module 1, 2nd drive
The single axis module that was previously used for the spin- Z axis Double motor module 2, 1st drive.
dle will now become the additional axis. Spindle Double motor module 2, 2nd drive.
The 3 axis + spindle DriveCLiQ configuration can be seen
below: When the new hardware is connected and powered reapplied,
the system will detect the new hardware and issue an alarm.
In order to keep the original Sinamics drive settings (Bico’s)

intact, the topology recognition process for the drives should
not be carried out. This action will reset the Bico’s to factory
status.
Instead, the function is available where the extra hardware
can be manually added.
Notes

When the new hardware is fitted and the controller powered The procedure is carried out using the Start-up Tool.
up, the system will detect the extra hardware and issue an
alarm. Run the Start-up tool:
Configuration with the additional axis can be seen below:
Ignore error 201416 which indicates that the system has

detected an additional component.
To add the new component use the following procedure:
The new hardware is displayed in red:
The new components and component numbers are displayed
Notes

The new drive has to be assigned to the correct NC axis
Select the new axis
Or
Select the axis from the “Setpoint” drop-down menu.
To complete the assignment an NCK power off/on is required.
The axis will automatically be selected for the “Actual value”.
Notes

The axis assignment function results in certain machine data

for the axis being set. This is normally enough for the axis to
be tested.
Testing will only be possible if the PLC interface signals for

the new axis are set.
Interface signals required for this example:
DB35.DBX1.5 Activate 1st measuring system

DB35.DBX2.1 Controller enable
DB35.DBX21.7 Pulse enable
A full list of interface signals is available in Appendix C.
Optimisation procedures should also be carried out on the

axis.
A016: END
Notes

A016 END Additional Axis Installation

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 com-
ponents.
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
Arrhenius’ Law
Choice of Cabinet
Cabinet Cooling
Equipment Mounting
Cables, plugs and sockets
Cabinet Sealing
Miscellaneous
A006
A006

Electrical Cabinet Design A006
Electrical Cabinet
Design:
START
Choosing a
Cabinet
Arrhenius’
Law
Cabinet
Cooling
Equipment
Mounting
Cables, plugs
and sockets
Cabinet
Sealing
Miscellaneous
Electrical Cabinet
Design:
END
Notes

Choosing a Cabinet A general rule is that the energy dissipated is approximately

50Watts/m² of free cabinet wall assuming a 10° temperature
Most of the heat within an electrical control cabinet is produced difference between the cabinet and the outside air.
by the drive components.
Example 1:- A cabinet with a width of 3 m, a height of 2 m and
Sinamics drives are available in internally or externally cooled a depth of 1 m sited with its back to a wall has an effective
variants. surface area of approximately 13 m².
The internally cooled drive types dissipate heat within the
cabinet and will usually require a cooling unit to remove this 2m x 3m = 6m² (Front)
heat. 2m x 1m = 2m² (left side)
The externally cooled drive types dissipate heat to the outside 2m x 1m = 2m² (Right side)
of the cabinet and may not require cooling units. 3m x 1m = 3m² (Top)
Total = 13m²
It may be preferable to always use cooler units as this allows
the cabinet to be sealed which is the best option for stopping Therefore this cabinet is able to dissipate approximately 650 W.
the entry of contaminants. Within the cabinets it may also be (50W x 13m²)
necessary to install fans to ensure the air is circulated and If the actual losses of the cabinet equipment are higher than
prevent “Hot spots” from forming. this, other cooling measures have to be implemented.
The technical specifications of the individual hardware compo- Example 2:-
nent will provide details of the power loss measured in Watts. Internally cooled 36Kw Active Line Module-Power loss = 630W
Calculations are made to see if the cabinet can dissipate the Internally cooled 18A Single Motor Module-Power loss = 165 W
heat naturally. Internally cooled 30A Single Motor Module-Power loss = 630 W
The cabinet manufacturer can supply details of the heat-loss of
the cabinet. These few items alone add up to 1425 W which would require
Natural heat dissipation occurs through the cabinet walls extra cooling if fitted into the cabinet described in example 1.
providing the wall is in free air and not against a wall for
example.
Cabinet Ambient Temperature
The ideal ambient temperature for the cabinet is 35°C.

The cooling unit should be set to achieve this temperature.
If the temperature is allowed to get too high the lifetime of the
components will be reduced.
If the temperature is set too low there is a risk of condensation
forming on the electronic components which can also be
detrimental to the equipment.
Notes

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 K 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

Cabinet Cooling
The inlets and outlets of the cooling units must have a
Cabinet cooling is usually accomplished using fans and filters clearance of at least 200mm.
or cooling units. Example:
≥ 200mm
The fans and filter option would normally be used on low pow- Roof mounted
er installations or where the drive units are of the cooling units
externally cooled type.
A drawback of this method is that the fans pull air from outside Outlet
the cabinet via filters. Even if the filters are serviced regularly it m
≥ 200mm 0m
is impossible to keep all contaminants out of the cabinet. 20
≥
t
le
le
In
In
Cooling units allow the cabinets to be air-tight as the air within Potential
the cabinet is re-circulated through the cooling unit. obstruction
A thermostat should be employed to regulate the temperature Electrical Electrical
cabinet cabinet
to the recommended 35°C.
If a higher temperature is unavoidable (max 50°C) the drive
units have to be de-regulated.
It is important to position the cabinet and cooling devices to

ensure correct operation.
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 use of baffles is recommended to prevent ventilation short
The cooling device should also be positioned to ensure the circuits where the exhaust air is taken directly into the cooling
cool air is reaching the desired areas and that the warm air is units.
extracted and not allowed to cause hot spots within the cabi-
net.
Cabinets with cooling units. Outlet Cooling

unit
Inlet
Correct installation of cooling units.
The cool air should be directed to the bottom of the drive. The
internal drive fans and natural convection will draw the air
through the drives.
The cool air from the cooling unit should not be directed
straight onto/into the drives, it should be allowed to mix with Ducting
the warmer air already in the cabinet, This will minimise the
risk of condensation forming.
Cabinet top mounted cooling units require a method of direct-

ing the cool air from the cooling unit to the bottom of the Drive
drives. equipment
In the case of a door mounted unit it may be necessary to

direct the cool air with the use of baffles.
Example of cabinet cooling with roof mounted cooling units:

Temperature
Measuring
point
Cabinet top mounted cooling unit.
Notes

Example of cabinet cooling with door mounted cooling units: 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
consideration when the cabinet thermostat is set.
Outlet
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 mount-
ed cooling units as any leaking water could drip directly onto
the drive equipment.
≥ 200mm Cooling
unit The outside of the cooling unit must be protected from any
Drive possible contamination such as coolant, machine waste etc.
equipment
Baffle
Temp.
Meas.
point Inlet
Cabinet door mounted cooling unit.
Outlet Cooling
Cabinet cooling sins. unit
Inlet
The following diagrams are examples of cabinet cooling sins:
Air short circuit due

to lack of ducting Cabinet top
mounted cooling
unit without
ducting
Drive
equipment
Notes

Cabinet cooling sins continued. Air short circuit/contamination

due to cabinet sealing problems
Air intake restricted due to
narrow gap between cooling
unit and drive equipment.
< 200mm
≥ 200mm
Drive
equipment Drive
equipment
Baffle
Temp.
Meas.
Cold air directed straight point
onto drive equipment will
cause condensation
problems. Air short circuit/
contamination due to cabi-
net sealing problems
Cold air outlet at the

top of the cooling
unit.
Drive
equipment
Warm air intake at the

bottom of the cooling
unit.
Wrong type of cooling unit used.
Notes

Cabinets Without Cooling Units
For cabinets with externally cooled drive units it is possible that Outlet
the cooling can be achieved with fans drawing air from the via filter
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. Drive Fan & filter type cool-
It is extremely important that the filters are service regularly to equipment ing system
avoid ingress of contaminants and to maintain the efficiency of
the cooling process.
Example: Cabinet with externally cooled drive units.
Temperature
Measuring points
Inlet via
Fan &
filter unit
Notes

Equipment Mounting Cable

ducting
The correct mounting of equipment is important with respect
to the cooling process and for Electromagnetic compatibility ≥ 80mm
measures.
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- Drive
bles, must be mounted a suitable distance away from the top equipment
and bottom sides of the drive units. The minimum clearance
distance for Sinamics S120 drives is 80mm.
Examples: Correct mounting methods for 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.
Example:- Externally cooled

Example:- Externally cooled
drive modules with heat-sink
drive module heat-sinks
cover and fan/filter.
protruding from the rear of a
The fan takes air in at the
cabinet with a cut-out ready to
bottom and the cover creates
accept another module.
a chimney effect to give a
good cooling effect.
Notes

Equipment Mounting continued. Example: A bare metal backplane ready for the drive modules
to be mounted, note the earth bonding cables, one for each
Electromagnetic Compatibility (EMC) drive module.
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.
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.
Example: How shielded cable can be grounded. Example of a filter, reactor and line module installation.
Filter
Cable screen
ground point
Reactor
Line Module
Notes

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

Cables, Plugs and Sockets

Example: Correctly shielded cables
Shielding
Shielded power cables are recommended between the Sin-

amics 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.
Failure to observe all of the above can lead to intermittent

faults.
The shielding of cables has a downside in that it causes addi-

tional losses in the line filter, reactor, in-feed and motor mod-
ules. This becomes worse the longer the cable length and can
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.
Example: An Incorrectly shielded cable Examples of cabinet cable entries:
Without plugs and sockets
With plugs and sockets
Shielding that is connected via a plug & socket housing must

use a metallic housing with a continuous metallic contact.
Metalized housings are not permitted, over a period of time the
metalized coating becomes worn and fails to be conductive to
the levels required.
To maintain the airtight properties of the cabinet, cable outlets
should use methods which form a seal and any unused open-
ings blanked off.
Notes

Cables, Plugs and Sockets Encoder and motor cables in close proximity.
Cabling Sins
Encoder and power cables in close proximity:
Cabinet Sealing
A cabinet that isn’t sealed correctly can lead to a multiple of

problems. Poor Sealing can be caused by cable entries, poorly
fitting doors, etc. Top
A poorly sealed cabinet can:-
 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 oth-

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

causing component failure.
Bottom
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.
Notes

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 Electrical Cabinet Design

Appendix A Hardware Differences
Sinumerik
Operate
Hardware
Differences:
START
NCU
Differences
Digital I/O
Hardware
Differences:
END
Sinumerik
Appendix A
NCU7x0.3: X122, X132 & X142 Interface Description

Ext. 24V
X122, X132 & X142 digital I/O interfaces are located beneath
the flip-down cover of the NCU. + M
X124
+ Sinumerik NCU7x0
+
X122 X132 X142 M
M
X122
1 DI 0
2 DI 1
3 DI 2
4 DI 3
5 DI 16
6 DI 17
7 M1
2*
8 M
9 DI/DO 8 1*
10 DI/DO 9 1*
11 M
12 DI/DO 10 1*
13 DI/DO 11 1*
14 M
3*
X132
1 DI 4
2 DI 5
3 DI 6
4 DI 7
5 DI 20
6 DI 21
7 M2
2*
8 M
9 DI/DO 12 1*
10 DI/DO 13 1*
11 M
12 DI/DO 14 1*
The Binary Connectors (BiCos) of X122 and X132 are used to 13 DI/DO 15 1*
assign Sinamics inputs/outputs to a specific function e.g. Ena- 14 M
3*
bling of drives, BERO’s, automatic line contactor control etc. X142
X142 is used for NC digital inputs and outputs. 1 Not used
2 Not used
default, remaining terminals can be assigned to a function via 3 NCK DI1
machine data. 4 NCK DI2
5 M
The status of the terminals is transferred to CU parameter 6 NCK DI3
r0722 which is referred to when assigning a function. 7 NCK DI4
8 M
9 NCK DO1
10 NCK DO2
11 M
1* Fast inputs/outputs (Must be shielded). 12 NCK DO3
2* Electrical isolation for digital inputs (DI) if jumper open.
13 NCK DO4
3* Can be parameterised as Inputs or outputs.
14 M
Notes
Appendix A Page 2 840D sl SINUMERIK Operate

Hardware Differences Appendix A
X122 - Sinamics I/O
X122 Signal Function/Default Setting BICO connection

Source Destination

CU-r0722.0 Infeed p0840
Pin 1 Sinamics DI 0
Infeed ready for non DriveCLiQ
SLM X21.1 Drive p0864
SLM (SLM <16Kw)
p0849
group)
(SH enable = p9601)
group)
(SH enable = p9601)
SH/SBC – Group 1 (Input) p9774 bit 1
Sinamics DI/O8
Pin 9 SINAMICS Safety Integrated CU-p0738 BICO from CU after the 1st
(Rapid input)
drive in the group
Sinamics DI/O9 p9774 bit 1
SH/SBC – Group 2 (Input) CU-p0739
Pin 10 (Rapid input) BICO from CU after the 1st
drive in the group
Sinamics DI/O10
(Rapid input)
Sinamics DI/O11 Probe 1: central measuring Each drive p0488, Index
Pin 13 CU p680[0]=3
(Rapid input) (Input) (MD13210=0) encoder 1, 2, 3=0
Notes
840D sl SINUMERIK Operate Page 3 Appendix A

