BA 802D 05 05 - University of Colorado Boulderucc.colorado.edu/siemens/802Dsl_BE_0505_en.pdfiii SINUMERIK 802D sl Instruction Manual (BA), 05/2005 Edition 6FC5 397-0CP10-1BA0 Preface

Instruction Manual 05/2005 Edition

sinumerik

SINUMERIK 802D slSiemens Automation Parts

https://industrialautomation.co/product-category/siemens/page/7256/

Valid for

Control system Software versionSINUMERIK 802D sl 1

05/2005 Edition

SINUMERIK 802D sl

Instruction Manual

System Overview 1

Component Description 2

Operator Controls and Displays 3

Interfaces 4

Dimensional Drawingsand Drill Patterns 5

Installation 6

Connection 7

Technical Data 8

Start-Up 9

Creating a Drive Project 10

Starting Up the PLC 11

Data Backup and Series Machine Start-Up 12

Machine/Setting Data A

Standards and Approvals B

ESD Directive C

Terms of License DSiemens Automation Parts


Siemens AGAutomation and DrivesPostfach 4848D–90437 NÜRNBERGGERMANY

Copyright () Siemens AG 2005.6FC5397–0CP10–1BA0

Siemens AG 2005Subject to change without prior notice.

Safety NotesThis Manual contains information which you should carefully observe to ensure your own personal safetyand the prevention of material damage. The notices are highlighted by a warning triangle and, depending onthe degree of hazard, represented as shown below:

!Danger

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

!Warning

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

!Caution

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

Caution

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

Attention

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

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

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

Use as intendedPlease note the following:

!Warning

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

TrademarksAll designations with the trademark symbol are registered trademarks of Siemens AG. Other designationsin this documentation may be trademarks whose use by third parties for their own purposes may infringe therights of the owner.

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

iiiSINUMERIK 802D sl Instruction Manual (BA), 05/2005 Edition6FC5 397-0CP10-1BA0

Preface

SINUMERIK Documentation

The SINUMERIK documentation is organized in 3 parts:

General Documentation

User Documentation

Manufacturer/Service Documentation

More detailed information about other publications concerning SINUMERIK 810D and 840Dand publications that apply to all SINUMERIK control systems (e.g., Universal Interface,Measuring Cycles, etc.) can be obtained from your local Siemens branch office.

A list of documents, updated on a monthly basis, is available on the Internet for the availablelanguages at:http://www.siemens.com/motioncontrolSelect “Support”/“Technical Documentation”/“Overview of Documents”.

The Internet version of the DOConCD (DOConWEB) is available at:http://www.automation.siemens.com/doconweb

Target readership of this documentation

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

Standard version

This Instruction Manual describes the functionality of the standard scope. Extensions orchanges made by the machine manufacturer are documented by the machine manufacturer.

Other functions not described in this documentation might be executable in the control. Thisdoes not, however, represent an obligation to supply such functions with a new control orwhen servicing.

Hotline

If you have any questions, please contact the following hotline:A&D Technical SupportPhone: +49 (0) 180 / 5050 – 222Fax: +49 (0) 180 / 5050 – 223Internet: http://www.siemens.com/automation/support–request

If you have any comments, suggestions, or corrections regarding this documentation, pleasefax or e-mail them to:

Fax: +49 (0) 9131 / 98 – 63315E-mail: [email protected]

Fax form: See the reply form at the end of the brochure.

Siemens Automation Parts


Preface

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

6FC5 397-0CP10-1BA0

Internet address

http://www.siemens.com/motioncontrol

Table of Contents

vSINUMERIK 802D sl Instruction Manual (BA), 05/2005 Edition6FC5 397-0CP10-1BA0

Table of Contents

1 System Overview 1-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 Description 2-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 Operator Controls and Displays 3-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1 Operator controls 3-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2 Error and status displays 3-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 Interfaces 4-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1 CNC operator panel (PCU) interfaces 4-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.1 Compact flash card (CF card) slot 4-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.2 Ethernet interface 4-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.3 USB port (available soon) 4-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.4 RS232 COM interface 4-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.5 PROFIBUS DP interface 4-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.6 DRIVE CLiQ interface 4-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.7 Handwheel connection 4-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.8 Digital inputs/digital outputs 4-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2 MCPA module interfaces 4-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3 PP 72/48 I/O module interfaces 4-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 Dimension Drawings 5-39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1 Dimension drawing and drilling pattern for the CNC operator panel (PCU) 5-40. . . . . . . . . . . . .

5.2 Dimension drawing and drilling pattern for the machine control panel (MCP) 5-42. . . . . . . . . . .

5.3 Dimension drawings and drilling patterns for the NC full keyboard 5-44. . . . . . . . . . . . . . . . . . . .

5.4 Dimension drawing for the PP72/48 I/O module 5-48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 Installation 6-49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 Connecting 7-51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1 General rules for operation of a SINUMERIK 802D sl 7-52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.2 Rules regarding current consumption and power loss of a cubicle arrangement 7-53. . . . . . . .

7.3 Overall design of the SINUMERIK 802D sl 7-54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.4 Connecting the protective conductor for the individual components 7-55. . . . . . . . . . . . . . . . . . .

7.5 Connection overview for the SINUMERIK 802D sl 7-56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.6 Connecting the MCPA module 7-59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.7 Connecting the analog spindle 7-60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.8 Connecting the power supply 7-61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.9 Connecting the full keyboard to the CNC operator panel 7-63. . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.10 Connecting the Ethernet interface 7-64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.11 Connecting the RS232 COM port 7-65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.12 Connecting the PP72/48 I/O module and the drive 7-66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.13 Connecting the SINAMICS drive to the DRIVE-CLiQ interface 7-70. . . . . . . . . . . . . . . . . . . . . . .

7.14 Connecting the digital inputs/outputs to the PCU 7-71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.15 Connecting the digital inputs/digital outputs to the PP72/48 I/O module 7-72. . . . . . . . . . . . . . . .

7.16 Connecting the machine control panel to the PP72/48 I/O module 7-73. . . . . . . . . . . . . . . . . . . .



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7.17 Connecting shielded lines via the shield connection (PCU) 7-74. . . . . . . . . . . . . . . . . . . . . . . . . .

8 Technical Data 8-75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 Commissioning 9-79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.1 General 9-79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1.1 Access levels 9-80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1.2 Structure of machine data (MD) and setting data (SD) 9-81. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1.3 RCS802D Commissioning and Diagnostic tool 9-82. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.2 Turning on and booting the control system 9-83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.3 Language setting and file management 9-84. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3.1 Creating a project 9-84. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3.2 Help, language and alarm files 9-85. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3.3 Transmitting data to the 802D 9-85. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.4 Setting the technology 9-88. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.5 Entering the machine data 9-90. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.6 Setting the Profibus address 9-91. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.7 Starting Up the PLC 9-92. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.8 Configuring SINAMICS S120 with 802D sl 9-93. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8.1 Commissioning using predefined macros without the STARTER commissioning tool 9-93. . . . 9.8.2 Starting up motors without SMI 9-97. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8.3 Faults and warnings when starting up the SINAMICS S120 drive 9-97. . . . . . . . . . . . . . . . . . . . . 9.8.4 Setpoint/actual-value assignment 9-98. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8.5 Default settings of the axis machine data for feed axes 9-99. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8.6 Default settings of the axis machine data for the spindle 9-101. . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.9 STARTER start-up tool 9-105. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9.1 Explanations regarding the STARTER user interface 9-105. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9.2 Operating philosophy of the STARTER commissioning tool for SINAMICS S120 9-106. . . . . . . .