X132-Sinamics I/O
X132 Signal Default setting (In bold)/ BICO connection

suggested setting
Source Destination
Pin 4 Sinamics DI 7 Line contactor feedback signal CU-r0722.7 LM-p0860

Sinamics DI/O Infeed operation (Output)
Pin 9 LM-r0863.0 CU-p0742
12 (Line Module with DriveCLiQ)
Sinamics DI/O Infeed ready to start (Output)
Pin 10 LM-r0899.0 CU-p0743
13 (If L M with DriveCLiQ)
Sinamics DI/O
14
Sinamics DI/O Probe 2: central measuring (Input) CU-p680[1]=6 Each drive p0489,
Pin 13
15 (MD13210=0) CU-p728 bit 15=0 Index 1, 2, 3=0
Notes

X142-NCK I/O

Pin 5 GND Ground
Pin 8 GND Ground
Pin 11 GND Ground
Pin 14 GND Ground
Notes

NCU 7x0.2: X122 & X132 Interface Description Connection diagram for X122/X132
X122 & X132 digital I/O interfaces are located beneath the flip-
down cover of the NCU.
External 24V
+ M
X122 X132
X124 Sinumerik NCU7x0

+
+
M
M
X122
1 DI 0
2 DI 1
3 DI 2
4 DI 3
5 M1
2*
6 M
7 DI/DO 8
8 DI/DO 9 1*
9 M
10 DI/DO 10 1*
11 DI/DO 11 1*
12 M
3*
X132
1 DI 4
2 DI 5
3 DI 6
4 DI 7
5 M1
2*
6 M
7 DI/DO 12
8 DI/DO 13 1*
9 M
10 DI/DO 14 1*
The Binary Connectors (BiCos) of X122 and X132 are used to 11 DI/DO 15 1*
assign Sinamics inputs/outputs to a specific function e.g. ena- 12 M
bling of drives, BERO’s, automatic line contactor control etc. 3*

default, remaining terminals can be assigned to a function via
1* Fast inputs/outputs (Must be shielded).
machine data.
2* Electrical isolation for digital inputs (DI) if jumper open.
The status of the terminals is transferred to CU parameter
r0722 which is referred to when assigning a function.
3* Can be parameterised as Inputs or outputs.
Notes

X122 - Sinamics I/O

suggested setting
Source Destination
Sinamics DI 0 CU-r0722.0 Infeed p0840
Pin 1 (Positive edge
required) Infeed ready for non DriveCLiQ
SLM X21.1 Drive p0864
SLM (SLM <16Kw)
p0849
p9620
(all drives in the group)
(SH enable = p9601)
p9620
(all drives in the group)
(SH enable = p9601)
Pin 5 Ground (M1) Ground for pins 1 to 4
Pin 6 Ground (M) Ground for pins 7, 8, 10, 11
SH/SBC 1 – Group 1 (Output) p9774 bit 1
Pin 7 Sinamics DI/O8 SINAMICS Safety Integrated CU-p0738 BICO from CU after the 1st
drive in the group
p9774 bit 1
SH/SBC 1 – Group 2 (Output) CU-p0739
Pin 8 Sinamics DI/O9 BICO from CU after the 1st
drive in the group
Pin 10 Sinamics DI/O10 Bero 1 - external zero mark (Input) CU-r0722.10 Drive p0495=2
Probe 1: Central Measuring
Each drive p0488,
Pin 11 Sinamics DI/O11 (Input) CU p680[0]=3
Index 1, 2, 3=0
(MD13210=0)
Notes

X132-Sinamics I/O

suggested setting
Source Destination
Pin 1 Sinamics DI 4 Digital Input $A_IN[1] CU-r0722.4 CU-p2082[0]
Digital Input $A_IN[4] CU-r0722.7 CU-p2082[3]
Pin 4 Sinamics DI 7 Line contactor feedback signal when set via
CU-r0722.7 LM-p0860
wizard screen
Pin 5 Ground (M1) Ground for pins 1 to 4

Digital Output $A_OUT[4] CU-p2091.3 CU-p0742
Pin 7 Sinamics DI/O 12 Infeed operation (Output)
LM-r0863.0 CU-p0742
(Line Module with DriveCLiQ)
Digital Output $A_OUT[3]
CU-p2091.2 CU-p0743
(If no DriveCLiQ LM)
Pin 8 Sinamics DI/O 13
Infeed ready to start (Output)
LM-r0899.0 CU-p0743
(If L M with DriveCLiQ)
Pin 10 Sinamics DI/O 14
Bero 2 - external zero mark (Input) CU-r0722.14 Drive p0495=5
Pin 11 Sinamics DI/O 15 Probe 2: Remote Measuring (Input) CU-p680[1]=0 Each drive p0489,
(MD13210=1) CU-p728 bit 15=0 Index 1, 2, 3=6
Appendix A: END
Notes

Appendix B
Sinumerik
Operate
Technology
Settings:
START
General
Machine Data
51000-51999
Channel
Machine Data
52000-52999
Axis
Machine Data
53000-53999
General Setting
Data
54000-54999
Sinumerik
Channel Setting
Data
55000-55999
Technology
Settings:
END
Siemens assumes no responsibility for its contents. Appendix B
General Machine Data
840D sl SINUMERIK Operate
Technology Settings
MD Identifier Description Old MD/GUD
51000 $MNS_DISP_RES_MM Display resolution in mm

51001 $MNS_DISP_RES_MM_FEED_PER_REV Display resolution in mm feedrate/rev
51002 $MNS_DISP_RES_MM_FEED_PER_TIME Display resolution in mm feedrate/min
51003 $MNS_DISP_RES_MM_FEED_PER_TOOTH Display resolution in mm feedrate/tooth
51004 $MNS_DISP_RES_MM_CONST_CUT_RATE Display resolution constant cutting speed m/min
51010 $MNS_DISP_RES_INCH Display resolution in inch 9011
51011 $MNS_DISP_RES_INCH_FEED_P_REV Display resolution in inch feedrate/rev
51012 $MNS_DISP_RES_INCH_FEED_P_TIME Display resolution in inch feedrate/min
51013 $MNS_DISP_RES_INCH_FEED_P_TOOTH Display resolution in inch feedrate/tooth
51014 $MNS_DISP_RES_INCH_CUT_RATE Display resolution constant cutting speed ft/min
51020 $MNS_DISP_RES_ANGLE Display resolution of angle
51021 $MNS_DISP_RES_SPINDLE Decimal places in speed entry field 9010, 9664
Page 2
51022 $MNS_DISP_RES_ROT_AX_FEED Display resolution of rotary axis feedrate

51023 $MNS_ACT_VALUE_SPIND_MODE Only display spindles in actual values window
This affects the display of the spindles in the axis actual values window.
0 = Spindles are always displayed
1 = Spindles are displayed only if in axis mode
51024 $MNS_BLOCK_SEARCH_MODE_MASK_JS Bit mask for available search modes (ShopMill/ShopTurn single-channel)
Bit 0: Block search with calculation without approach
Bit 1: Block search with calculation with approach
Bit 3: Skip EXTCALL programs
Bit 5: Block search with test run
51025 $MNS_FRAMES_ACT_IMMEDIATELY Active data (frames) are activated immediately after change 9440
51026 $MNS_AXES_SHOW_GEO_FIRST When the machine data value is 1, the geometry axes of the channel are displayed first. 9421
Appendix B
51027 $MNS_ONLY_MKS_DIST_TO_GO Distance-to-go display in work window 9420
51028 $MNS_BLOCK_SEARCH_MODE_MASK Bit mask for available block search modes
Appendix B
Bit 0: Block search with calculation without approach

Bit 1: Block search with calculation with approach
Bit 3: Skip EXTCALL programs
Bit 4: Block search without calculation
Bit 5: Block search with test run
Appendix B
Appendix B
51029 $MNS_MAX_SKP_LEVEL The machine data defines how many skip levels are made available for operation. 9423
51030 $MNS_SPIND_MAX_POWER Maximum value of the permissible spindle power rating in percent; the display bar in the 9428
machine image is shown in green within the range between 0 and the value stored in
SPIND_MAX_POWER.
51031 $MNS_SPIND_POWER_RANGE Scale end value for spindle power rating in percent; value must be equal to or greater than 9429
Technology Settings
SPIND_MAX_POWER.
The display bar in the machine image is shown in red in the range between the values of
SPIND_MAX_POWER and SPIND_POWER_RANGE.
51032 $MNS_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 $MNS_TU_DISPLAY_BASE Number basis for display of rotary axis position TU 9243
00: no display
Page 3
02: binary value display

10: decimal value display
16: hexadecimal value display
51034 $MNS_TEACH_MODE Teach mode to be activated 9026
Bit 0: Default teach-in
Taught-in block is transferred to the program using the Accept softkey.
Bit 1: Acceptance of teach block can be blocked by the PLC.
DB19.DBX13.0 = 0 block is accepted.
DB19.DBX13.0 = 1 block is not accepted.
Bit 2: Block selection only explicitly
51035 $MNS_WRITE_FRAMES_FINE_LIMIT Input limit for all work offsets fine
51036 $MNS_ENABLE_COORDINATE_REL Display REL coordinate system
0 = no relative coordinate system selectable
1 = REL coordinate system can be selected as an alternative of the WCS/SZS coordinate
system
51037 $MNS_ENABLE_COORDINATE_ACS Activate settable coordinate system 9424

0 = WCS coordinate system is displayed.
1 = SZS coordinate system is displayed.
(SZS is WCS reduced by the offset components defined in MD24030)
Technology Settings
51038 $MNS_SET_ACT_VALUE Set actual value selection 9422
0 = Set actual value is not offered.
1 = If a user frame (settable work offset e.g. G54) is active, it will be used. In G500 Set ac-
tual values is not offered (system frame is no longer used).
51039 $MNS_PROGRAM_CONTROL_MODE_MASK Options for machine - program influence:
Bit 0: Program test function available
51040 $MNS_SWITCH_TO_MACHINE_MASK Automatic operating area switchover to machine
Bit 0: When selecting a program in the program manager, the operating area does not
automatically switch over to Machine.
Bit 1: When switching the type of operation via the MCP, the operating area is not auto-
matically switched over to Machine.
Bit 2: Do not switch automatically in Programs during program selection.
Bit 3: No auto. Start of block search on selection / execution under Programs.
51041 $MNS_ENABLE_PROGLIST_USER Activates the PLC program list of the USER area. The programs entered there can be se-
lected by the PLC for processing.
51042 $MNS_ENABLE_PROGLIST_INDIVIDUAL Activates the PLC program list of the INDIVIDUAL area. The programs entered here can be
Page 4
selected by the PLC for processing.

51043 $MNS_ENABLE_PROGLIST_MANUFACT Activates the PLC program list of the MANUFACTURER area. The programs entered here
can be selected by the PLC for processing.
51044 $MNS_ACCESS_SHOW_SBL2 Display protection level SBL2 9227
51045 $MNS_ACCESS_TEACH_IN Protection level TEACH IN 9219
51046 $MNS_ACCESS_CLEAR_RPA Protection level delete R variables 9221
51047 $MNS_ACCESS_READ_GUD_LUD Read user variable protection level 9211
51048 $MNS_ACCESS_WRITE_GUD_LUD Write protection level of user variables
51049 $MNS_ACCESS_WRITE_PRG_COND Write program control protection level 9214
51050 $MNS_ACCESS_WRITE_PROGRAM Write part program protection level 9217
51051 $MNS_ACCESS_WRITE_RPA Protection level write R variables 9222
Appendix B
51052 $MNS_ACCESS_WRITE_SEA Protection level write setting data 9215
Appendix B
51053 $MNS_ACCESS_WRITE_BASEFRAME Write basic work offset (basic frame) protection level
51054 $MNS_ACCESS_WRITE_CYCFRAME Write cycle frame protection level 9186

51055 $MNS_ACCESS_WRITE_EXTFRAME Write external work offset protection level 9188
Appendix B
Appendix B
51056 $MNS_ACCESS_WRITE_PARTFRAME Write table reference protection level 9184
51057 $MNS_ACCESS_WRITE_SETFRAME Write basic reference protection level
51058 $MNS_ACCESS_WRITE_TOOLFRAME Write basic tool reference protection level 9183

51059 $MNS_ACCESS_WRITE_TRAFRAME Write transformation frame protec. level 9187
Technology Settings
51060 $MNS_ACCESS_WRITE_USERFRAME Write settable work offset (G54 ... G599) protection level
51061 $MNS_ACCESS_WRITE_WPFRAME Write workpiece reference protection level 9185
51062 $MNS_ACCESS_WRITE_FINE Write protection level for fine offset of all work offsets 9203
51063 $MNS_ACCESS_SET_ACT_VALUE Set actual value protection level 9220

51064 $MNS_ACCESS_WRITE_PROGLIST Write protection level of program list in USER area
51065 $MNS_NUM_DISPLAYED_CHANNELS Number of channels displayed simultaneously 9034
51066 $MNS_ORDER_DISPLAYED_CHANNELS Channel numbers of the channels displayed

Page 5
Contains the numbers of the channels to be displayed under machine in the multi-
channel view, in the desired order and separated by commas, semicolons or spaces.
51067 $MNS_ENABLE_HANDWHEEL_WINDOW Show handwheel window.
If the machine data is set to 0, the window for handwheel assignment is hidden.
51068 $MNS_SPIND_DRIVELOAD_FROM_PLC1 Machine axis index of spindle 1 utilization display from PLC
51069 $MNS_SPIND_DRIVELOAD_FROM_PLC2 Machine axis index of spindle 2 utilization display from PLC
51070 $MNS_ACCESS_CAL_TOOL_PROBE Protection level for calibration of the tool probe (ShopTurn)
51071 $MNS_ACCESS_ACTIVATE_CTRL_E Protection level of CTRL-Energy
51072 $MNS_ACCESS_EDIT_CTRL_E Protection level of CTRL-Energy for changing profiles
51073 $MNS_ACCESS_SET_SOFTKEY_ACCESS Protection level of ”Adapt softkeys”
51160 $MNS_ACCESS_WRITE_CA_MACH_JOG Write protection level collision monitoring machine jog

51161 $MNS_ACCESS_WRITE_CA_MACH_AUTO Write protection level collision monitoring machine automatic
51162 $MNS_ACCESS_WRITE_CA_TOOL Write protection level collision monitoring tool
51198 $MNS_ACCESS_READ_TM_ALL_PARAM Protection level TM details - read all parameters
51199 $MNS_ACCESS_WRITE_TM_GRIND Protection level of tool management for writing grinding data
Technology Settings
51200 $MNS_ACCESS_WRITE_TM_GEO Write tool offset geometry data protection level 9201
51201 $MNS_ACCESS_WRITE_TM_WEAR Write tool offset wear data protection level 9202
51202 $MNS_ACCESS_WRITE_TM_WEAR_DELTA Protection level for restricted writing of tool wear values, 9203
s. SD 54213: TM_WRITE_DELTA_LIMIT
51203 $MNS_ACCESS_WRITE_TM_SC Write tool offset sum offset protection level 9204
51204 $MNS_ACCESS_WRITE_TM_EC Write tool offset use offsets protection level 9205
51205 $MNS_ACCESS_WRITE_TM_SUPVIS Write tool offset monitoring data protection level 9206
One authorization applies to all limit values: quantity, service life, wear and the monitor-
ing type.
51206 $MNS_ACCESS_WRITE_TM_ASSDNO Write tool offset unique D number protection level 9207
51207 $MNS_ACCESS_WRITE_TM_WGROUP Write tool offset wear groups (magazine location / magazine) protection level 9208
51208 $MNS_ACCESS_WRITE_TM_ADAPT Write tool offset tool adapter geometry data protection level 9209
Page 6
51209 $MNS_ACCESS_WRITE_TM_NAME Write tool offset tool name and duplo data protection level 9240
51210 $MNS_ACCESS_WRITE_TM_TYPE Write tool offset tool type protection level 9241
51211 $MNS_ACCESS_READ_TM Read tool offset data protection level 9200
51212 $MNS_TM_WRITE_WEAR_ABS_LIMIT With TM_WRITE_WEAR_ABS_LIMIT, the max. possible value of a tool wear is limited 9639
absolutely, independently of the current protection level (keyswitch position), i.e. also
independently of ACCESS_WRITE_TM_WEAR. Absolute and incremental wear limita-
tion can be combined, i.e. the wear can be changed incrementally up to the absolute
limit, see MD 51213.
51213 $MNS_TM_WRITE_WEAR_DELTA_LIMIT When entering tool offsets, the value of the change from the previous value to the new 9450
value cannot exceed the value set here.
With TM_WRITE_WEAR_DELTA_LIMIT, the change to a tool wear can be limited incre-
mentally, if the current protection level is the same as or higher than the one set in AC-
CESS_WRITE_TM_WEAR_DELTA. With the current protection level being the same or
higher than ACCESS_WRITE_TM_WEAR, an incremental limitation is no longer per-
Appendix B
formed. incremental wear limitation can be combined, i.e. the wear can be changed up
to the absolute limit, see MD 51212.
Appendix B
51214 $MNS_TM_WRITE_LIMIT_MASK Validity of the restricted tool wear input 9449

Bit 0: Use for cutting edge data, wear
Bit 1: Use for SC data, sum offsets
Bit 2: Use for EC data, use offsets
Bit 0+1+2: Use for all data, wear, SC, EC
Appendix B
Appendix B
51215 $MNS_ACCESS_WRITE_TM_ALL_PARAM Protection level TM details - write all parameters
51216 $MNS_ACCESS_TM_TOOL_CREATE Protection level TM create tool
51217 $MNS_ACCESS_TM_TOOL_DELETE Protection level TM delete tool
51218 $MNS_ACCESS_TM_TOOL_LOAD Protection level TM load tool
Technology Settings
51219 $MNS_ACCESS_TM_TOOL_UNLOAD Protection level TM unload tool
51220 $MNS_ACCESS_TM_TOOL_MOVE Protection level TM relocate tool
51221 $MNS_ACCESS_TM_TOOL_REACTIVATE Protection level TM reactivate tool
51222 $MNS_ACCESS_TM_TOOL_MEASURE Protection level TM measure tool
51223 $MNS_ACCESS_TM_TOOLEDGE_CREATE Protection level TM create tool cutting edge
51224 $MNS_ACCESS_TM_TOOLEDGE_DELETE Protection level TM delete tool cutting edge

Page 7
51225 $MNS_ACCESS_TM_MAGAZINE_POS Protection level TM position magazine
51226 $MNS_FUNCTION_MASK_SIM Function mask Simulation

Bit 0: No automatic start on simulation selection
Bit 1: Deactivate simulation
Bit 6: Enable handwheel as simulation override
Bit 7: Interpretation of handwheel values as absolute values
51228 $MNS_FUNCTION_MASK_TECH Function mask Cross-technology
Bit 0: G code programming without multi-channel data
Bit 1: Enable print function of editor
51230 $MNS_ENABLE_LADDER_DB_ADDRESSES Activation of DB addresses in PLC Ladder Viewer
51231 $MNS_ENABLE_LADDER_EDITOR Activation of PLC Ladder Editor
51233 $MNS_ENABLE_GSM_MODEM Activation of GSM Modem for Easy Message

51235 $MNS_ACCESS_RESET_SERV_PLANNER Protection level for acknowledgement of maintenance tasks
51600 $MNS_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 $MNS_MEA_CAL_EDGE_NUM The gauging block is exclusively used to calibrate the workpiece probe of the Turning
technology!
Technology Settings
51602 $MNS_MEA_CAL_TP_NUM The geometry data and calibration data of the tool probe refer to the machine coordinate system
(MCS)!
51603 $MNS_MEA_CAL_TPW_NUM The geometry data and calibration data of the tool probe refer to the workpiece coordinate sys-
tem (WCS)!
51618 $MNS_MEA_CM_ROT_AX_POS_TOL Entries in parameter $MN_MEA_CM_ROT_AX_POS_TOL are effective only if MD51740

$MNS_MEA_FUNCTION_MASK Bit 2 or Bit 16 is set.
The real angle position of the rotary axes can deviate from the programmed one (exact stop fine
window).
This deviation depends on the position control features of the axis. The maximum deviation ex-
pected on the concrete axis must be entered in this parameter. When the tolerance is exceeded,
alarm 61442 "Toolholder not in parallel with the geometry axes" is displayed.
51740 $MNS_MEA_FUNCTION_MASK Function mask for measuring cycles
Bit 0: Workpiece measurement, calibration status monitoring, measuring in automatic
Bit 1: Workpiece measurement, length reference of probe in infeed axis, for milling
Bit 2: Workpiece measurement, support of orientable toolholders
Bit 3: Workpiece measurement, correction angle for mono probe
Page 8
Bit 4: Workpiece measurement, probe fixed to machine, cannot be positioned

Bit 15: Workpiece measurement, traverse measuring block with path behaviour G60 exact stop
Bit 16: Tool measurement, support of orientable toolholders
51750 $MNS_J_MEA_M_DIST This parameter defines the measuring path in front of and behind the measuring setpoint. 9752
51751 $MNS_J_MEA_M_DIST_MANUELL Measuring path, manual measurement ((for "Measure in JOG")) [mm] (in front of and behind the 9753
measuring setpoint)
51752 $MNS_J_MEA_M_DIST_TOOL_LENGTH Measuring path for tool length measuring. 9754
51753 $MNS_J_MEA_M_DIST_TOOL_RADIUS Measuring path for tool radius measuring. 9755
51757 $MNS_J_MEA_COLL_MONIT_FEED Feedrate in the working plane with active collision detection. 9757
51758 $MNS_J_MEA_COLL_MONIT_POS_FEED Feedrate of the infeed axis with active collision detection, for "Measure in JOG". 9758
51770 $MNS_J_MEA_CAL_RING_DIAM Calibration ring diameter, for probe sphere calibration in the plane, for "Measure in JOG"
51772 $MNS_J_MEA_CAL_HEIGHT_FEEDAX Calibration height in the infeed axis for probe length calibration, for "Measure in JOG"
Appendix B
The calibration height must be entered with reference to the the workpiece coordinate system
(WCS)!
Appendix B
51780 $MNS_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"
51784 $MNS_J_MEA_T_PROBE_APPR_AX_DIR Effective grinding wheel diameter of the tool probe for length measurement on milling tools, for 9768
"Measure in JOG"
51786 $MNS_J_MEA_T_PROBE_MEASURE_DIST Measuring path for tool probe calibration and tool measuring with stationary spindle, in front of 9772
and behind the expected switching position.
Channel Machine Data
Appendix B
Appendix B
52000 $MCS_DISP_COORDINATE_SYSTEM With this MD you adapt the operator panel of the coordinate system to the machine's coordinate 9650
system. Depending on the selected position, all help screens, the sequence graphic, the simula-
tion and the input fields with the circular direction specified will change automatically.
Also note MD 52210 $MCS_FUNCTION_MASK_DISP, bit 1.
52005 $MCS_DISP_PLANE_MILL Plane selection Milling 9660
0: plane selection on the operator panel
17: always G17
Technology Settings
18: always G18
19: always G19
52006 $MCS_DISP_PLANE_TURN Plane selection Turning
0: plane selection on the operator panel
17: always G17
18: always G18
19: always G19
52010 $MCS_DISP_NUM_AXIS_BIG_FONT Number of actual values with large font
52011 $MCS_ADJUST_NUM_AXIS_BIG_FONT Adapt the number of actual values with large font if the number of geometry axes changes, e.g.
Page 9
due to transformations like TRANSMIT or TRACYL.

0 = Only MD 52010 "DISP_NUM_AXIS_BIG_FONT" is valid. The number is assigned as a fixed
value.
1 = Only the geometry axes are displayed in large font. MD 52010
"DISP_NUM_AXIS_BIG_FONT" is ignored.
2 = The number of geometry axes plus the content of MD 52010 "DISP_NUM_AXIS_BIG_FONT"
are displayed in large font.
52200 $MCS_TECHNOLOGY Technology 9020
0: no specific configuration
1: turning
2: milling
Also note MD 52201 $MCS_TECHNOLOGY_EXTENSION.
52201 $MCS_TECHNOLOGY_EXTENSION Extended technology
0: no specific configuration
1: turning
2: milling
Also note MD 52200 $MCS_TECHNOLOGY.