9.10 Start-up sequence when working with STARTER 9-109. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10.1 Creating a drive object OFFLINE 9-109. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10.2 Operating the STARTER control panel (motor rotating) 9-110. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10.3 Creating a drive project ONLINE (recommended) 9-110. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.11 Diagnosis via STARTER 9-111. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11.1 Function generator 9-112. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11.2 Trace function 9-115. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11.3 Measuring function (SERVO) (available soon) 9-116. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11.4 Measuring sockets (available soon) 9-119. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.12 Completing the start-up 9-120. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.13 Service display of the axis drive behavior 9-121. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 Creating a Drive Project 10-123. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.1 Creating a drive project OFFLINE 10-123. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1.1 Creating a project 10-123. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1.2 Configuring a drive unit 10-131. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.2 Operating the control panel in STARTER (with the motor rotating) 10-140. . . . . . . . . . . . . . . . . . . . 10.2.1 Loading the project into the drive unit 10-140. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2.2 Operating the control panel 10-143. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.3 Creating a drive project ONLINE 10-150. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3.1 Creating a project 10-150. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3.2 Acquiring the component topology and configuring the drive unit automatically 10-153. . . . . . . . . 10.3.3 Configuring and checking the topology of the drives 10-157. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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viiSINUMERIK 802D sl Instruction Manual (BA), 05/2005 Edition6FC5 397-0CP10-1BA0

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

11.1 Commissioning the PLC 11-164. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.2 Start-up modes of the PLC 11-164. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.3 PLC alarms 11-166. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3.1 General PLC alarms 11-167. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3.2 User alarms 11-167. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.4 PLC programming 11-170. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.4.1 Command overview 11-171. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.4.2 Explanation of the stack operations 11-174. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.4.3 Program organization 11-181. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.4.4 Data organization 11-181. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.4.5 Interface to the control system 11-181. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.4.6 Testing and monitoring your program 11-182. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.5 PLC applications Download/Upload/Copy/Compare 11-183. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.6 User interface 11-185. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 Data Backup and Series Machine Start-Up 12-187. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12.1 Data backup 12-187. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1.1 Internal data backup 12-187. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1.2 External data backup 12-188. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1.3 Data backup via V24 12-189. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1.4 External data backup via CF Card 12-189. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12.2 Series machine start-up 12-190. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12.3 Data backup in case of backlight failure 12-193. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A Machine and Setting Data 802D A-195. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A.1 List of machine data A-196. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.1 Display machine data A-196. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.2 General machine data A-201. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.3 Channelspecific machine data A-206. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.4 Axisspecific machine data A-214. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A.2 Setting data A-226. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A.3 SINAMICS parameters A-230. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B Standards and Approvals B-231. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B.1 Electromagnetic compatibility B-232. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B.2 Transport and storage conditions B-234. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B.3 Mechanical and climatic ambient conditions for operation B-234. . . . . . . . . . . . . . . . . . . . . . . . . . .

B.4 Information on insulation tests, safety class, and degree of protection B-236. . . . . . . . . . . . . . . . .

B.5 Safety of electronic control systems B-237. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C Directive for handling electrostatically sensitive devices (ESD) C-239. . . . . . . . . . . .

C.1 What does ESD mean? C-239. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C.2 Electrostatic charging of persons C-240. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C.3 Basic protective measures against discharge of static electricity C-241. . . . . . . . . . . . . . . . . . . . .



Table of Contents

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

6FC5 397-0CP10-1BA0

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

D.1 General Terms and Conditions for the Use of Software for Sinumerik and Drive Technology D-243. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

D.2 General Terms and Conditions for the Use of Software for Sinumerik and Drive Technology D-244. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

D.2.1 Delivery of the Software to licensees and granting of rights of use in the Software D-244. . . . . . D.2.2 License type D-245. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.2.3 Software type D-246. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.2.4 Upgrade and PowerPack D-246. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D.2.5 Further rights and duties of the Licensee D-247. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

D.3 License Provisions for Free Software Components D-248. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

D.4 Liability for Free Software D-248. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

D.5 see gpl.txt on the Toolbox CD under /licenses D-249. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

D.6 see bsd.txt on the Toolbox CD under /licenses D-249. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

D.7 see zlip.txt on the Toolbox CD under /licenses D-249. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

D.8 see lgpl.txt on the Toolbox CD under /licenses D-249. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E Abbreviations E-251. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-9SINUMERIK 802D sl Instruction Manual (BA), 05/2005 Edition6FC5 397-0CP10-1BA0

System Overview

Overview

The operator panel of the SINUMERIK 802D sl control systems combines all CNC, PLC,HMI and communication tasks in one component. The maintenance-free hardware integra-tes the PROFIBUS interface for the drives and for the I/O modules with the slimline operatorpanel into a ready-to-install unit (Panel Control Unit).

The SINUMERIK 802D sl can control up to 5 axes digitally. Up to 2 of these 5 axes can beconfigured as a spindle.

1



System Overview

1-10SINUMERIK 802D sl Instruction Manual (BA), 05/2005 Edition

6FC5 397-0CP10-1BA0

System overview: SINUMERIK 802D sl with SINAMICS S120

Digital inputs/digital outputs

CNC operator panel (PCU)

Feed motor 1

Feed motor 2

Feed motor 3

Feed motor 4

Electronic handwheel (max. 2)

Main spindle motor1) when using a

machine control panel

I/O module PP72/48 1)

PROFIBUS DP

PROFIBUS DP

DRIVE-CLiQ

DRIVE-CLiQ

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

SINAMICS S120

Machine control panel (MCP)

1

2 6

Smart Line or Active Line Modules(mains supply)

Single motor module(power section)

...

Mains supplyconductor

654321

I/O module PP72/48

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

System Overview


Components

The components of the SINUMERIK 802D sl control system are:

CNC operator panel (PCU) with NC full keyboard (upright or broad format)

Machine control panel (MCP)

Incorporates all keys and switches required for the operation of a machine (millingmachine).

I/O module PP72/48

The PP72/48 I/O module is a straightforward and low-cost module (without a separatehousing) within the framework of an automation system based on PROFIBUS DP forconnecting digital inputs/outputs.

The module offers the following main features:

– PROFIBUS DP connection (max 12 Mbits/s)

– 72 digital inputs and 48 digital outputs

– On-board status display via 4 diagnostic LEDs

To supply the module and the digital outputs, an external voltage source (+24 V DC) isrequired.

Drive units

– SINAMICS S120

The communication between the SINUMERIK 802D sl control system and theSINAMICS S 120 drive is provided via the DRIVECLiQ communication system(Drive Component Link with IQ).

System software

The following system software is installed in the retentive internal memory of the PCU ofeach SINUMERIK 802D sl by default:

Boot software – starts the system

Human Machine Interface (HMI) software – realizes all operator functions

NCK software (NC Kernel) – realizes all NC functions. It controls up to 5 axes (2 axescan be configured as spindles).

Programmable Logic Control (PLC) software – executes the integrated PLC userprogram cyclically.



System Overview


6FC5 397-0CP10-1BA0

Toolbox

A tool box is delivered on CD ROM together with the appropriate system software.

The toolbox contains software tools for configuring the control system. It must be installedon your PC/PG.

The following software can be found in the Toolbox:

Setup file for the technologies

Cycle packages for the technologies

Reloadable languages

Reloadable system blocks (SDB)

RCS802D Commissioning and Diagnostic tool

This program can be used to transfer texts, user data and programs from the PC to theCNC operator panel (PCU) and vice versa.

“PLC 802 Programming Tool” – tool for creating the PLC user program

PLC user library

“Starter” – parameterization and commissioning tool for the SINAMICS drive

Note

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


Description 2



Description


6FC5 397-0CP10-1BA0

View

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

Graphicaldisplay

Front view of the CNC operator panel(PCU)

Rear view of the CNC operator panel (PCU)

Horizontal softkeys

Vertical softkeys

Power supplyconnection X40

Ethernet interface X5

NC full keyboardconnection X9

PROFIBUS DPinterface X6

DRIVE CLiQ interfaceX1and X2

Digital inputs/outputsX20, X21

RS232 COM port X8

USB port X10

HandwheelconnectionX30

Compact flash card slot

Error and statusdisplays

Front hatch, opened

Optional interface

Grounding screw

Rating plate

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

Description


CNC operator panel (PCU) interfaces

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

Table 2-1 PCU interfaces

Interfaces Function

Compact flash card (CF card)slot

50-pin slot for CF cards, and 4 LEDs

see Chapter 4.1.1

Power supply connectionX40

3-pin screw-type terminal connection for connecting the 24 V loadpower supply

For connecting SINUMERIK 802 D sl, please refer to Chapter 7.8

Ethernet interfaceX5

8-pin RJ45 socket connector for connection to an IndustrialEthernet

see Chapter 4.1.2

USB portX10

4-pin USB host for connecting USB accessories

see Chapter 4.1.3

NC full keyboard connectionX9

6-pin PS/2 socket for connecting the NC full keyboard

see Chapter 7.9

RS232 COM portX8

9-pin DSub connector for connecting a PG/PC

see Chapter 4.1.4

PROFIBUS-DP interfaceX6

9-pin DSub socket for connection to PROFIBUSDP

see Chapter 4.1.5

DRIVE-CLiQ interfaceX1 and X2

8-pin RJ45 socket for connecting the SINAMICS S120 drive

see Chapter 4.1.6

Handwheel connectionX30

12-pin screw-type male connector for connecting max. 2 hand-wheels

see Chapter 4.1.7

Digital inputs/digital outputsX20 and X21

12-pin screw-type male connector for connecting the digital inputsand outputs

see Chapter 4.1.8

TB30 interface 48-pin female connector for connecting the MCPA module

see Chapter 4.2



Description


6FC5 397-0CP10-1BA0

Notes


Operator Controls and Displays

3.1 Operator controls

Use the horizontal and vertical softkeys to select defined functions. For a description of theindividual softkeys, please refer to the SINUMERIK 802D sl Programming and Operator’sGuide.