Example:
Turning machine with milling technology
MD 52200 $MCS_TECHNOLOGY = 1
MD 52201 $MCS_TECHNOLOGY_EXTENSION = 2
Technology Settings
52206 $MCS_AXIS_USAGE Meaning of the axes in the channel

0 = no special meaning 9705, 9708,
1 = tool spindle (driven tool) 9802, 9803,
2 = auxiliary spindle (driven tool) 9804, 9805,
3 = main spindle (turning) 9806, 9807,
4 = C axis of the main spindle (turning) 9808.
5 = counter spindle (turning)
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)
11 = reserved
12 = B axis of the counter spindle (turning)
13 = Traverse travel X of the counter spindle (turning)
52207 $MCS_AXIS_USAGE_ATTRIB Axis attributes
Bit 0: Rotates around the 1st geometry axis (applies to rotary axes) 9653, 9720,
Bit 1: Rotates around the 2nd geometry axis (applies to rotary axes) 9703, 9704,
Page 10
Bit 2: Rotates around the 3rd geometry axis (applies to rotary axes) 9706, 9707,
Bit 3: Positive direction of rotation is counterclockwise (applies to rotary axes) 9822, 9823,
Bit 4: Displayed direction of rotation for M3 is counterclockwise (applies to spindles) 9824, 9825.
Bit 5: Direction of rotation M3 corresponds to rotary axis minus (applies to spindles)
This bit must be set analog to PLC bit DBnn.DBX17.6!
(nn = 31 + machine data index)
Bit 6: Show rotary axis as offset target for measuring
Bit 7: Offer rotation axis in position pattern 9727
Bit 8: Offer rotation axis to accept blank (at milling machines)
Bit 9: Spindle is not SPOS-capable
52210 $MCS_FUNCTION_MASK_DISP Function mask Display
Bit 0: Measuring system for programs always in the base system 9626 Bit 9
Bit 1: Front view for turning in school coordinate system 9719
Bit 2: Hide “T,S,M” soft key in JOG area
Bit 3: Generate automatic end-of-program in MDI (with the “Delete blocks” soft key)
Bit 4: Show follow-on tool in T,F,S window
Appendix B
Bit 5: Hide softkey “Actual machine values“
Bit 6: Hide tool radius/diameter in T,F,S window
Bit 7: Hide tool length in T,F,S window
Appendix B
Bit 8: Hide tool icon in T,F,S window

Appendix B
Appendix B
52211 $MCS_FUNCTION_MASK_DISP _ZOA Function screen for displaying overview of work offsets
Bit 0: Show machine position
Bit 1: reserved
Bit 2: Display DRF offset
Bit 3: Display $AA_OFF position offset
Bit 4: Display $P_PARTFRAME
Bit 5: Display $P_SETFRAME
Technology Settings
Bit 6: Display $P_EXTSFRAME
Bit 7: Display $P_ISO1FRAME
Bit10: Display $P_ACTBFRAME
Bit 11: Display $P_IFRAME
Bit 12: Display $P_TOOLFRAME
Bit 13: Display $P_WPFRAME
Bit 14: Display $P_TRAFRAME
Bit 15: Display $P_PFRAME
Bit 17: Display $P_CYCFRAME
Page 11
Bit 18: Display sum of work offsets

Bit 19: Display offset of active tool
Bit 20: Display Work position
52212 $MCS_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)
Bit 5: Call block search cycle for SERUPRO
Bit 6: Work offset value ZV cannot be entered (ShopTurn)
Bit 7: Detect the expiry of tool lives (ShopMill/ShopTurn)
Bit 8: Manual machine (ShopMill/ShopTurn)
Bit 9: Selection/deselection of work offset via softkey
Bit 10: reserved
Bit 11: Switch off layer check for drilling and milling tools (ShopTurn)
Technology Settings
52214 $MCS_FUNCTION_MASK_MILL Function mask Milling

Bit 0: Enable cylinder surface transformation (ShopMill) 9721
Bit 1: Offer table to accept blank (at milling machines)
Bit 2: reserved
Bit 3: Enable inside/rear machining
Bit 4: Enable spindle clamping (C axis) 9843
Bit 5: Enable spindle control of tool spindle via surface
Bit 6: Enable spindle control of turning spindle via surface
52216 $MCS_FUNCTION_MASK_DRILL Function mask Drilling
Bit 0: CYCLE84 Unhide technology fields
Bit 1: CYCLE840 Unhide technology fields
Bit 2: Thread tapping also without encoder (ShopMill)
52218 $MCS_FUNCTION_MASK_TURN Function mask Turning
Bit 0: Enable zoom under manual for tool measurement 9840
Bit 1: Enable parts gripper for cut-off 9841
Bit 2: Enable tailstock 9842
Bit 3: Enable spindle control of main spindle via surface 9897Bit 0
Page 12
Bit 4: Enable spindle control of counterspindle via surface 9897Bit 1

Bit 5: Enable spindle control of tool spindle via surface 9897Bit 2
Bit 6: Enable balance cutting for dual-channel stock removal
Bit 7: Retraction during stock removal along contour with G1
Bit 8: Input spindle chuck data in the program
Bit 9: Additional entry of tailstock data in the program
Bit 12: Deactivate thread synchronization
Bit 13: Stock rem. contour with CYCLE95 (828D programGUIDE without Advanced Technology)
52229 $MCS_ENABLE_QUICK_M_CODES Enable fast M functions
Bit 0: Coolant OFF
Bit 1: Coolant 1 ON
Bit 2: Coolant 2 ON
Bit 3: Coolant 1 and 2 ON
52230 $MCS_M_CODE_ALL_COOLANTS_OFF M code for all coolants OFF 9686
52231 $MCS_M_CODE_COOLANT_1_ON M code for coolant 1 ON 9680
Appendix B
52232 $MCS_M_CODE_COOLANT_2_ON M code for coolant 2 ON 9681
Appendix B
52233 $MCS_M_CODE_COOLANT_1_AND_2_ON M code for coolant 1 + 2 ON 9668
52240 $MCS_NAME_TOOL_CHANGE_PROG Tool change program for G code steps

Appendix B
Appendix B
52244 $MCS_SUB_SPINDLE_PARK_POS_Y Parking position of the Y axis with counter spindle 9849
52248 $MCS_REV_2_BORDER_TOOL_LENGTH Limit value of tool length X for 2nd revolver: 9838
Limit value = 0: There is only one revolver
Tool length < limit value: Tool belongs to 1st revolver/multifix
Tool length >= limit value: Tool belongs to 2nd revolver/multifix
52250 $MCS_M_CODE_CHUCK_OPEN M code for Open chuck with non-rotating spindle.
Technology Settings
Example: "M34" or "M1=34"
Elements:
[0]: Main spindle
[1]: Counterspindle
52251 $MCS_M_CODE_CHUCK_CLOSE_OPEN_ M code for Open chuck with rotating spindle.
ROT Example: "M34" or "M1=34"
Elements:
[0]: Main spindle
[1]: Counterspindle
52252 $MCS_M_CODE_CHUCK_CLOSE M code for Close chuck
Page 13

Elements:
[0]: Main spindle
[1]: Counterspindle
52253 $MCS_M_CODE_TAILSTOCK_FORWARD M code for quill forward
Elements:
[0]: Quill opposite main spindle
[1]: Quill opposite counterspindle
52254 $MCS_M_CODE_TAILSTOCK_BACKWARD M code for quill backward
Elements:
[0]: Quill opposite main spindle
[1]: Quill opposite counterspindle
52260 $MCS_MACHINE_JOG_INTERRUPT_PRIO Priory for start ASUP under machine JOG
Technology Settings
52270 $MCS_TM_FUNCTION_MASK Function mask Tool management

Bit 0: Create tool on magazine location not allowed. Tools can only be created outside the maga- 9478 Bit 3
zine.
Bit 1: Load/unload disable, if machine is not in reset. Tools can only be loaded/unloaded, if the 9478 Bit 9
appropriate channel is in reset state.
Bit 2: Load/unload disable on Emergency stop. Tools can only be loaded/unloaded, if Emergen- 9478 Bit 12
cy stop is not active.
Bit 3: Load/unload tool to/from spindle or relocate tool is disabled. Tools cannot be loaded to or 9478 Bit 15
unloaded from the spindle or relocated.
Bit 4: Loading is executed directly in the spindle. Tools are loaded exclusively directly in the spin- 9478 Bit 20
dle.
Bit 5: Use grinding configuration file.
Bit 6: Permit relocating to/from spindle despite a block (Bit 3).
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 in-
terface.
Bit 10: Reactivate tool using Position magazine. Prior to reactivating the tool is positioned on the
Page 14
loading position.
Bit 11: Reactivate tool in all monitoring modes. When reactivating a tool, all monitoring modes
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 $MCS_TM_MAG_PLACE_DISTANCE Distance between individual magazine locations. 9479

Is used for graphical display of magazine and tools in tool management.
52272 $MCS_TM_TOOL_LOAD_DEFAULT_MAG Default magazine for tool loading 9671
0 = No default magazine
52273 $MCS_TM_TOOL_MOVE_DEFAULT_MAG Default magazine for tool relocation 9687
0 = No default magazine
52274 $MCS_TM_TOOL_LOAD_STATION Number of load station 9673
0 = All configured stations are taken into account
52281 $MCS_TOOL_MCODE_FUNC_ON M code for tool-specific function ON 9739, 9741,
Appendix B
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.
Appendix B
52282 $MCS_TOOL_MCODE_FUNC_OFF M code for tool-specific function OFF 9740, 9742,

Value -1 means that the M function is not output. If both M commands of a function equal -1, the 9744, 9746.
corresponding field will not be displayed in the user interface.
Appendix B
Appendix B
52290 $MCS_SIM_DISPLAY_CONFIG Location of status display of the channel in the simulation (OP019 only)
Bit 0: Corner left/top
Bit 1: Corner right/top
Bit 2: Corner left/bott
Bit 3: Corner right/bott
52740 $MCS_MEA_FUNCTION_MASK Function mask for measuring cycles 9750, 9751
Bit 0: Workpiece measurement, CNC probe input _CHBIT[0]
Technology Settings
Bit 1: Workpiece measurement, measurement in third geometry axis (Y), for turning _CHBIT[19]
Bit 14: reserved
Bit 15: reserved
Bit 16: Tool measurement, CNC probe input _CHBIT[1]
52750 $MCS_J_MEA_FIXPOINT Z value for measuring against fixed point 9748
52751 $MCS_J_MEA_MAGN_GLAS_POS Zoom position for tool measurement 9820, 9821
[0] = Position in 1st axis
[1] = Position in 2nd axis
52800 $MCS_ISO_M_ENABLE_POLAR_COORD Polar coordinates
Page 15
0: OFF
1: ON
52802 $MCS_ISO_ENABLE_INTERRUPTS Interrupt process
0: OFF
1: ON
52804 $MCS_ISO_ENABLE_DRYRUN Machining skipped during tapping G74/G84 at DRY RUN
0: OFF
1: ON
52806 $MCS_ISO_SCALING_SYSTEM Basic system
0: not defined
1: METRIC
2: INCH
52808 $MCS_ISO_SIMULTAN_AXES_START Simultaneous approach to the boring position on all programmed axes
0: OFF
1: ON
52810 $MCS_ISO_T_DEEPHOLE_DRILL_MODE Select the type of deep hole drilling

0: deep hole drilling with chip breaking
1: deep hole drilling with stock removal
Axis Machine Data
Technology Settings
53220 $MAS_AXIS_MCS_POSITION Position of axis in the Machine
53230 $MAS_SIM_START_POSITION Axis position at start of simulation
53240 $MAS_SPINDLE_PARAMETER Spindle chuck data

[0]: Chuck dimension
[1]: Stop dimension
[2]: Jaw dimension
53241 $MAS_SPINDLE_CHUCK_TYPE Spindle jaw type
0 = Clamp from outside 9829
1 = Clamp from inside
53242 $MAS_TAILSTOCK_PARAMETER Tailstock data
[0]: Tailstock diameter 9836
[1]: Tailstock length 9837
53250 $MAS_CLAMPING_TOLERANCE Permissible tolerance when an axis jams
Page 16
General Setting Data

54215 $SNS_TM_FUNCTION_MASK_SET Function mask Tool management
Bit 0: Diameter display for rotating tools. For rotating tools the diameter is displayed instead of
the radius value. 9663
Bit 1: Default direction of rotation for all turning tools is M4. When creating turning tools the direc- 9826
tion 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. 9478 Bit 6
Bit 4: Input disable for loaded tools, if the channel is not in Reset. 9478 Bit 10
Bit 5: Calculate tool wear inputs additively. Wear data are input additively to the already existing
wear value. 9478 Bit 11
Bit 6: Numerical input of the tool ident. Only numbers are permissible for tool ident input.
Bit 7: Fade out tool monitoring parameters. The tool monitoring parameters are faded out on the
Appendix B
user interface.
Bit 8: Diameter display for transverse axis - Geometry. The geometry value of the transverse axis
is displayed as diameter value.
Appendix B
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.
Bit 11: Creating tool in gripper disabled.
Bit 12: Do not unload measuring tools if ”Unload all” function is executed.
Appendix B
Appendix B
54600 $SNS_MEA_WP_BALL_DIAM Effective sphere diameter of the probe sphere for the workpiece probe. _WP[x,0]
The value of this parameter is created by the operation "Calibrate workpiece probe"!
54601 $SNS_MEA_WP_TRIG_MINUS_DIR_AX1 Trigger point of the 1st measuring axis (abscissa) in negative traversing direction (X at G17) of the _WP[x,1]
workpiece probe.
The term "negative traversing direction" refers to the currently active workpiece zero point refer-
ence!
Technology Settings
54602 $SNS_MEA_WP_TRIG_PLUS_DIR_AX1 Trigger point of the 1st measuring axis (abscissa) in positive traversing direction (X at G17) of the _WP[x,2]
workpiece probe.
The term "positive traversing direction" refers to the currently active workpiece zero point refer-
ence!
54603 $SNS_MEA_WP_TRIG_MINUS_DIR_AX2 Trigger point of the 2nd measuring axis (ordinate) in negative traversing direction (Y at G17) of the _WP[x,3]
workpiece probe.
ence!
Page 17
54604 $SNS_MEA_WP_TRIG_PLUS_DIR_AX2 Trigger point of the 2nd measuring axis (ordinate) in positive traversing direction (Y at G17) of the _WP[x,4]
workpiece probe.
ence!
54605 $SNS_MEA_WP_TRIG_MINUS_DIR_AX3 Trigger point of the 3rd measuring axis (applicate) in negative traversing direction (Z at G17) of the _WP[x,5]
workpiece probe.
ence!
54606 $SNS_MEA_WP_TRIG_PLUS_DIR_AX3 Trigger point of the 3rd measuring axis (applicate) in positive traversing direction (Z at G17) of the _WP[x,6]
workpiece probe.
ence!
Technology Settings
54607 $SNS_MEA_WP_POS_DEV_AX1 The position deviation in the 1st measuring axis represents a geometrical offset of the centre _WP[x,7]
point of the probe sphere related to the electrical centre point of the probe in this axis!
54608 $SNS_MEA_WP_POS_DEV_AX2 The position deviation in the 2nd measuring axis represents a geometrical offset of the centre _WP[x,8]
point of the probe sphere related to the electrical centre point of the probe in this axis!
54609 $SNS_MEA_WP_STATUS_RT Calibration status of the axis positions reserved for internal use! _WP[x,9]
54610 $SNS_MEA_WP_STATUS_GEN Calibration status in general reserved for internal use! _WP[x,10]
54611 $SNS_MEA_WP_FEED Measure workpiece measuring feed for calibration.