References: /BP/, Programming and Operator’s Guide

Horizontal softkeys

Vertical softkeys

Fig. 3-1 CNC operator panel

3



3.2 Error and status displays

Operator Controls and Displays


6FC5 397-0CP10-1BA0

3.2 Error and status displays

LEDs on the operator panel CNC (PCU)

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

ERR RDY NC DPERR RDY NC CF

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

Table 3-1 Status and fault displays

LED Meaning

ERR (red) Fault condition

RDY (green) Readiness for operation

NC (yellow) Sign-of-life monitoring

CF (yellow) Reading from / writing to CF card

Note

For error descriptions, see SINUMERIK 802D sl Diagnostics Guide.

References: /DG/, Diagnostics Guide

LEDs on the PP 72/48 I/O module

The following LEDs are installed on the I/O module (see Fig. 4-3): The individual LEDs andtheir functions are described in the table below.

Table 3-2 Status displays

LED Meaning

POWER (green) Power supply of the electronic equipment ready for operation

READY (red) I/O module ready for operation; however, no cyclic data exchange isperformed with DP Master

EXCHANGE (green) I/O module ready for operation; cyclic data exchange with DP Master isperformed

OVTEMP (red) Overtemperature display


Interfaces

4.1 CNC operator panel (PCU) interfaces

4.1.1 Compact flash card (CF card) slot

Only type 1 compact flash cards can be used.

The compact flash card can be used, for example:

for start-up data

for NC programs

to carry out software updates

to store user data

to save parameters which have been set by the user.

4




Interfaces


6FC5 397-0CP10-1BA0

4.1.2 Ethernet interface

A PG/PC can be connected to the Ethernet interface via a Fast Ethernet network. Thedevice connected must possess an Ethernet card and the appropriate software.

Industrial Ethernet is a communication network providing a transmission rate of10/100 Mbps.

Female connector pin assignment

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

Table 4-1 Pin assignment of female connector X5

Schematic view of the female connector, mounting position and labeling

Pin Name Description

1 81 TXP Transmitted data +

2 TXN Transmitted data –

A B 3 RXP Received data +

X5 IEA B

4 not assigned –

5 not assigned –

6 RXN Received data –

7 not assigned –

8 not assigned –

You can obtain additional information about the different cable systems for Ethernet from your SIEMENS contact person.

4.1.3 USB port (available soon)

Interfaces



4.1.4 RS232 COM interface

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

Connector pin assignment

Designation: X8 (RS232)Type: 9-pin D-Sub plug terminal strip

Table 4-2 Pin assignment of connector X8

Schematic view of the femaleconnector, mounting position and labeling


X8RS232

1 DCD Received LineSignal DetectorCarrier Detector

Received signal level

1 2 RXD Received Data Received data

3 TXD Transmitted Data Transmitted data9 4 DTR Data Terminal

ReadyTerminal ready

5 M Ground Ground (GND)

6 DSR Data Set Ready Readiness foroperation

7 RTS Request To Send Transmission request

8 CTS Clear To Send Ready to send

9 notassigned

– –




Interfaces


6FC5 397-0CP10-1BA0

4.1.5 PROFIBUS DP interface

The CNC operator panel (PCU) communicates with the I/O modules via the PROFIBUS DPinterface.

The PROFIBUS DP protocol is used for the communication.

The baud rate of the PROFIBUS DP interface is 12 Mbit/s; the baud rate cannot be chan-ged. Converters for optical fiber cable (OLMs, OLPs) or repeaters are not permitted.

The operator panel CNC provides master functionality.


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


Schematic view of the femaleconnector, mounting positionand labeling


X6DP

1 notassigned

–

X6 2 M24 24 V reference potential (teleservice)1 3 B Data input/output (RS485)

4 RTS Transmission request

9 5 M5 5 V reference potential

6 P5 5 V power supply 90 mA, short-circuit-proof

7 P24 24 V power supply (teleservice) 150 mA, short-circuit-proof, not isolated

8 A Data input/output (RS485)

9 notassigned

–

The CNC operator panel has a fixed PROFIBUS DP address.

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

Interfaces



4.1.6 DRIVE CLiQ interface

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


Designation: X1, X2Type: 8-pin RJ45 socket

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



1 TXP Transmitted data +

81 8 1 2 TXN Transmitted data –81 8 1

3 RXP Received data +

4 not assigned –

X1 X2A AB B 5 not assigned –X1 X2

6 RXN Received data –

7 not assigned –

8 not assigned –

A not assigned –

B not assigned –

Blanking plate for DRIVE-CLiQ interface: Molex corp., order no. 85999-3255




Interfaces


6FC5 397-0CP10-1BA0

4.1.7 Handwheel connection

Max. 2 electronic handwheels can be connected to connector X30 on the CNC operatorpanel (PCU).

The handwheel must meet the following requirements:

Transmission technique: 5 V square wave signals (TTL level or RS422)

Signals: Track A as a true and negated signal (Ua1, Ua1)Track B as a true and negated signal (Ua2, Ua2)

Max. output frequency: 500 MHz

Phase shift oftracks A to B: 90° 30°

Power supply: 5 V, max. 250 mA


Designation: X30Type: 12-pin connector


Schematic view of theconnector


1 3P5 5 V DC supply voltage

1 2 M Ground (GND)

3 1 A Track A, channel 1

4 X1A Track A_N, channel 1

5 1B Track B, channel 1

6 X1B Track B_N, channel 1

7 3P5 5 V DC supply voltage

128 M Ground (GND)

X3012

9 2A Track A, channel 2

10 X2A Track A_N, channel 2

11 2B Track B, channel 2

12 X2B Track B_N, channel 2

Interfaces



4.1.8 Digital inputs/digital outputs

Various sensors and actuators can be connected to the connectors X20 and X21 via digitalinputs/digital outputs.

Max. 16 or 8 digital inputs and 8 digital outputs can be used.

Wiring diagram and block diagram

PROFIBUS

DR

IVE

-CL

iQ s

ock

et 1

X1 X2

CNC operator

panel (PCU)

DR

IVE

-CL

iQ s

ock

et 0

X21

X20

24 V DC ext. power supply

X40

P24

M

PE PE

M

+ 24 V

MP24

DI1

DI0

DI3

DI2

P24_1M3

DI/DO1

DI/DO0

DI/DO2

M_1

M_1

DI/DO3

DI5DI4

DI7DI6

P24_2

M_4

DI/DO5DI/DO4

DI/DO6M_2

M_2

DI/DO7

1

12

P24 M

2

3

4

5

67

8

910

11

X6

1

12

2

3

4

5

67

8

910

11

Grounding

1

23

Fig. 4-1 Connection example




Interfaces


6FC5 397-0CP10-1BA0


Designation: X30Type: 12-pin connector

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

Schematicview

Pin Name Description Technical details

1 DI0 Digital input 0 Input:Voltage: DC 24 V (20 4 28 8 V)1 2 DI1 Digital input 1Voltage: DC 24 V (20.4 ... 28.8 V)Level:

3 DI2 Digital input 2 0 signal: –3...5 V1-signal: 11...30 V

4 DI3 Digital input 31-signal: 11...30 VInput delay:0 → 1 signal: 15 s (typ 6)

5 M_3 Ground for DI0...DI30 → 1 signal: 15 s (typ. 6)1 → 0 signal: 150 s (typically 40)

12

6 P24_1 DC 24 V Supply voltage forDI/DO0...DI/DO3 (requiredfor digital outputs)

For the output:max. output current:1 signal: 5 mA ... 0.5 ATotal current of all outputs:

X2012

7 DI/DO0 Digital I/OTotal current of all outputs: max. 2 A (in case of simultaneous occur-rence 50 %)

8 DI/DO1 Digital I/Orence 50 %)Output delay:0 → 1 signal: 500 s

9 M_1 Ground for DI/DO0...DI/DO3

0 → 1 signal: 500 s(typ. 150 s)1 → 0 signal: 500 s(typ 150 s)

10 DI/DO2 Digital I/O(typ. 150 s)each with RL = 60 ohmsSwitching frequency:

11 DI/DO3 Digital I/OSwitching frequency:100 Hz (ohmic load)2 Hz (inductive load)


2 Hz (inductive load)

For the input:Data see connector X21

1 DI4 Digital input 4 Input:f th d t t X201 2 DI5 Digital input 5for the data, see connector X20

3 DI6 Digital input 6


5 M_4 Ground for DI4...DI7

6 P24_2 DC 24 V Supply voltage forDI/DO4...DI/DO7 (requiredfor digital outputs)

Output:for the data, see connector X20

Input:

X2112 7 DI/DO4 Digital I/O

Input:Voltage: DC 24 V (20.4 ... 28.8 V)Level:X21 8 DI/DO5 Digital I/OLevel:0 signal: –3...5 V


0 signal: 3...5 V1 signal: 11...30 VInput delay:0 → 1 signal: 15 s (typ 6)

10 DI/DO6 Digital I/O0 → 1 signal: 15 s (typ. 6)1 → 0 signal: 150 s (typically 40)

11 DI/DO7 Digital I/O

1 → 0 signal: 150 s (typically 40)


Interfaces



!Danger

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

Digital inputs (PCU)These fast inputs correspond to Standard IEC 1131-2/DIN EN 61131-2, characteristic curvetype 2 (24 V-P-switching). Switches or proximity encoders (2 or 3-wire encoders) can beconnected.

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



4.2 MCPA module interfaces

Interfaces


6FC5 397-0CP10-1BA0


Overview

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

X1020

X1021

X2

X1X701

X110

LED status display

1

1

10

10

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

Table 4-7 Interfaces

Interfaces Function

Interfaces to the MCPX1 and X2

40-pin plug connectors for connecting the machine control panel (MCP)

I/O interfaceX1020 and X1021

10-pin plug connectors for connection of the power supply and of thedigital inputs and ouptuts

Analog spindle connectionX701

9-pin D-Sub connector for connecting an analog spindle with directlymounted spindle actual-value encoder (TTL)

Interface to the PCUX110

48-pin plug connectors for connecting the MCPA module to the PCU

Assignment of the interface to the MCP

Designation: X1, X2Type: 40-pin ribbon-cable connector

Interfaces



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

X1

Pin Name Description Pin Name Description

1 KEY1 Input bit 2 KEY2 Input bit




9 GND 10 KEY9 Input bit




17 KEY16 Input bit 18 GND





27 GND 28 LED1 Output bit

29 LED2 Output bit 30 LED3 Output bit

31 LED4 Output bit 32 LED5 Output bit

33 LED6 Output bit 34 not assigned –

35 not assigned – 36 GND

37 not assigned – 38 not assigned –


X2


3 KEY27 Input bit 4 not assigned –



9 GND 10 FEED_OV_A Input bit

11 FEED_OV_B Input bit 12 FEED_OV_C Input bit

13 FEED_OV_D Input bit 14 FEED_OV_E Input bit



19 SPINDLE_OV_A Input bit 20 SPINDLE_OV_B Input bit

21 SPINDLE_OV_C Input bit 22 SPINDLE_OV_D Input bit

23 SPINDLE_OV_E Input bit 24 not assigned –












Interfaces


6FC5 397-0CP10-1BA0

Assignment of the I/O interface connectors

Designation: X1020, X1021Type: 10-pin connector

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

Schematic view Pin Name Description

11






X1020


X10208 DI6 Digital input 6


10

11 P24 24 V DC supply voltage

1 2 Q0 Digital output 0

3 Q1 Digital output 1




10 7 Q5 Digital output 5

X1021 8 Q6 Digital output 6


10 M Ground (GND)

Interfaces



Connector pin assignment (analog output to the drive)

Designation: X701Type: 9-pin D-Sub terminal strip




X8RS232

1 AnalogOUT

Analog output with signal level 10 V

X8

12 not

assigned–

3 Uni-Dir2 Digital output for unipolar spindle +24 V9 4 Uni-Dir2 Digital output for unipolar spindle +24 V

5 Enable 1 Analog drive enable (contact: electrically isolatedn.o. contact)

6 AnalogOUT

Analog output 0 V Reference signal

7 notassigned

–

8 notassigned

–

9 Enable 2 Analog drive enable (contact: electrically isolatedn.o. contact)



4.3 PP 72/48 I/O module interfaces

Interfaces


6FC5 397-0CP10-1BA0


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

X333 X222 X111

EXCHANGE

READY

OVERTEMP

POWER

I/O moduleinterfaces X111,X222 and X333

Status displays

Terminal stripconverter

to the machine control panel

PROFIBUS DPinterface (X2)

Power supplyconnectionX41

DIL switchS1

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

and a terminal strip converter

PROFIBUS DPinterface (X2)

Power supplyconnectionX41

I/O moduleinterfaces X111,X222 and X333

DIL switchS1

Statusdisplays


X333 X222 X111

EXCHANGE

READY

OVERTEMP

POWER

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

strip converters

Interfaces



PP 72/48 interfaces

The interfaces and the operator controls of the PP 72/48 I/O module and their functions aredescribed in the table below.

Table 4-11 Interfaces

Interfaces Function

PROFIBUS DP interface 9-pin Sub-D socket X2 for connection to the PROFIBUS DP

Power supply connection 3-pin screw-type terminal connection X1 for connecting the 24 V load power supply

For connecting SINUMERIK 802 D sl, please refer to Chapter 7.8

I/O interface 50-pin pin connectors X111, X222, X333 for connecting the machinecontrol panel or the terminal strip converters for the digital inputs/outputs

DIL switch DIL switch S1 for setting the PROFIBUS DP address

see Chapter 7.12

PROFIBUS DP interface (X2)

The PROFIBUS DP protocol is used for the communication.

The baud rate of the PROFIBUS DP interface is 12 Mbps.

The PP 72/48 I/O module provides slave functionality.


Designation: X6Type: 9-pin D-Sub socket connector


Schematic view of theconnector


1 notassigned

–

12 not

assigned –

9 3 B Data input/output (RS485)

4 RTS Transmission requestX2 5 M5 5 V reference potential

6 P5 5 V power supply 90 mA, short-circuit-proof

7 notassigned

–

8 A Data input/output (RS485)

9 notassigned

–




Interfaces


6FC5 397-0CP10-1BA0

I/O interface

The following devices can be connected to the connectors X111, X222 and X333 (50-pin rib-bon-cable plug):

either one machine control panel (MCP) and one terminal strip converter for digital inputs/digital outputs (see Fig. 4-3)

or

three terminal strip converters for digital inputs/digital outputs (see Fig. 4-4)

The terminal strip converters are connected to the PP 72/48 I/O module via ribbon cable.The individual wiring can be performed at the terminal strips according to your particularapplication.


Designation: X111, X222, X333Type: 50-pin ribbon-cable connector

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

Pin Name Description Pin Name Description

1 M Ground (GND) 2 P24OUTINT DC 24 V, internal supplyvoltage for the inputs

3 DI m+0.0 Input bit 4 DI m+0.1 Input bit












27 notassigned

– 28 notassigned

–

29 notassigned

– 30 notassigned

–

31 DO n+0.0 Output bit 32 DO n+0.1 Output bit




39 DO n+1.0 Output bit 40 DO n+1.1 Output bit1) x = 1 for connector X111; x = 2 for connector X222; x = 3 for connector X333

m = 0 for connector X111; m = 3 for connector X222; m = 6 for connector X333n = 0 for connector X111; n = 2 for connector X222; n = 4 for connector X333

Interfaces



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

Pin DescriptionNamePinDescriptionName




47 DOCOMx1) DC 24 V Supply voltage for 48 DOCOMx1) DC 24 V Supply voltage for

49 DOCOMx1)

pp y gthe outputs 50 DOCOMx1)

pp y gthe outputs

1) x = 1 for connector X111; x = 2 for connector X222; x = 3 for connector X333m = 0 for connector X111; m = 3 for connector X222; m = 6 for connector X333n = 0 for connector X111; n = 2 for connector X222; n = 4 for connector X333

!Danger


Note

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




Interfaces


6FC5 397-0CP10-1BA0

Digital inputs

The diagram below shows the connector pin assignment for the digital inputs at connectionX111 (example). The connector pin assignment of X222 and X333 should be performedanalogously.

PP72/48

X111Pin number:

2

26

4

3

:::

P24OUTINT(+24 V DC)

:::

M

1

24 V DC ext. powersupply

+24 V

0 V

1

Receiver

Receiver

Receiver

2

1

2

when using the internal P24OUTINT power supply

when using an external power supply

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

Internal power supply (P24OUTINT)

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

Caution

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

External power supply

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

In this case, X111, X222, X333: Pin 1 (P24OUTINT) remains open.

Interfaces



Digital outputs

The diagram below shows the connector pin assignment for the digital outputs at connectionX111 (example). The connector pin assignment of X222 and X333 should be performedanalogously.

Driver

Driver

Driver

::

PP72/48 X111Pin number:

47, 48, 49, 50(DOCOM1)

M

31

1 (M)

::

Relay

24 V DC ext. powersupply

+24 V 0V

32

46

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

To supply the digital outputs, an external 24 V DC power supply must be connected toDOCOMx (X111, X222, X333: pins 47, 48, 49, 50).

The reference ground of the external power supply must be connected to X111, X222, X333:pin 1 (M).

Caution

It is the user’s responsibility to ensure that the max. current consumption per DOCOMx pin(X111, X222, X333: pins 47 through 50) does not exceed 1 A.

It is imperative to connect the 24 V power supply for the digital outputs for DOCOMx to allfour pins (X111, X222, X333: pins 47 through 50).