This measuring feed is used for all subsequent workpiece measuring programs in conjunction
with the probe field.
54615 $SNS_MEA_CAL_EDGE_BASE_AX1 Calibration groove base of the 1st measuring axis (abscissa, Z at G18) _KB[x,2]
Page 18
This parameter is a geometrical component of the calibration groove and must be supplied by the
user!
54617 $SNS_MEA_CAL_EDGE_PLUS_DIR_AX1 Calibration groove edge in positive direction of the 1st measuring axis (abscissa, Z at G18) _KB[x,3]
user!
54618 $SNS_MEA_CAL_EDGE_MINUS_DIR_AX1 Calibration groove edge in negative direction of the 1st measuring axis (abscissa, Z at G18) _KB[x,4]
user!
Appendix B
Appendix B
Appendix B
Appendix B
54619 $SNS_MEA_CAL_EDGE_BASE_AX2 Calibration groove base of the 2nd measuring axis (ordinate, X at G18) _KB[x,6]
This parameter is a geometrical component of the calibration groove and must be supplied by
the user!
54620 $SNS_MEA_CAL_EDGE_UPPER_AX2 Calibration groove upper edge of the 2nd measuring axis (ordinate, X at G18) _KB[x,5]
the user!
54621 $SNS_MEA_CAL_EDGE_PLUS_DIR_AX2 Calibration groove edge in positive direction of the 2nd measuring axis (ordinate, X at G18) _KB[x,0]
Technology Settings
the user!
54622 $SNS_MEA_CAL_EDGE_MINUS_DIR_AX2 Calibration groove edge in negative direction of the 2nd measuring axis (ordinate, X at G18) _KB[x,1]
the user!
54625 $SNS_MEA_TP_TRIG_MINUS_DIR_AX1 Trigger point of the 1st measuring axis in negative direction (abscissa, X at G17, Z at G18) _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 19
54626 $SNS_MEA_TP_TRIG_PLUS_DIR_AX1 Trigger point of the 1st measuring axis in positive direction (abscissa, X at G17, Z at G18) _TP[x,1]
tem!
54627 $SNS_MEA_TP_TRIG_MINUS_DIR_AX2 Trigger point of the 2nd measuring axis in negative direction (ordinate, Y at G17, X at G18) _TP[x,2]
tem!
54628 $SNS_MEA_TP_TRIG_PLUS_DIR_AX2 Trigger point of the 2nd measuring axis in positive direction (ordinate, Y at G17, X at G18) _TP[x,3]
tem!
54629 $SNS_MEA_TP_TRIG_MINUS_DIR_AX3 Trigger point of the 3rd measuring axis in negative direction (applicate, Z at G17, Y at G18) _TP[x,4]
tem!
Technology Settings
54630 $SNS_MEA_TP_TRIG_PLUS_DIR_AX3 Trigger point of the 3rd measuring axis in positive direction (applicate, Z at G17, Y at G18) _TP[x,5]
tem!
54631 $SNS_MEA_TP_EDGE_DISK_SIZE Effective edge length or grinding wheel diameter of the tool probe. _TP[x,6]
Milling tools are normally measured with wheel-shaped probes while turning tools are measured 9765
with square probes.
54632 $SNS_MEA_TP_AX_DIR_AUTO_CAL Enabling axes and traversing directions for "Automatic calibration" of milling tool probes. _TP[x,7]
The default setting refers in X and Y to the plus and minus direction respectively, in Z only to the 9764
minus direction.
The parameter is divided into three components the functions of which are to be assigned to 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 20
Ones: 1st geometry axis (X)

Tens: 2nd geometry axis (Y)
Hundreds: 3rd geometry axis (Z)
Value:
=0: Axis not enabled
=1: Only minus direction possible
=2: Only plus direction possible
=3: Both directions possible
54633 $SNS_MEA_TP_TYPE Tool probe type _TP[x,8]
0: Cube 9763
101: Wheel in XY, working plane G17
201: Wheel in ZX, working plane G18
301: Wheel in YZ, working plane G19
54634 $SNS_MEA_TP_CAL_MEASURE_DEPTH Distance between the upper tool probe edge and the lower milling tool edge. _TP[x,9]
For tool probe calibration this distance defines the calibration depth and for milling tool measuring 9767
the measuring depth!
Appendix B
This parameter does not apply to turning tool measuring!
54635 $SNS_MEA_TP_STATUS_GEN Calibration status general, reserved for internal use!
Appendix B
The value of this parameter is assigned when the “Calibrate tool probe“ procedure is executed!
54636 $SNS_MEA_TP_FEED Measuring feed for tool probe calibration in WMCS
This measuring feed is used for all subsequent tool measuring programs in conjunction with the
probe filed!
Appendix B
Appendix B
54640 $SNS_MEA_TPW_TRIG_MINUS_DIR_AX1 Trigger point of the 1st measuring axis in negative direction (abscissa, X at G17, Z at G18) _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 $SNS_MEA_TPW_TRIG_PLUS_DIR_AX1 Trigger point of the 1st measuring axis in positive direction (abscissa, X at G17, Z at G18) _TPW[x,1]
Technology Settings
tem!
54642 $SNS_MEA_TPW_TRIG_MINUS_DIR_AX2 Trigger point of the 2nd measuring axis in negative direction (ordinate, Y at G17, X at G18) _TPW[x,2]
tem!
54643 $SNS_MEA_TPW_TRIG_PLUS_DIR_AX2 Trigger point of the 2nd measuring axis in positive direction (ordinate, Y at G17, X at G18) _TPW[x,3]
Page 21
tem!
54644 $SNS_MEA_TPW_TRIG_MINUS_DIR_AX3 Trigger point of the 3rd measuring axis in negative direction (applicate, Z at G17, Y at G18) _TPW[x,4]
tem!
54645 $SNS_MEA_TPW_TRIG_PLUS_DIR_AX3 Trigger point of the 3rd measuring axis in positive direction (applicate, Z at G17, Y at G18) _TPW[x,5]
tem!
54646 $SNS_MEA_TPW_EDGE_DISK_SIZE Effective edge length or grinding wheel diameter of the tool probe. _TPW[x,6]
Milling tools are normally measured with wheel-shaped probes while turning tools are measured
with square probes.

Technology Settings
54647 $SNS_MEA_TPW_AX_DIR_AUTO_CAL Enabling axes and traversing directions for "Automatic calibration" of milling tool probes. _TPW[x,7]
The default setting refers in X and Y to the plus and minus direction respectively, in Z only to the
minus direction.
The parameter is divided into three components the functions of which are to be assigned to cali-
bration data records 1, 2 or 3!
The calibration data records are firmly assigned to tool measuring in the working planes G17 (1),
G18 (2) and G19 (3)!
Meaning of the parameter components
Decimal position:
Ones: 1st geometry axis (X)
Tens: 2nd geometry axis (Y)
Hundreds: 3rd geometry axis (Z)
Value:
=0: Axis not enabled
=1: Only minus direction possible
=2: Only plus direction possible
=3: Both directions possible
Page 22
54648 $SNS_MEA_TPW_TYPE Tool probe type _TPW[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
54649 $SNS_MEA_TPW_CAL_MEASURE_DEPTH Distance between the upper tool probe edge and the lower milling tool edge. _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!
54650 $SNS_MEA_TPW_STATUS_GEN Calibration status general, reserved for internal use!
The value of this parameter is assigned when the “Calibrate tool probe“ procedure is executed!
54651 $SNS_MEA_TPW_FEED Measuring feed for tool probe calibration in WCS
This measuring feed is used for all subsequent tool measuring programs in conjunction with the
probe filed!
54652 $SNS_MEA_INPUT_TOOL_PROBE_SUB CNC measurement input for tool probe with reference to the counterspindle 9828
Appendix B
=0: Toolsetter no.=n+1, with reference to the main spindle
CNC measurement input corresponds to the value of $MCS_MEA_FUNCTION_MASK, bit16
=10: Toolsetter no.=n+1, with reference to the counterspindle
Appendix B
units digit =0, corresponds to CNC measurement input 1

=11: Toolsetter no.=n+1, with reference to the counterspindle
units digit =1, corresponds to CNC measurement input 2
Appendix B
Appendix B
54670 $SNS_MEA_CM_MAX_PERI_SPEED Max. permissible peripheral speed of the tool to be measured when the spindle rotates. _CM[0]
Monitoring parameter for tool measuring with rotating spindle. 9759
54671 $SNS_MEA_CM_MAX_REVOLUTIONS Max. permissible tool speed for tool measuring with rotating spindle. _CM[1]
The speed is automatically reduced when this value is exceeded. 9760
Monitoring parameter for tool measuring with rotating spindle.
54672 $SNS_MEA_CM_MAX_FEEDRATE Max. permissible feed for contact of the tool to be measured with the probe when the spindle ro- _CM[4]
Technology Settings
tates. 9771
54673 $SNS_MEA_CM_MIN_FEEDRATE Min. feed for first contact of the tool to be measured with the probe when the spindle rotates. _CM[4]
Too small feeds for large tool radii are thus avoided! 9761
54674 $SNS_MEA_CM_SPIND_ROT_DIR Direction of spindle rotation for tool measuring with rotating spindle (default: 4 = M4) _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!
Page 23
54675 $SNS_MEA_CM_FEEDFACTOR_1 Feedrate factor 1, for tool measuring with rotating spindle _CM[6]
=0: Single probing with the feedrate calculated by the cycle (but at least with the value of 9769
$SNS_MEA_CM_MIN_FEEDRATE)
>=1: First probing with calculated feedrate (but at least with the value of
$SNS_MEA_CM_MIN_FEEDRATE).
54676 $SNS_MEA_CM_FEEDFACTOR_2 Feedrate factor 2, for tool measuring with rotating spindle _CM[7]
=0:Second probing with the feedrate calculated by the cycle (only effective with 9770
MEA_CM_FEEDFACTOR_1 > 0)
>=1: Second probing with calculated feedrate, feedrate factor 2
Third probing with calculated feedrate (tool speed is influenced by SD54749
$SNS_MEA_FUNCTION_MASK_TOOL, Bit 12)
Notice: - Feedrate factor 2 should be smaller than feedrate factor 1!
- If the value of feedrate factor 2 is 0, a third probing will not be not performed!
Technology Settings
54677 $SNS_MEA_CM_MEASURING_ACCURACY Required measuring accuracy for tool measuring _CM[3]
The value of this parameter always refers to the last contact of the tool with the probe! 9762
54689 $SNS_MEA_T_PROBE_MANUFACTURER Tool probe type (manufacturer) _TP_CF

These indications are required for tool measuring with rotating spindle. 9774
=0: No indication
=1: TT130 (Heidenhain)
=2: TS27R (Renishaw)
54691 $SNS_MEA_T_PROBE_OFFSET Measurement result offset for tool measuring with rotating spindle. _MT_COMP
=0: No offset 9775
=1: Cycle-internal offset (only effective with SD54689
$SNS_MEA_T_PROBE_MANUFACTURER<>0)
=2: Offset through user-defined offset table
54692 $SNS_MEA_T_CIRCULAR_ARC_DIST Arc distance for single cutting edge measuring from the radius
54693 $SNS_MEA_T_MAX_STEPS Max. number of contacts for single cutting edge measuring from the radius
Page 24
54695 $SNS_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 radi-
us and 1st peripheral speed
$SNS_MEA_RESULT_OFFSET_TAB_RAD2[2] ... offset value for radius regarding 2nd radi-
$SNS_MEA_RESULT_OFFSET_TAB_RAD2[3] ... offset value for radius regarding 3rd radi-
$SNS_MEA_RESULT_OFFSET_TAB_RAD2[4] ... offset value for radius regarding 4th radi-
Appendix B
Appendix B
Appendix B
Appendix B
$SNS_MEA_RESULT_OFFSET_TAB_RAD3[0] ... 2nd peripheral speed
$SNS_MEA_RESULT_OFFSET_TAB_RAD3[1] ... offset value for radius regarding 1st radius
and 2nd peripheral speed
$SNS_MEA_RESULT_OFFSET_TAB_RAD3[2] ... offset value for radius regarding 2nd radius
$SNS_MEA_RESULT_OFFSET_TAB_RAD3[3] ... offset value for radius regarding 3rd radius
Technology Settings
$SNS_MEA_RESULT_OFFSET_TAB_RAD3[4] ... offset value for radius regarding 4th radius
$SNS_MEA_RESULT_OFFSET_TAB_RAD4[0] ... 3rd peripheral speed
and 3rd peripheral speed
Page 25