!Danger





Interfaces


6FC5 397-0CP10-1BA0

Use of two PP 72/48 I/O modules

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

Table 4-14 Assignment of the input/output bytes

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

Connector X111 X222 X333

Input byte 0...2 3...5 6...8

Output byte 0...1 2...3 4...5

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

Connector X111 X222 X333

Input byte 9...11 12...14 15...17

Output byte 6...7 8...9 10...11


Dimension Drawings 5



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

Dimension Drawings


6FC5 397-0CP10-1BA0

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

Dimension drawing CNC operator panel (PCU)

Required clearance

Req

uir

ed c

lear

ance

708.27

50

330

1515

355

302.

929

5.6

7.2

13.8

0 309.

4

154.

7

161.2

90

321

90°

A

13

∅ 4

.5 (

8x)

A

5020

13

20

A-A

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

Dimension Drawings

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


Drilling pattern for the CNC operator panel (PCU)

0

Z

281.

80.

15

295

0.15

140.

90.

1

281.

80.

15

5 1.6

285

0.3

23

3020.3

5

152

0.1

286.

60.

15

312

0.15

1)M

4 riv

et-d

own,

inse

rt n

ut o

r M

4 ex

trud

ed h

ole

(8x)

2)D

rill h

oles

for

fixin

g th

e po

sitio

n ∅

5.2

mm

(2x

)

Pan

el c

utou

t

Z M4

1)

2)2)

0.5

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



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

Dimension Drawings


6FC5 397-0CP10-1BA0

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

Dimension drawing of the machine control panel (MCP)

6

128

68.7

170

19

3433

159.8

330

152.2

263

∅ 4.5 (6x)

154

17.2

8

90°AA

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

Dimension Drawings

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


Drilling pattern for the machine control panel (MCP)

140

M4

(6x)

1)

290

147

301

141.

2 0

11

7

0

2

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

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



5.3 Dimension drawings and drilling patterns for the NC full keyboard

Dimension Drawings


6FC5 397-0CP10-1BA0


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

Connection socket

0

172.2

86.1

0

2)

320

001033

0

Grounding screw M5

290 2020

24

161.

2

7.7

157.2

165158.8

13.4

330

321 9

15

172.2

142.

2

Note:

1) Add the height of the connector(15 mm) to this dimension (24 + 15) = 39 mm

2) Pin for fixing the position (2∅4.7)

1)

2)

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

Dimension Drawings



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

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

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

3) Please observe the cutting direction.

M4 (6x) 1)

146

151.9

0

Up 3)

73

145.7

0.3

143.

7

5 (2x) 2)

2+3

0.5

303.

5

302.

5

295

0 7.5

8.5

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




Dimension Drawings


6FC5 397-0CP10-1BA0

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

0

309.4

302.2

0

7.2

154.7

145

0

87.5

24

2)

175

0

7.7

1)

2)

13.8

15

295.6

309.4

15

6

169

175

1527

9.4

15

Grounding screw M5

Connection socket

Note:

1) Add the height of the connector (15 mm) to this dimension (24 + 15) = 39 mm

2) Pin for fixing the position (2∅4.7)

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

Dimension Drawings



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

290

76.5

M4

(6x)

1)

153

158

0.5

5 (2

x) 2

)

2 +

3

142.5

285

283.4

1.6

0

5

50

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

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

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



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

Dimension Drawings


6FC5 397-0CP10-1BA0

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

Dimension drawing for the PP72/48 I/O module32

5

10

194

6.5

306

10.5

10 170

35

35

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


Installation

Overview

To install SINUMERIK 802D sl, first secure the individual components on the site of installa-tion and then connect them with each other. When doing so, observe the Section “Configu-ring the electrical design” (see Chapter 7, “Connecting”).

Open-type equipment

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

General procedure when installing SINUMERIK 802D sl

!Warning

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

Note

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

6



Installation


6FC5 397-0CP10-1BA0

Mounting the CNC operator panel (PCU)

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

!Caution

If you do not have access from the rear during installation, you must connect the CNCoperator panel prior to its installation. When doing so, note that connector X40 (powersupplyconnection) and the lines connected to it protrude beyond the mounting edge.

When installing the CNC operator panel, do not pull off the connector; otherwise, thecables could be damaged!

Installing the machine control panel

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

Installing the CNC full keyboard

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

Installing the PP72/48 I/O module

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

Installing the SINAMICS S120 drive

For information regarding the SINAMICS S120 drive system (design, connection, planning,dimensioning, configuring, etc.), see:

References: /GH1/, /GH2/, Equipment Manuals


Connecting

General rules

The present chapter describes various general rules for electrical design. You must observethese rules to ensure trouble-free operation.

Safety rules

To ensure safe operation of your plant, realize the following measures and adapt them toyour particular conditions:

An EMERGENCY STOP strategy in accordance with generally accepted rules of currentengineering practice(e.g., European Standards EN 60204, EN 418, and the like).

additional measures for the limiting of limit positions of axes(e.g. hardware limit switches).

devices and measures for protection of motors and power electronics according to thedesign guidelines for SIMODRIVE or SINAMICS.

To identify hazard sources for the entire plant, we additionally recommend a risk analysis inaccordance with the general safety requirements/Annex 1 of the EC Machinery Directive89/392/EEC.

In this context, observe also Chapter D, “Guideline for handling electrostatically sensitivedevices (ESD)” in this Manual.

Further references

For further information on EMC guidelines, we recommend the publication: EMC InstallationGuideline, Planning Guide (HW)

References: /EMV/, Description

Standards and regulations

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

7



7.1 General rules for operation of a SINUMERIK 802D sl

Connecting


6FC5 397-0CP10-1BA0

7.1 General rules for operation of a SINUMERIK 802D sl

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

Starting the plant after certain events

In case of ... ...

Startup after voltage drop or power failure all hazardous operating conditions must be avoi-ded. If necessary, force an EMERGENCY STOP.

A startup after unlocking the EMERGENCY-OFFequipment

no uncontrolled or undefined start must occur.

Mains voltage

With ... make sure that ...

stationary plants or systems without all-polemains disconnector

building installation must contain a mainsdisconnect switch or a fuse.

load power supplies, power supply modules the set range of the rated voltage complies withthe local mains voltage.

all current circuits deviation of the line voltage from the rated valuemust be within the permitted tolerance (refer to“Technical specifications of the installedcomponents”).

24 V DC power supply

With ... ensure ...

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

Protection against external electrical phenomena

With ... make sure that ...

all plants, installations and systems in which SINUMERIK is installed

the plant, installation or system is connected tothe protective conductor for divertingelectromagnetic interference.

power supply, signal, and bus cables the wiring arrangement and installation complieswith EMC regulations.

signal and bus cables a cable or wire break cannot lead to undefinedstatuses in the plant or system.

Connecting

7.2 Rules regarding current consumption and power loss of a cubicle arrangement


7.2 Rules regarding current consumption and power loss of a cubiclearrangement

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

Note

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

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



7.3 Overall design of the SINUMERIK 802D sl

Connecting


6FC5 397-0CP10-1BA0

7.3 Overall design of the SINUMERIK 802D sl

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

DOCOMx

L1L2L3NPE

CNC operator panel

Grounding rail in the cubicle

M

P24

X40

PE

24 V DC

Cubicle

X1

I/O module PP72/48

M

P24

PE

Low voltage distributione.g. TNS system (3 x 400 V)

Machine controlpanel (MCP)

NC full keyboardHandwheel(option)

P24

M

X111/222/333 1) 2)

M

DOCOMxDOCOMxDOCOMx

1) For use of an external power supply for digital inputs, see Section 4.3 “Digital inputs”.

Ext. power supply

2) The load power supply is configured by the user.

Fig. 7-1 Possibility of supplying the modules

Connecting

7.4 Connecting the protective conductor for the individual components


7.4 Connecting the protective conductor for the individualcomponents

!Caution

The components shown in Fig. 7-1 require connection to a protective conductor. Theindividual components must be connected to the central grounding point.

Make always sure that a low-resistance connection is provided to the protective conductor.

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

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



7.5 Connection overview for the SINUMERIK 802D sl

Connecting


6FC5 397-0CP10-1BA0


SINUMERIK 802D slCNC operator panel (PCU)

X40 24 V DC power supply

X5Ethernet-bus cable

X10

X9 included in the scope ofsupply of the keyboard

X8

X6

X1 and X2

X30

X20andX21

Ethernet node

USB port

NC full keyboard

Electronic hand-wheel (max. 2)


RS232 COMinterface

X111

X222

X333

X2

PP72/48 I/O module(max. 2)

X1

Machine control panel(MCP)


SINAMICS S120(max. 5 axes)

DRIVE-CLiQ


Preassembled cableSingle wiring

X200

6FX80021BA01....