$SNS_MEA_RESULT_OFFSET_TAB_RAD5[0] ... 4th peripheral speed
and 4th peripheral speed
Technology Settings
$SNS_MEA_RESULT_OFFSET_TAB_RAD6[0] ... 5th peripheral speed
54705 $SNS_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
Page 26
$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
Appendix B
Appendix B
Appendix B
Appendix B
$SNS_MEA_RESULT_OFFSET_TAB_LEN4[0] ... 3rd peripheral speed
Technology Settings
$SNS_MEA_RESULT_OFFSET_TAB_LEN5[0] ... 4th peripheral speed
Page 27

$SNS_MEA_RESULT_OFFSET_TAB_LEN6[0] ... 5th peripheral speed
Technology Settings
54740 $SNS_MEA_FUNCTION_MASK Function mask for measuring cycles
Bit 0: Workpiece measurement, repeat measurement if _TDIF and _TSA are exceeded _CBIT[0]
Bit 1: Workpiece measurement, repeat measurement with alarm output and cycles stop at M0 _CBIT[1]
Bit 2: Workpiece measurement, exceeding _TUL, _TLL, _TDIF, cycles stop at M0 _CBIT[2]
Bit 3: Workpiece measurement, accept calibrated probe radius in the tool data _CBIT[15]
Bit 4: Workpiece measurement, calibr. meas. planes different for turn .mill. tech.
Bit 16: Tool measurement, repeat measurement if _TDIF and _TSA are exceeded _CBIT[0]
Bit 17: Tool measurement, repeat measurement with alarm output and cycles stop at M0 _CBIT[1]
Bit 18: Tool measurement, exceeding _TDIF, cycles stop at M0 _CBIT[2]
Bit 19: Tool meas. milling machine, spindle speed reduction during last touching _CHBIT[22]
54750 $SNS_MEA_ALARM_MASK Expert mode for cycle alarms
Bit 0 - 7 Workpiece measurement
Bit 0 =1 Alarms with cycle-internal states and coding are displayed (expert mode)!
Bit 1 - 7 Reserved
Bit 8 -16 Tool measuring
Bit 0 - 7 Reserved
54760 $SNS_MEA_FUNCTION_MASK_PIECE Setting for input screen, measuring cycles in Automatic, workpiece measuring
Page 28
Bit 1: Display softkey 3D measurement

Bit 3: Select probe calibration data field, enable
Bit 4: Select Calibrate Input measuring feed
Bit 6: Enable selection of WO compensation in basic reference
Bit 7: Enable selection of WO compensation in channel-specific basic WO
Bit 8: Enable selection of WO compensation in global basic WO
Bit 9: Enable selection of WO compensation in work offset
Bit 10: Enable selection of WO compensation in course and fine
Bit 11: Enable selection of tool offset wear and geometry
Bit 12: Enable selection of tool offset not inverted and inverted
Bit 13: Enable selection of tool offset radius, length L1, L2, L3
Bit 14: Enable selection of tool offset work offset
Bit 15: Enable selection of tool offset dimensional difference check
Bit 16: Selection of workpiece measurement with spindle reversal
Bit 17: Selection align workpiece probe in switching direction
Bit 18: Select Number of measurements
Bit 19: Select Offset with averaging
Appendix B
Bit 20: Select Empirical values
Bit 21: Select Additive setup offset
Bit 22: Select Calibrate to unknown or known center point
Appendix B
Bit 24: Select Calibrate with or without positional deviation

Bit 25: Selection zero offset when measuring the angularity of the spindle
Appendix B
Appendix B
54762 $SNS_MEA_FUNCTION_MASK_TOOL Setting for input screen, measuring cycles in Automatic, tool measuring
Bit 4: Select Calibrate Input measuring feed
Bit 5: Select Input feed and spindle speeds for contacting
Bit 7: Select Measure in MCS and WCS
Bit 8: Select Measure absolute and incremental
Bit 9: Select Tool offset Geometry and wear
Bit 10: Selection single cutting edge measuring
Technology Settings
Bit 11: Selection spindle reversal when calibrating on the plane
Bit 12: Select Number of measurements
Bit 13: Select Empirical values
54764 $SNS_MEA_FUNCTION_MASK_TURN Setting for input mask, Measuring cycles in Automatic, Workpiece turning
Bit 0: Measure Diameter inside/outside with reversal
Bit 1: Measure Diameter inside/outside “Travel under turning center“?
54780 $SNS_J_MEA_FUNCTION_MASK_PIECE Setting for input screen, Measure in JOG, workpiece measurement 9747
Bit 2: Activate calibration for electronic workpiece probe
Bit 5: Select WO as measuring basis
Page 29
Bit 6: Select WO compensation in basic reference, enable

Bit 7: Select WO compensation in channel basic frame, enable
Bit 8: Select WO compensation in global basic frame, enable
Bit 9: Select WO compensation in settable frame, enable
54782 $SNS_J_MEA_FUNCTION_MASK_TOOL Setting for input screen, Measure in JOG, tool measurement 9749
Bit 2: Enable automatic tool measurement
Bit 3: Select tool probe calibration data field, enable
Bit 10: Selection single cutting edge measuring
Bit 11: Selection spindle reversal when calibrating on the plane
Channel Setting Data
Technology Settings
55200 $SCS_MAX_INP_FEED_PER_REV Feedrate input upper limit for mm/rev 9665
55201 $SCS_MAX_INP_FEED_PER_TIME Feedrate input upper limit for mm/min 9664

55202 $SCS_MAX_INP_FEED_PER_TOOTH Feedrate input upper limit for mm/tooth 9666
55212 $SCS_FUNCTION_MASK_TECH_SET Function mask Cross-technology
Bit 0: Tool preselection active 9667
Bit 1: Calculate thread depth from metric thread lead 9640
Bit 2: Refer to the table for thread diameter and depth
55214 $SCS_FUNCTION_MASK_MILL_SET Function mask Milling
Bit 0: Default setting - milling cycles with synchronous operation 9827
Bit 2: Depth calculation in milling cycles without parameter SC _ZSD[9]
= 0: Depth calculation in milling cycles is carried out between reference plane + safety
clearance and depth
= 1: Depth calculation in milling cycles is carried out without inclusion of the safety clear-
ance
Note: Bit 2 is active with the following milling cycles: CYCLE61, CYCLE71, CYCLE76, CYCLE77, _ZSD[1]
Page 30
CYCLE79, CYCLE899, LONGHOLE, SLOT1, SLOT2, POCKET3, POCKET4

55216 $SCS_FUNCTION_MASK_DRILL_SET Function mask Drilling
Bit 0: reserved
Bit 1: Consider rotation of the tool plane (CYCLE86)
Bit 2: Consider swiveled table kinematics (CYCLE86)
Bit 3: Monitoring spindle MD 31050/31060 (CYCLE84)
Bit 4: Monitoring spindle MD 31050/31060 (CYCLE840)
Bit 5: reserved
Bit 6: Adapt spindle position to the tool orientation (CYCLE86)
Bit 7: Adapt direction of retraction path in the plane to active mirroring (CYCLE86)
55218 $SCS_FUNCTION_MASK_TURN_SET Function mask Turning
Bit 0: New thread table during thread cutting
Bit 1: Reserved (CYCLE93)
Bit 2: Reserved (CYCLE93)
Bit 3: Chamfer in CYCLE930 as chamfer length (CHF)
55220 $SCS_FUNCTION_MASK_MILL_TOL_SET Function mask High Speed Settings CYCLE832
Appendix B
Bit 0: Unhide technology fields CYCLE832
Bit 1: Orientation tolerance (OTOL) as a tolerance factor, enter it directly
Appendix B
Appendix B
Appendix B
55221 $SCS_FUNCTION_MASK_SWIVEL_SET Function mask Swivel CYCLE800
Bit 0: Display input field "No swivel"
Bit 1: Retraction variant Z, Z XY or fixed position
= 0: Retract Z or retract Z XY
= 1: Retract to fixed position 1 or 2
Bit 2: Allow selection "Deselection" of the swivel data block
Bit 3: Show active swivel plane under Swivel in JOG
Bit 4: Optimized positioning in basic position (pole position) of the kinematics
Technology Settings
Bit 5: reserved
Bit 6: Do not offer swivel mode “directly under swivel in JOG
55230 $SCS_CIRCLE_RAPID_FEED Rapid traverse feedrate in mm/min for positioning on circle path between circumferential grooves 9724
and contour elements
55231 $SCS_MAX_INP_RANGE_GAMMA Maximum input area alignment angle gamma 9863
55232 $SCS_SUB_SPINDLE_REL_POS Z retraction position for the counter spindle 9851
55260 $SCS_MAJOG_SAFETY_CLEARANCE Safety clearance for machine JOG
55261 $SCS_MAJOG_RELEASE PLANE Retraction plane for machine JOG

Page 31
55410 $SCS_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
55420 $SCS_MILL_SWIVEL_RESET_RETRACT Initial setting swivel: retract
= 0: no change
= 1: no
= 2: Z
= 3: Z XY
= 4: Tool direction max.
= 5: Tool direction inc.
55421 $SCS_MILL_SWIVEL_RESET_TRACK Initial setting swivel: tool correction
= 0: no change
= 1: do not correct
= 2: correct
55441 $SCS_MILL_TOL_TECHNO_ROUGH Settings for roughing High Speed Settings cycle CYCLE832 of G group 59 _TOLT[1]
55442 $SCS_MILL_TOL_TECHNO_SEMIFIN Settings for pre-finishing High Speed Settings cycle CYCLE832 of G group 59 _TOLT[2]
55443 $SCS_MILL_TOL_TECHNO_FINISH Settings for finishing High Speed Settings cycle CYCLE832 of G group 59 _TOLT[3]
55446 $SCS_MILL_TOL_VALUE_ROUGH Tolerance value for roughing High Speed Settings cycle CYCLE832 _TOLV[1]
55447 $SCS_MILL_TOL_VALUE_SEMIFIN Tolerance value for pre-finishing High Speed Settings cycle CYCLE832 _TOLV[2]
55448 $SCS_MILL_TOL_VALUE_FINISH Tolerance value for finishing High Speed Settings cycle CYCLE832 _TOLV[3]
Technology Settings
55460 $SCS_MILL_CONT_INITIAL_RAD_FIN This data affects the radius of the approach circle during contour pocket finishing. 9670
-1: The radius is selected to maintain a safety clearance to the finishing allowance in the starting
point.
>0: The radius is selected to maintain the value of this setting data to the finishing allowance in the
starting point.
55481 $SCS_DRILL_TAPPING_SET_GG12 Settings for tapping G group 12 cycle CYCLE84 and CYCLE840: 9855[0]
G group 12: Block change behaviour at exact stop (G60) 9856[1]
0 = Exact stop behaviour, same as before the cycle call
1 = G601
2 = G602
3 = G603
Index[0]: for tool spindle
Index[1]: for main spindle - for drilling in centre
55482 $SCS_DRILL_TAPPING_SET_GG21 Settings for tapping G group 21 cycle CYCLE84: 9855[0]
G group 21: Acceleration profile (SOFT, BRISK, ..) 9856[1]
0 = Acceleration behaviour, same as before the cycle call
Page 32
1 = SOFT
2 = BRISK
3 = DRIVE
55483 $SCS_DRILL_TAPPING_SET_GG24 Settings for tapping G group 24 cycle CYCLE84 and CYCLE840: 9855[0]
G group 24: Feedforward control (FFWON, FFWOF ) 9856[1]
0 = Feedforward control, same as before the cycle call
1 = FFWON
2 = FFWOF
55484 $SCS_DRILL_TAPPING_SET_MC Setting for tapping cycle CYCLE84 spindle operation at MCALL 9855[0]
0= Reactivate spindle operation at MCALL 9856[1]
1= Maintain position-controlled spindle operation at MCALL
Appendix B
55489 $SCS_DRILL_MID_MAX_ECCENT Maximum centre offset for centre drilling 9862
Appendix B
55490 $SCS_DRILL_SPOT_DIST Rough drilling depth for drill and thread milling 9682
Appendix B
Appendix B
55500 $SCS_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.
55505 $SCS_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 $SCS_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.
Technology Settings
-1: The distance is specified internally.
55510 $SCS_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
55540 $SCS_TURN_PART_OFF_CTRL_DIST Path for cut-off check 9859
55541 $SCS_TURN_PART_OFF_CTRL_FEED Feedrate for cut-off check 9860
55542 $SCS_TURN_PART_OFF_CTRL_FORCE Force in percent for cut-off check 9861
Page 33
55543 $SCS_TURN_PART_OFF_RETRACTION Retraction path prior to cut-off with counter spindle
55550 $SCS_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 setting data 55551
$SCS_TURN_FIXED_STOP_FEED).
55551 $SCS_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 $SCS_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 $SCS_TURN_FIXED_STOP_RETRACTION Retraction path prior to chucking after travel to fixed stop 9857
55580 $SCS_TURN_CONT_RELEASE_ANGLE This setting data defines the angle by which the tool is retracted from the contour during contour
turning roughing.
55581 $SCS_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 $SCS_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.
Technology Settings
55583 $SCS_TURN_CONT_VARIABLE_DEPTH Percentage for variable cutting depth during contour turning 9556
55584 $SCS_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 $SCS_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 $SCS_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 $SCS_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.
Page 34
Example:
If this MD is set to 50% and if the finishing allowance is 0.5 mm, the residual material which is
thinner than 0.25 mm is not removed in a separate machining step, but during finishing.
55588 $SCS_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
thinner than 0.25 mm is not removed in a separate machining step, but during finishing.
55595 $SCS_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 $SCS_TURN_CONT_TURN_RETRACTION Retraction depth prior to plunge turning 9561
Appendix B
Appendix B
Appendix B
Appendix B
55613 $SCS_MEA_RESULT_DISPLAY Measurement result display _CHBIT[10]