2 x 50-pin 2)

1) Delivered length: 50 m2) standard yard ware

Cable6FX8008-1BD61-1FA0 1)

3 mConnector6FC9348-7HX

Fig. 7-2 Connection overview without MCPA

Connecting



SINUMERIK 802D slCNC operator panel (PCU)

X40 24 V DC power supply

X5Ethernet-bus cable

X10

X9 included in the scope ofsupply of the keyboard

X8

X6

X1 and X2

X30

X20andX21

Ethernet bus nodes

USB port

NC full keyboard

Electronic hand-wheel (max. 2)


RS232 COM port

X111

X222

X333

X2

PP72/48 I/O module(max. 2)

X1Machine control panel(MCP)

MCPA module

SINAMICS S120(max. 5 axes)

DRIVE-CLiQ


Preassembled cableSingle wiring

X200

6FX8002-1BA01-....

1) Delivery length: 50 m

Cable6FX8008-1BD61-1FA0 1)

3 mConnector6FC9348-7HX


X1201 X1202

X1 X2

X110

Fig. 7-3 Connection overview with MCPA




Connecting


6FC5 397-0CP10-1BA0

Note

Connect the lines as shown in Fig. 7-2 or 7-3.

The preassembled cable sets from Siemens provide optimum interference immunity.

For information regarding the cables (cable designations, connector types, etc.) shown in theillustrations, see:

References: /BU/, Catalog or /Z/, Catalog

For information regarding PROFIBUS DP and Ethernet, see:

References: /IKPI/, Catalog

Connecting

7.6 Connecting the MCPA module


7.6 Connecting the MCPA module

The MCPA module is connected to the PCU via X110. The new machine control panel(MCP) is connected using the supplied ribbon cable. X1 is connected to X1201, and X2 toX1202 (see Fig. 7-3).

The power supply to the MCPA module is provided via connector X1021 (PIN1 24 V; PIN10 0 V).

Note

The variable assignment of the machine control panel is described in the PLC user interface(please refer to: Description of Functions 802Dsl).

See also: PLC subroutine library V01.07.00 of SINUMERIK 802D sl.



7.7 Connecting the analog spindle

Connecting


6FC5 397-0CP10-1BA0

7.7 Connecting the analog spindle

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

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

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

Table 7-1 Assignment of the X520 interface

Description of the femaleconnector


1 Reserved, not assigned

–

15 2 Reserved, not assigned

–

1


–

14 P_Encoder 5 V / 24 V Sensor power supply

X520 5 P_Encoder 5 V / 24 V Sensor power supplyX5206 P_Sense Sense input sensor power supply

7 M_Encoder (M) Ground for sensor power supply


–

9 M_Sense Ground sense input

10 R Reference signal R

11 R* Inverted reference signal R

12 B* Inverted incremental signal B

13 B Incremental signal B

14 A* Inverted incremental signal A

15 A Incremental signal A

Caution

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

Connecting

7.8 Connecting the power supply



Connect the required 24 V DC load power supply to the following connectors:

to screw-terminal block X40 of the CNC operator panel

to screw-terminal block X1 of the PP72/48 I/O module

Features of the load power supply

!Danger

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

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

Parameter Values Conditions

Voltage range mean value 20.4...28.8 V

Ripple 3.6 Vss

Non-periodic overvoltage 35 V500 ms duration50 s recovery time

Rated current consumption

CNC operator panel

PP72/48 I/O module

typically 1 A

–

Starting current

CNC operator panel

PP72/48 I/O module

2.6A

–

Power consumption

CNC operator panel

PP72/48 I/O module

max. 50 W

max. 11 W

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

Terminal Signal Description

1 P24 24 V DC

2 M Ground (GND)

3 PE Protective earth

Note

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




Connecting


6FC5 397-0CP10-1BA0

Connecting the mains lines

!Warning

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

For connecting the power supply, use flexible lines with a line cross-section of at least1 mm2.

If you only connect one line per connection, end sleeves are not absolutely necessary.

If you connect several lines per connection, you should use end sleeves.

Remove the isolation from the cable end, fit an end sleeve if necessary, insert the cable end(with end sleeve) into the screw-terminal connection and tighten the fastening screw.

Insert the screw terminal with the cables to connection X40 on the CNC operator panel.

Polarity reversal protection

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

Note

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

Fuse

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

Connecting

7.9 Connecting the full keyboard to the CNC operator panel


7.9 Connecting the full keyboard to the CNC operator panel

The interconnecting cable for connecting the NC full keyboard to the CNC operator panel isincluded in the scope of supply. Connect the female connector X9 on the CNC operatorpanel to the PS/2 socket on the rear of the NC full keyboard.

For more information, please refer to:

References: /BU/, Catalog



7.10 Connecting the Ethernet interface

Connecting


6FC5 397-0CP10-1BA0

7.10 Connecting the Ethernet interface

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

Connecting

7.11 Connecting the RS232 COM port


7.11 Connecting the RS232 COM port

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

Note

Use only shielded lines twisted in pairs; the shield must be connected to the metal ormetalized connector casing on the side of the control system.

The cable set offered as accessories provides maximum interference immunity.

Connection diagram

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

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

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

Shield Shield

RXD

TXD

RXD

TXD

MDSRRTSCTS

DSR

DTR

2

543

78

CTSRTS

DCD DCD

MDTR

1

6

Shield Shield

RXDTXDRXD TXD

MDSRRTSCTS

DSR

DTR

CTSRTS

DCD DCD

MDTR

2

720

3

45

8

6

2

543

78

1

6

2

543

78

1

6

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



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

Connecting


6FC5 397-0CP10-1BA0


PNO design guidelines

For electrical PROFIBUS networks, observe also the PROFIBUS DP/FMS design guidelinesof the PROFIBUS user organization. The contain important measures with reference to thecable routing and for starting up PROFIBUS networks.

Issued by: PROFIBUS-Nutzerorganisation e.V.Haid-und-Neu-Strasse 7D-76131 KarlsruheTel: +49 721 / 9658 590Fax: +49 721 / 9658 589Internet: http://www.profibus.com

Guideline, order no. 2.112

Bus stations

The following bus stations can be connected via the PROFIBUS DP interface:

CNC operator panel (always master)

PP72/48 I/O module (slave)

Bus connector and bus cable

The PROFIBUS cable is a two-core, stranded and shielded cable which must not be twisted,stretched or squeezed.

For more information regarding the bus connector, the bus cable and the cable length,please refer to:


Connecting



Connecting a bus connector

To connect the bus connector, proceed as follows:

1. Connect the bus connector to the module.

2. Screw the bus connector tight.

3. If the bus connector is at the start or end of the PROFIBUS DP connection, you mustconnect the terminator on the connector (switch position “ON”).

Terminatorconnected

Terminator notconnected

on

off

on

off

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

!Warning

A bus segment must always be terminated on both ends; otherwise, the data traffic at thebus could be disturbed.

Make sure that the stations at which the terminator is connected, is always powered, bothduring booting and operation.

The terminator is without effect if the last station to which a bus connector is connected isdead, since the bus connector is powered from the station.

Setting the PROFIBUS DP address

Each bus station must be assigned a PROFIBUS DP address at the PROFIBUS DP for un-ambiguous identification. Each PROFIBUS DP address must be assigned at the bus onlyonce.

On the PP72/48 I/O module, the PROFIBUS DP address is set using the DIL switch S1 (seeFig. 4-3). Use a screw driver to set the PROFIBUS DP address. It results from the additionof the switches to be found on the right (ON position).




Connecting


6FC5 397-0CP10-1BA0

PROFIBUS-DP address

ÉÉÉÉÉÉÉÉÉÉ

ÉÉÉÉÉÉÉÉÉÉ

ÉÉÉÉ1

2

3

4

5

6

7

8

20 (1)

21 (2)

22 (4)

23 (8)

24 (16)

25 (32)

26 (64)

ON

Example: PROFIBUS DP address = 9

1

ÉÉ

ÉÉÉÉ

ÉÉÉÉ1

2

3

4

5

6

7

8

ON

not assigned

8

1 + 8 = 9

ÉÉÉÉ

ÉÉÉÉÉÉÉÉ

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

Changing the PROFIBUS DP address

You can change the PROFIBUS DP address once set at any time. However, the controlsystem will accept the newly set PROFIBUS DP address only after turning off/turning on the24 V DC power supply.

Connecting



Networking example

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

SINUMERIK 802D sl

X6

0 to x PROFIBUS DP addresses of the stations

CNC operatorpanel (PCU)

X2

1. PP72/48I/O module

X2

2. PP72/48I/O module

DP master DP slave

Terminator activated

Maximum cable length of 100 m (from one terminator to another)

12 MBaud

9 8

Cable routing (bus connector):

Terminator

A1

B1

ON

B1

A1 A1

B1

OFF

B2

A2 A1

B1

ON

B2

A2

PCU 1. PP72/48

2. PP72/48

1)

1) Shield connected within the connector

1)

A1, 2 = green; B1, 2 = red

Fig. 7-7 Networking example



7.13 Connecting the SINAMICS drive to the DRIVE-CLiQ interface

Connecting


6FC5 397-0CP10-1BA0

7.13 Connecting the SINAMICS drive to the DRIVE-CLiQ interface

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

SINAMICS

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

SINAMICS

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

*) Input of the measuring system

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

Connecting

7.14 Connecting the digital inputs/outputs to the PCU


7.14 Connecting the digital inputs/outputs to the PCU

Connection cables

To connect the digital inputs and outputs, you should use flexible lines with a cross-sectionof at least 0.5 mm2.

If you only connect one line per connection, end sleeves are not absolutely necessary.

If you connect two lines per connection, lines with a cross-section between 0.25 and0.75 mm2 with end sleeve must be used.

Fasten the lines to the supplied screw terminals and insert the terminals to the connectorsX20 and X21 on the CNC operator panel.

Note

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

The max. line length is 30 m.



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

Connecting


6FC5 397-0CP10-1BA0

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

You can use the I/O interfaces X111, X222, X333 as digital inputs or digital outputs. To thisend, fasten the insulation displacement connector to the ribbon cable and route it from theI/O module to the terminal strip converter. The individual wiring can be performed on the ter-minal strip connectors.

Remove the insulation from the cable end, insert the cable end (with end sleeve) into thescrew terminal connection and tighten the fastening screw.

Connecting

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


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

To connect the machine control panel (X1201 and X1202) to the PP72/48 I/O module (e.g. X222and X333), use two ribbon cables.

For more information, please refer to:


Note

More information regarding the machine control panel and the pin assignment of theconnectors X1201 and X1202 is to be found on the installed toolbox at:

Start > Programs > Toolbox802sl > PLC802slLibrary > Description.



7.17 Connecting shielded lines via the shield connection (PCU)

Connecting


6FC5 397-0CP10-1BA0

7.17 Connecting shielded lines via the shield connection (PCU)

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

Shield connection

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

Mounting the shield connection

1. Remove the isolation from the shield according to the EMC shield clip.

2. PLace the shield on the housing in the appropriate place (see Fig. 7-10).

3. Snap the EMC shield clip into the appropriate cutout on the housing.

Ensure firm fit of the cable on the housing.

4. For mechanical strain relief of the lines and cables, you can use the cable clamp or theEMC shield clip (see Fig. 7-10).

Cable clamp (4x)

Cutouts for snapping in the4 EMC shield clips

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


Technical Data

User data memory

Compact flash card, type 1 (CF card)

Connected loads of the PCU

Table 8-1 Connected loads

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

Ripple 3.6 Vss

Current consumption from 24 V Basic configuration

typically 1.5 A (inputs/outputs open)

Power loss

CNC operator panel (PCU) with NC fullkeyboard

Machine control panel

PP72/48 I/O module

max. 50 W

5 W

max. 11 W

Starting current, total 5 A

Dimensions and weight

Table 8-2 Weights and dimensions

CNC operator panel (PCU)

Dimensions W H D [mm] 310 330 85

Weight [g] approx. 4,900

NC full keyboard (upright design)



NC full keyboard (broad format)



8



Technical Data


6FC5 397-0CP10-1BA0

Table 8-2 Weights and dimensions, continued

Machine control panel



PP72/48 I/O module


Weight [g]

without mounting plate

with mounting plate

approx. 300

approx. 1,200

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

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

Number of inputs 24 each per terminal strip converter

Parameter min. typical max. nominal

Voltage with high level (UH) 15 V 1) 30 V 24 V

Input current IIn at UH 2 mA – 15 mA –

Voltage with low level (UL) –30 V – 5 V 0 V

Signal delay time TPHL 2) 0.5 ms – 3 ms –

1) Supply voltage for the digital inputsTypical output voltage: VCC – IOUT * RONVCC: Current operating voltage (P24OUTINT) at X111, X222,

X333: Pin 22) In addition, take into account the PROFIBUS DP communication time and the application cycle time.A polarity reversal does not cause a high signal level nor does it destroy the inputs.

Technical Data


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

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

Number of outputs 16 each per terminal strip converter

Parameter min. typical max. nominal

Voltage with high level (UH) VCC – 3 V 1) VCC 24 V

Iout – – 0.25 A –

Voltage with low level (UL) – – – Output open

Leakage current at low signal level – 50 µA 400 µA –

Signal delay time TPHL 2) – – 0.5 ms –

max. switching frequency 2)

ohmic load

inductive load

lamp

100 Hz

2 Hz

11 Hz

–

–

–

–

–

–

–

–

–

1) Supply voltage for the digital outputsTypical output voltage: VCC – IOUT * RONVCC: Current operating voltageMax. output currentIOUT: 0.25 A Max. short-circuit current: 4 A (max. 100 µs, VCC = 24 V)Internal resistanceRON: 0.4 Ω

2) In addition, take into account the PROFIBUS DP communication time and the application cycle time.A polarity reversal does not cause a high signal level nor does it destroy the outputs.

General electric features:

Galvanic isolation through opto-couplers

Current limited to max. 0.25 A

Protection from:

– short-circuit

– overtemperature

– loss of grounding

automatic shutdown in case of undervoltage



Technical Data


6FC5 397-0CP10-1BA0

Notes


Commissioning

9.1 General

Commissioning requirements

You will need the following:

– SINUMERIK 802D sl User Documentation

– SINUMERIK 802D sl Description of Functions

– A PC for commissioning and data backup

– Tools installed from the Toolbox CD:RCS802D Commissioning and Diagnostic ToolPLC802 Programming Tool802D sl Configuration DataPLC LibrarySTARTER (for optimizing the drive)Adobe Acrobat Reader

The mechanical and electrical installation of the system must be completed.

Commissioning sequence

To commission the SINUMERIK 802D sl, proceed as follows:

1. Check that the PCU boots.

2. Set the language.

3. Setting the technology

4. Set the general machine data.

5. Start up the PLC.

6. Start up the drive.

7. Set the axis/spindle-specific machine data.

– Match the encoder to the axis/spindle.

– Match the setpoint to the axis/spindle.

8. Perform a dry run for the axes and for the spindle.

9. Optimize the drive.

10.Complete the commissioning; perform a data backup.

9



9.1 General

Commissioning


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9.1.1 Access levels

Protection levels

The SINUMERIK 802D sl provides a concept of protection levels for enabling data areas.There are the protection levels 0 to 7 whereby 0 is the highest and 7 the lowest level.

The protection levels can be set for certain function areas (e.g. program editor) using thedisplay machine data (USER_CLASS...).

The control system is delivered with default passwords for the protection levels 1 to 3; ifnecessary, these passwords can be changed by the person authorized to do so.

Table 9-1 Protection level concept

Protectionlevel

Locked by Area

0 Siemens, reserved

1 Password: SUNRISE (default) Expert mode

2 Password: EVENING (default) Machine manufacturer

3 Password: CUSTOMER (default) Authorized operator, setter

4 to 7 No password anduser interface from PLC NCK

Authorized operator, setter or appro-priate graduations as desired

Protection levels 1 ... 3

The protection levels 1 to 3 require a password. The passwords can be changed after acti-vation. For example, if the passwords are no longer known, the control system must be reini-tialized (booting with default machine data). This will reset all passwords to their defaultsaccording to the software release you have acquired.

The password remains set until it is reset by selecting the Delete password softkey.POWER ON will notreset the password.

Protection levels 4 ... 7

Protection level 7 is set automatically if no password is set and no protection level interfacesignal is set. The protection levels 4 to 7 can be set from the PLC user program evenwithout a password by setting the bits in the user interface.

Note to the reader

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

Commissioning

9.1 General


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

Number and identifier

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

Activation

The activation stages are listed according to their priority. If any data is changed, it comesinto effect after:

POWER ON (po) Turning off/turning on the SINUMERIK 802D sl

NEW_CONF (cf) With RESET at the PLC interface (V3000 0000.7)

RESET (re) With RESET at the PLC interface (V3000 0000.7) or at the end of theprogram M2/M30

IMMEDIATELY (im) After input of the value

Protection level

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

Unit/system of units

Depending on MD 10240 SCALING_SYSTEM_IS_METRIC, the physical units of themachine data (MD) differ as follows:

MD 10240 = 1 MD 10240 = 0

mm inch

mm/min inch/min

m/s2 inch/s2

m/s3 inch/s3

mm/rev. inch/rev.

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

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



9.1 General

Commissioning


6FC5 397-0CP10-1BA0

9.1.3 RCS802D Commissioning and Diagnostic tool

For commissioning and diagnostic tasks, the RCS802D tool included on the supplied toolboxCD can be used.