=0: No measurement result display _CHBIT[11]
=1: The measurement result is displayed until cycle end _CHBIT[18]
=2: The measurement result is displayed until the start/call of the next cycle
=3: With the measurement result display, the cycle is stopped by an internal M0, with NC start,
the measuring cycle is continued and the measurement result display is deselected
=4: The measurement result display is only shown for cycle alarms 61303, 61304, 61305, 61306
Same behavior as with setting 3!
Technology Settings
55618 $SCS_MEA_SIM_ENABLE Selection of measuring cycle response in a simulated environment
= 0: Measuring cycles are not executed (measuring cycle is skipped internally)
= 1: Measuring cycles are executed; real axes are required!
During calibration no values are entered in the probe data fields,
no measurement result is displayed,
the measuring cycle is not logged,
the travel is performed without collision detection.
55619 $SCS_MEA_SIM_MEASURE_DIFF With this parameter simulated measurement errors can be specified on the measuring points. _MC_SIMDIFF
Provided that SD55618 $SCS_MEA_SIM_ENABLE=1 is used and that the measuring cycles are
Page 35
executed in a simulated environment of HMI Advanced or ShopMill / ShopTurn, a measurement

difference can be entered in this parameter. The value of the measurement difference must be
smaller than the measuring path in parameter _FA!
Otherwise cycle alarm 61301 "Probe does not switch" is output during active simulation.
55622 $SCS_MEA_EMPIRIC_VALUE_NUM Number of empirical values _EVMVNUM[0]
55623 $SCS_MEA_EMPIRIC_VALUE In its default setting the empirical value memory consists of 20 memory elements. _EV[n]
Using parameter $SCS_MEA_EMPIRIC_VALUE_NUM the number of memory elements can be
defined! Currently, however, these 20 memory elements can-not be changed!
In the empirical value memory, empirical values can be stored which are cleared with the currently
calculated difference between the setpoint and the actual value.
Using parameter _EVNUM the empirical value element to be cleared is addressed!
55624 $SCS_MEA_AVERAGE_VALUE_NUM Number of mean values _EVMVNUM[1]

Technology Settings
55625 $SCS_MEA_AVERAGE_VALUE In its default setting the mean value memory consists of 20 memory elements. _MV[n
Using parameter $SCS_MEA_AVERAGE_VALUE_NUM the number of memory elements can be
defined! Currently, however, these 20 memory elements can-not be changed!
In the mean value memory, the mean values calculated in connection with functionality "Automatic
tool offset with mean value creation" are stored.
Using parameter _EVNUM the mean value element to be used is addressed!
55628 $SCS_MEA_TP_FEED_MEASURE Feed for calibrating a tool probe with stationary spindle in AUTO and JOG 9773
55630 $SCS_MEA_FEED_MEASURE Feed for calibrating a workpiece probe in Automatic and JOG 9756
55632 $SCS_MEA_FEED_RAPID IN_PERCENT Traverse velocities for positioning in the measuring cycle between the measuring positions, with _SPEED[0]
rapid traverse velocity in per cent, with collision detection not active
Note:
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!!
Page 36
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 (SD55740 $SCS_MEA_FUNCTION_MASK Bit0/Bit16=1) or
- without collision detection (SD55740 $SCS_MEA_FUNCTION_MASK Bit0/Bit16=0).
Depending on this setting different velocities are used for the approach:
- with collision detection (SD55740 $SCS_MEA_FUNCTION_MASK Bit0/Bit16=1):
With SD55634 $SCS_MEA_FEED_PLAN_VALUE the traversing feed is performed in the plane
and with SD55636 $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 (SD55740 $SCS_MEA_FUNCTION_MASK Bit0/Bit16=0):
The intermediate positions are approached with the maximum axis velocity (rapid traverse) in per-
cent as specified in SD55632 $SCS_MEA_FEED_RAPID_IN_PERCENT.
With SD55632 $SCS_MEA_FEED_RAPID_IN_PERCENT=0 and SD55632
$SCS_MEA_FEED_RAPID_IN_PERCENT=100 the maximum axis velocity is effective.
Appendix B
55634 $SCS_MEA_FEED_PLANE_VALUE Traverse velocity for intermediate positioning in the plane _SPEED[1]
Appendix B
Appendix B
Appendix B
55636 $SCS_MEA_FEED_FEEDAX_VALUE Traverse velocities for intermediate positioning in the measuring cycle in the infeed axis, with and _SPEED[2]
without collision detection.
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!!
Technology Settings
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 (SD55740 $SCS_MEA_FUNCTION_MASK Bit0/Bit16=1) or
- without collision detection (SD55740 $SCS_MEA_FUNCTION_MASK Bit0/Bit16=0).
Depending on this setting different velocities are used for the approach:
- with collision detection (SD55740 $SCS_MEA_FUNCTION_MASK Bit0/Bit16=1):
With SD55636 $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
Page 37
and the alarm "Probe collision" is output.

- without collision detection (SD55740 $SCS_MEA_FUNCTION_MASK Bit0/Bit16=0):
The intermediate positions are approached with the maximum axis velocity (rapid traverse) in per-
cent as specified in SD55632 $SCS_MEA_FEED_RAPID_IN_PERCENT.
With SD55632 $SCS_MEA_FEED_RAPID_IN_PERCENT=0 and SD55632
$SCS_MEA_FEED_RAPID_IN_PERCENT=100 the maximum axis velocity is effective.
55638 $SCS_MEA_FEED_FAST_MEASURE Rapid measuring feed _SPEED[3]
Note:
If necessary, adjust the value of the velocity to the probe type used and to the machine characteris-
tics!
This means that the maximum deflection of the actual probe type must be considered!!
The use of "Rapid measuring feed" depends of SD55740 $SCS_MEA_FUNCTION_MASK Bit4!
55640 $SCS_MEA_FEED_CIRCLE Circular feed for measuring circle segment
55642 $SCS_MEA_EDGE_SAVE_ANG Additional safe angle for measuring corner

Set $SCS_MEA_EDGE_SAVE_ANG=10 for compatibility programs.

Technology Settings
55740 $SCS_MEA_FUNCTION_MASK Function mask for measuring cycles

Bit 0: Workpiece measurement, collision monitoring _CHBIT[2]
Bit 1: Workpiece measurement, coupling spindle with coordinate rotation around Z in automatic _CHBIT[13]
Bit 2: Workpiece measurement, coupling spindle , positioning direction of spindle _CHBIT[14]
Bit 3: Workpiece measurement, no. of meas. attempts with non-switching of probe _CHBIT[15]
Bit 4: Workpiece measurement, approach velocity to the measuring point _CHBIT[17]
Bit 5: Workpiece measurement, retraction velocity from the measuring point _CHBIT[16]
Bit 6: Workpiece measurement, probe activation/deactivation with spindle motions
Bit 7: Measure kinematics, normalization basis of orientation vectors
Bit 8: Measure kinematics, measuring with TRAORI or TCARR (CYCLE800) active
Bit 14: Workpiece measurement, coupling spindle with coordinate rotation around Z in JOG E_MESS_SETT[0]
Bit 15: Workpiece measurement, known/unknown reference ring center point in JOG E_MESS_SETT[1]
Bit 16: Tool measurement, collision monitoring _CHBIT[2]
Bit 17: Tool measurement, no. of meas. attempts with non-switching of probe _CHBIT[15]
Bit 18: Tool measurement, approach velocity to the measuring point _CHBIT[17]
Bit 19: Tool measurement, retraction velocity from the measuring point _CHBIT[16]
55800 $SCS_ISO_M_DRILLING_AXIS_IS_Z Selection of the drilling axis
Page 38
0: Drilling axis is vertical to the active plane

1: Drilling axis is always "Z", independently of the active plane
55802 $SCS_ISO_M_DRILLING_TYPE Tapping type
0: Tapping without compensating chuck
1: Tapping with compensating chuck
2: Deep hole tapping with chip breakage
3: Deep hole tapping with stock removal
55804 $SCS_ISO_M_RETRACTION_FACTOR Factor for retraction speed (0...200%)
55806 $SCS_ISO_M_RETRACTION_DIR Retraction direction for precision drilling and reverse counter-sinking G76/G87
0: G17(-X) G18(-Z) G19(-Y)
1: G17(+X) G18(+Z) G19(+Y)
2: G17(-X) G18(-Z) G19(-Y)
3: G17(+Y) G18(+X) G19(+Z)
4: G17(-Y) G18(-X) G19(-Z)
Appendix B
55808 $SCS_ISO_T_RETRACTION_FACTOR Factor (1-200%) for retraction speed at tapping G84/G88
Appendix B
55810 $SCS_ISO_T_DWELL_TIME_UNIT Dwell time evaluation for deep hole drilling G83/G87
0: Seconds
1: Revolutions
Appendix B: END
Appendix C PLC Interface
Sinumerik
Operate
PLC Interface:
START
DB21-30
NC
Channels
Machine
Control
Panel
DB31-61
Axis/Spindle
DB2
PLC
Messages
DB71-74
Tool
Management
DB10
NCK
Interface
DB77
MCP
Signals
DB11
Mode
Group
PLC Interface:
END
DB18
SI
Signals
DB19
HMI
Sinumerik
Interface
DB20
PLC
Machine
Data
Appendix C
Appendix C PLC Interface Structure
Interface Description
Signals from/to Operator Component
Machine control panel, M version
Signals from machine control panel (keys)

Input display

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 Reset Key- Single block Feedrate override
switch posi-
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
IB n + 5 Axis selection
Y Z 5th axis Traverse 9th axis 8th axis 6th axis
R2 R3 R5 command R11 R9 R8 R6
MCS/WCS
IB n + 6 Unassigned customer keys
T9 T10 T11 T12 T13 T14 T15

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

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

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

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

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

Input display

IB n + 1 Machine function
REPOS REF Var. INC 10000 INC 1000 INC 100 INC 10 INC 1 INC
IB n + 2 Keyswitch Keyswitch Spindle start *Spindle stop Feed start *Feed stop NC Start *NC Stop
position 0 position 2
IB n + 3 Reset Keyswitch Single block Feed override
position 1
E D C B A
IB n + 4 Direction keys Keyswitch Direction keys
position 3
+Y -Z -C
R15 R13 R14 R1 R4 R7 R10
IB n + 5 Direction keys
+X +C Rapid 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
QB n + 4 Unassigned customer keys Direction key

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

Machine control panel, slimline

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

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

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

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

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

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

T9 T10 T11 T12 T14 T15 T16

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

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

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

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

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

T9 T10 T11 T12 MCS/WCS T14 T15 T16

T1 T2 T3 T4 T5 T6 T7 T8
Notes

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

Input display

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

edgement
Keyswitch E D C B A
Digital
display
Notes

Signals to handheld unit (LEDs)

Output display

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

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

Interface HT 8  PLC

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

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

Signals to machine control panel simulation

Interface PLC  HT 8

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

PLC alarms / messages

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

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

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


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


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


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


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


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


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

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

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

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

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


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


(Message type)
Notes

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

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

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

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

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

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

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

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

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

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

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

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

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

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


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


(Message
type)
Notes

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


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


(Message type)
Notes


(Message type)
Notes

Signals from/ to NCK, PLC, HMI

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

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

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

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

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

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

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

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

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

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

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

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

displayed WCS
Notes

DB10 Signals from (NCK -> PLC)

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

DBB85 MCP2AxisFromHMI
HT 8  HMI
DBB86 Reserved
DBB88 Reserved
Notes

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

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

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

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

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

General signals from NCK (DB10)

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

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

15 14 13 12 11 10 9 8

23 22 21 20 19 18 17 16

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

7 6 5 4 3 2 1 0

15 14 13 12 11 10 9 8

23 22 21 20 19 18 17 16

31 30 29 28 27 26 25 24
Notes


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

External digital inputs of the NCK (DB10)

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



Notes

External digital outputs of the NCK (DB10)

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


Notes

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

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

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

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

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


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

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

Analog input and output signals of the NCK (DB10)

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

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

Ethernet-Handrad stands still

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

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

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

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

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

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

/Z1-K1/
REF REPOS TEACH IN

Notes

DB11 Signals to mode group 2 (PLCNCK)

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

DBB24 Strobe mode
HMI  PLC /Z1-K1/
JOG MDA AUTO
DBB25 Strobe machine function
HMI à PLC /Z1-K1/
REF REPOS TEACH IN
DBB26 All channels NCK internal Mode group Mode group Active operating mode
in reset state JOG active reseted ready /Z1-K1/
/Z1-K1/ /Z1-K1/ /Z1-K1/
/Z1-K1/
JOG MDA AUTO
DBB27 Active machine function
/Z1-K1/
REF REPOS TEACH IN
DBB28 Machine functions
Notes

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

DBB0- unassigned
DBW34
DBB36 Stop E SPL READY

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

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


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

Supplementary data areas

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

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

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

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

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

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

F_SENDDP (transmitter)

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

DBW200
ERR_REAC
DBB203
DBW204 DIAG
DBW206 RETVAL14
DBW208 RETVAL15

DBW210
ERR_REAC
DBB213
DBW214 DIAG
DBW216 RETVAL14
DBW218 RETVAL15
Notes

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

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

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

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

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

DBD256 SPL_USER_DATA[0]
Notes

Signals from/to operator panel (DB19)

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

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

DB19 Signals from operator panel (HMI  PLC)

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

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


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

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

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

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

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

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


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

1st online interface
DBB117 Direct key address

2nd nline interface
DBB118 TCU index

1st online interface
DBB119 TCU index

nd
2 online interface
Online interface HMI 1 (user)

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

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

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


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

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

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

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

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

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

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

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

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

DBB250 - Commands
DBB256 - Commands for Paramtm.exe

DBB268 Traffic light status

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

DBD394 Optional package TPM on HMI-Advanced required
Notes

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

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

Channel signals (DB21 - DB30)

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

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

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

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

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

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


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

Notes

Operating signals from HMI/status signals from NC channel

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

DBB24 Dry run M01 select- Select NCK- DRF select- ePS loading pro-
HMI  feedrate ed /Z1-K1/ related M01 ed /Z2-H1/ gram
selected /
PLC Z1-V1/
DBB25 Program REPOS Feedrate REPOSPATHMODE
HMI  test select- MODE override for
ed /Z1-K1/ EDGE rapid traverse
PLC 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
on
DBB31 Skip block active REPOS REPOSPATHMODE
PLC  MODE EDGE
NCK /9 /8 2 1 0
DBB32 Last action M00/M01 Approach Action Execution from
NCK  block ac- active block active / block ac- external source
PLC tive /Z1- /Z1-K1/ Z1-K1/ tive /Z1- active
K1/ K1/
DBB33 Program Transfor- M02/M30 Block search Handwheel Revolutio-nal Orientable Referencing active
NCK  test active / mation active active override feedrate active toolholder ac- /Z1-R1/
PLC Z1-K1/ active /Z1- /Z1-K1/ /Z1-K1/ active /Z1-V1/ tive
K1/ /Z2-H1/
/K2-M1/
DBB34 OEM channel signals feedback
NCK 
PLC
DBB35 Channel status /Z1-K1/ Program status /Z1-K1/

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

DB21 – Signals from NCK channel (NCK  PLC,

DB30 HMI  PLC, PLC  NCK)

DBB37 Stop at Read-in ena- CLC CLC CLC Contour handwheel active /Z2-H1/
NCK  block end ble is ignored stopped stopped active
PLC with SBL is /Z1-K1/ upper lower limit / /Z3-TE1/ Handwheel 3 Handwheel 2 Hand-
sup- limit /Z3- Z3-TE1/ wheel 1
pressed TE1/
DBB38 Nibbling and punching /Z2-N4/

NCK 
PLC Acknowl. manual Stroke
stroke enable enable
/Z2-N4/ active
/Z2-N4/
DBB39 Protection
NCK  zones not
PLC guaran-
teed
Notes

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

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

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

/Z2-H1/
DBB50
HMI  PLC

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

/Z2-H1/
DBB56
HMI  PLC
Notes

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

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

Transferred M/S functions

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

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

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

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

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

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

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

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

Transferred H/F functions

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

Decoded M signals (M0–M99)

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

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

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

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

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

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

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

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

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

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

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

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

/Z1-H2/
M99 M98 M97 M96
DBB207
Notes

Active G functions

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

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

Instruction controlled signals to NC channel

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




Notes

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

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

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


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



Cyclic Signals
DBB316 Active G functions

G00 geo.
DBB317
Tool missing PTP motion Travel re- Workpiece External
active quest drive setpoint language
/FB3/F2/ test reached mode active
DBB318
Overstore Dry-run Associat- Stop delayed TOFF move- TOFF active Search active ASUP
active feedrate edM01 ment active /FB1/F2 stopped
/F1/A2 active active /FB3/F2/ /FB1/K1/
/FB1/V1/ /FB3/H2/
DBB319
No tool Stop-delay- Repos Delay FTS Repos Path Repos Path Repos Path REPOS
change com- range not DEFERRA L Mode Ackn 2 Mode Ackn 1 Mode Ackn 0 MODE
mand active activated Chan /FB1/K1/ /FB1/K1/ /FB1/K1/ EDGE ACKN
FB1/K1 /FB1/K1/
Notes

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

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

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

erse override key stop (bit value coding)

plus minus Rapid Traversing Feed Activate handwheel

traverse key stop (bit value coding)
override disable
Notes


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

Active machine function

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

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

Notes

Tool management functions from NC channel

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

Signals from/to NC channel

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

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

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

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

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

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

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

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

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

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

Axis and
spindle
OEM axis signals

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

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

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


DB61
Start brake
test
DBB11
Delay refer- Modulo Limit 2nd software limit switch Hardware limit switch
DBB12 ence point Enabled /Z1-A3/ /Z1-A3/
Axis approach /Z1 plus minus plus minus
-R1/
Jogging to JOG fixed- JOG fixed- JOG fixed-
DBB13 position point ap- point ap- point ap-
Axis proach 2 proach 1 proach 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


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- OscillAxExt-
DBB28 axis /Z2-P5/ reversal point versal point point /Z2-P2/ Reset Reversal
Grinding /Z2-P5/ /Z2-P5/ /Z2-P5/ /Z2-P5/ /Z2-P2/
Pendeln
Disable auto- Start gantry

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


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

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

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

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

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

DB61
Position reached with exact References synchronizes /Z1 Encoder limit frequency ex- NCU_Link Spindle
DBB60 stop -R1/ ceeded /Z1-A3/ Axis active /no axis
Axis and /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 contain- Force fixed Fixed stop Activate trav- Measure- Revolutio-nal Handwheel Software
er rotation stop limited / reached el to fixed ment active feedrate overlay ac- cams active /
DBB62 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 pos- requested by
DBB68 /Z2-K5/ /Z2-K5/ sible PLC
/Z2-K5/ /Z2-K5/ D C B A
NCU number in NCU link network Control parameter block
DBB69 E D C B A C B A
Repos delay Repos shift Repos shift
DBB70 quit valid
PLC axis POS_RESTORED Brake test

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


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

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

DBB92 released function gen-
Drive erator Block
activ
Enable puls- n controller Drive Active motor /Z1-A2/ Active drive parameter set 0 … 7
DBB93 es 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
Drive complete -A2/
/Z1-A2/ /Z1-A2/ /Z1-A2/ /Z1-A2/
/Z1-A2/ Heat sink Motor
DBB95
Drive
Master/ Bitwert für CTR- Master/ Slave Axis control Error rotation
slave active LOUT_changed: active monitoring
Compen- coarse fine
DBB96 /Z3-TE3/ 1 0 /Z3-TE6/
sation con-
Change setpoint output as- troller activ
signment (for compile cycles)
Notes


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

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

Safety Integr.
Notes


DB61

Safety Integr.

Safety Integr.

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

Safety Integr. 4 3 2 1

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

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


DBB122 Nockenbereichsbit für Nockenspur 3

DBB123 Nockenbereichsbit für Nockenspur 3



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

Tool management interface

Interface for loading/unloading magazine (DB71)
DB71 Interface for loading/unloading magazine (NCK  PLC)
DBB0 Interface (I) active
I8 I7 I6 I5 I4 I3 I2 I1
DBB1
I16 I15 I14 I13 I12 I11 I10 I9
DBB2 Standard end-of-acknowledgement
I8 I7 I6 I5 I4 I3 I2 I1
DBB3
I 16 I 15 I 14 I 13 I 12 I 11 I 10 I9
DBB n + 0 Reserved Reserved Position- Order from NC- Positioning Relocate Unload Load
ing Program Magazine
Multitool
DBB n + 1 File in ex- Reserved Reserved Reserved Reserved Reserved Reserved 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

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
movement
DBB n + 29
Reserved
Initial addresses of the loading/unloading stations:

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

Interface for spindle as change position (DB72)

DB72 Signals from spindle (NCK  PLC)
I8 I7 I6 I5 I4 I3 I2 I1
DBB1
I16 I15 I14 I13 I12 I11 I10 I9
DBB2 Standard end-of-acknowledgement
I8 I7 I6 I5 I4 I3 I2 I1
DBB3
I 16 I 15 I 14 I 13 I 12 I 11 I 10 I9
DBB n Spindle Replace man- Replace manual OldT in buff- T0 Prepare Perform Compul-
ual tool tool er no (n-42) change change sory
Tool (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

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

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

Interface for circular magazine (DB73)

DB73 Signals from circular magazine (NCK  PLC)
I8 I7 I6 I5 I4 I3 I2 I1
DBB1
I16 I15 I14 I13 I12 I11 I10 I9
Standard end-of-acknowledgement
DBB2
I8 I7 I6 I5 I4 I3 I2 I1
DBB3
I 16 I 15 I 14 I 13 I 12 I 11 I 10 I9
DBB n
Reserved Replace Reserved Reserved T0 Reserved Perform change Obligatory
manual (initiation: change
tool T no.)
DBB n + 1 File in 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)
DBW n + 30 Tool new: size left (INT)
DBW n + 32 Tool new: size right (INT)
DBW n + 34 Tool new: size top (INT)
DBW n + 36 Tool new: size bottom (INT)
Notes

DB73 Signals from circular magazine (NCK  PLC)

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

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

Distance code
DBW n+0
Number of Multitool locations

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

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

Interface for spindle (Multitool) (DB1072)

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

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

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

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

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

DBW n+18
Tool size right

DBW n+20
Tool size above

DBW n+22
Tool size below

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

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

DBW n+32
Original location of new tool

DBW n+34
Reserved
DBW n+36
Notes

Interface for Revolver (Multitool) (DB 1073)

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

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

DBW n+8
Multitool location numberr (tool new)

DBW n+10
Multitool number (tool old)

DBW n+12
Multitool location numberr (tool old)

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

DBW n+18
Tool size right

DBW n+20
Tool size above

DBW n+22
Tool size below

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

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

DBW n+32
Original location of new tool

DBW n+34
Reserved
DBW n+36
Notes

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

En 840D SL Complete Service v45

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SINUMERIK 840D sl

This document was produced for training purposes.

Service Manual for

Sinumerik 840D sl Software 4.5

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

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

Content: 840D sl with TCU

840D sl with PCU50.x and TCU

A060 Page 2 840D sl Sinumerik Operate

840D sl Sinumerik Operate Page 3 A060

840D sl with TCU

X120 system network

A060 Page 4 840D sl Sinumerik Operate

DVI External monitor

OP0xx & PCU50.x

X120 system network

840D sl Sinumerik Operate Page 5 A060

840D sl with PCU50.x and TCU

X120 system network

A060 Page 6 840D sl Sinumerik Operate

SINUMERIK and SINAMICS automation system components.

840D sl Sinumerik Operate Page 7 A060

840D sl NCU and NX

840D sl NCU and NX

SINAMICS S120 Line Module

Property NCU 710.3 PN NCU 720.3 PN NCU 730.3 PN

Cooling ribs No Yes Yes

A060 Page 8 840D sl Sinumerik Operate

840D sl Sinumerik Operate Page 9 A060

Schematic representation of the NCU 7x0

Internal structure of the NCU

A060 Page 10 840D sl Sinumerik Operate

Measuring Sockets Location:

T1 Measuring socket 2 Load current: max. 3 mA

M Ground The reference potential is terminal M

840D sl Sinumerik Operate Page 11 A060

Name Function Status Meaning

Flashing red/orange Error accessing Compact Flash Card

A060 Page 12 840D sl Sinumerik Operate

840D sl Sinumerik Operate Page 13 A060

Status LEDs - NX10.3 / 15.3

LED Color Status Description

Green Continuous light NX is ready for operation

A060 Page 14 840D sl Sinumerik Operate

The following table illustrates this relation:

DRIVE-CLiQ Port Drive PROFIBUS addresses

840D sl Sinumerik Operate Page 15 A060

S120 Booksize Components

840D sl as central control unit

Line Modules for power supply :

One or several motor modules to control the motors

Optional DC Link Components

Additional Optional Components:

Sensor Modules: SMC10 (Resolver)

Terminal Modules: TM15, TM31, TM41

Active/ Smart Line Module

Single/ Double Motor Module