This tool provides the following functions:

File management (deletion of files, creation of directories, etc.)

Reading in/reading out setup files, text files, part programs, DDLs or pictures

Remote diagnosis and remote control

Install the RCS802D tool on the PC/PG which you want to use to access the control system.The starting window will be split into two halves. The drives of the control system and of thePC are displayed in the left-hand half, and the contents of the selected directories are dis-played in the right-hand half. Use the right mouse button to open the context menu dis-playing the “Properties” window. It displays the file size, the creation date and the DLLversion.

Commissioning

9.2 Turning on and booting the control system


9.2 Turning on and booting the control system

Procedure

Check the system visually for:

– correct mechanical design and check that all electrical connections are performedcorrectly.

– connected voltages

– connection of shielding and grounding.

Connect the control system (booting in the normal mode)

Booting in the normal mode

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

Booting in the start-up mode

After POWER ON and once the operating system has been started, the word “SINUMERIK”is displayed filling the whole screen. Once this word has disappeared, press the SELECTkey.

The START UP MENU is displayed. Use the arrow key to select an appropriate power-up/start-up mode and press INPUT to confirm.

The modes specified in the START-UP MENU have the following meanings:

normal startup

If this option is chosen, the control system will boot with the last machine data set andthe previously loaded programs.

reload saved user data

If this option is chosen, the user data (machine data, programs, etc.) backed up to theflash memory are accepted.

start-up with default data (is only displayed if protection level 1 or 2 is set)

If this option is chosen, the control system will boot with default machine data.

software update

In this case, the control system will not boot at all. The software can only be updated if aCF card with a software update is inserted in the slot for the CF card.

PLC stop

Select PLC Stop while the control system is booting if PLC Stop can not be triggered viathe user interface any more.



9.3 Language setting and file management

Commissioning


6FC5 397-0CP10-1BA0


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

9.3.1 Creating a project

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

Sequence

Start RCS802D on the PC.

Select the Toolbox > Controller menu item from the Settings menu bar and select theappropriate 802D control.

Thereafter, select the Toolbox version Settings > Toolbox > Select Version.

Use Settings > Toolbox > Select Project to select a project (1), insert front and back-ground languages (2) and create the project (3) (see Fig. 9-1).

Fig. 9-1 Creating a project

Commissioning



9.3.2 Help, language and alarm files

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

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

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

9.3.3 Transmitting data to the 802D

Sequence

Establish a V24 connection between the PC and the PCU (RS232).

Turn on the control system and wait until the control system has completed its bootingsequence without errors.

In the “System” operating area, set the password for protection level 2 or higher.

In the “System” operating area, PLC > STEP7 connect. Check that the settings dis-played on the screen are the same as the settings you have made (see Fig. 9-3); changeif necessary.

Use Connection on to establish the connection.




Commissioning


6FC5 397-0CP10-1BA0

Fig. 9-3 Default communication parameters

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

(default: COM1) and the PCU (RS232) using the appropriate icon . The 802D inter-face parameters can be adapted using the Tools menu in the menu bar, Connect menuitem.

In the menu bar, you can edit the functions Language (to select your 1st and 2nd lan-guages), Help System (contains text files for the online help) and OEM (containstext files for cycles and alarms) which have already been mentioned above underTools > Toolbox Manager, using Write Data to NC. See Fig. 9-4 and Fig. 9-5.

Click OK to transfer your selection to the 802D sl.

Restart the NC.

The required language files are now active.

Commissioning



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

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



9.4 Setting the technology

Commissioning


6FC5 397-0CP10-1BA0


Note

The SINUMERIK 802D sl is delivered with default machine data. In the next step, theappropriate setup file must be loaded from the toolbox into the control system.

The following setup files are offered to choose from:

setup_M.arc Milling machine with complete cycle package

trafo_Mx.ini Machine data for the Tracyl function – milling technology (x ... corresponds to rotary axis A, B, or C)

setup_T.arc Turning

setupTra_T.arc Turning with transformation

The setup file must be loaded during the commissioning after booting of the control system,but prior to the general configuration.

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

Note

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

Sequence

Establish an RS232 connection between the PC and the PCU (RS232 – X8).

Turn on the control system and wait until the control system has completed its bootingsequence without errors.

In the “System” operating area, set the password for protection level 2 or higher.

In the “System” operating area, select PLC > STEP7 connect. Check that the settingsdisplayed on the screen are the same as the settings you have made (cf. Fig. 9-3);change if necessary.

Use Connection on to establish the connection.

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

(default: COM1) and the PCU (RS232) using the appropriate icon . The 802D slinterface parameters can be adapted using the Tools menu in the menu bar, Connectmenu item.

Use Copy/Paste to copy the icon of the setup file into the “Data” folder of drive A of your802D sl (cf. Fig. 9-6).If the toolbox has been installed in the default directory, the setup files are to be found,e.g. at C:\Programs\Siemens\Toolbox 802Dsl\V030005\V01xxyyzz\ TECHNO\MIL-LING\CONFIG_xx\.

The control system boots automatically during the transmission several times.

The SINUMERIK 802D sl is now preset to the required technology.

Commissioning



Fig. 9-6



9.5 Entering the machine data

Commissioning


6FC5 397-0CP10-1BA0

9.5 Entering the machine data

Overview

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

Note

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

Entering the machine data (MD)

Before you can enter the machine data, the password for protection level 2 must be set.

Use the relevant softkey to select the following machine data areas and to change the ma-chine data if necessary:

General machine data MD 10000 ... 19999

Channel machine data MD 20000 ... 29999

Axis machine data MD 30000 ... 39999

Display machine data MD 1 ... 999

Drive machine data r0001 ... r9999 (read-only)p0001 ... p9999 (read and write-enabled)

The data you have entered are written to the data memory immediately. An exception is thedrive machine data. To save the drive machine data permanently, set the parameter p971 foreach individual drive object separately or set p977 of the CU (SINAMICS_I) to “1” and waituntil it is reset automatically. If you forget to save the data, the old data is effective againafter the next drive reset.

The machine data is activated depending on the machine data property “Activated”,Section 9.1.2.

Commissioning

9.6 Setting the Profibus address


9.6 Setting the Profibus address

Certain bus configurations have already been prepared for SINUMERIK 802D sl. Therequired configuration can be set via MD 11240[2]: PROFIBUS_SDB_NUMBER.

Depending on the physical plant configuration, set the relevant setting data bit (SDB) accor-dingly to select the machine data 11240[2] Profibus_SDB_NUMBER. NCK Reset will acceptthe changed machine data.

Table 9-2 SDB number

MD 11240[2] Number of axes

0 2 SINAMICS drive with Smart Line Module (SLM)




4 3 SINAMICS drive with Active Line Modules (ALM)



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

Table 9-3

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

0 PP module 1 9

PP module 2 8

PP module 3 7

Another preconfigured PB station: DP-DP coupler 6

PCU

Is master at PROFIBUS; address cannot be changed

PP 72/48

Is slave at PROFIBUS; max. three PP modules can be connected. The addresses are setusing DIL switch S1 on the PP module.

PB address DIL switch S1 (PP module)9 (default setting)

(PP module 1)

1 + 4 = ON

2 + 3 + 5 + 6 + 7 + 8 = OFF8

(PP module 2)

4 = ON

1 + 2 + 3 + 5 + 6 + 7 + 8 = OFF7

(PP module 3)

1+2+3 = ON

4 + 5 + 6 + 7 + 8 = OFF



9.7 Starting Up the PLC

Commissioning


6FC5 397-0CP10-1BA0

Note

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

9.7 Starting Up the PLC

After starting up the Profibus, the prepared PLC user program is ready to run and can beused for further start-up. To load the PLC user program, use the Programming Tool.

For a description, please refer to Section 11.5.

Commissioning

9.8 Configuring SINAMICS S120 with 802D sl



9.8.1 Commissioning using predefined macros without the STARTERcommissioning tool

Prerequisites

SMI components (motors and encoder with DRIVE CLiQ interface)

No direct measuring systems

Procedure

1. Firmware upgrade using macros

2. Reset to the default settings and loading the SINAMICS parameters with macros

3. Setting the Machine Data (Section 9.8.4)

Firmware upgrade using macros

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

Procedure:

Turn on the Sinumerik 802D sl and wait until the booting sequence is completed.

Use the System > Set Password softkeys to set the manufacturer password or higher.

Use the System > Machine data > Drive MD > Display parameters softkeys to selectthe integrated CU003 as SINAMICS_I (cf. Fig. 9-7) and check that P0009=1; if not,change.

Set P0015=150399 to start the macro. The LEDs of the drive modules will flash in REDand GREEN during the upgrade.

The upgrade is completed successfully if 7829 changes to “0”. Runtime approx.5 ... 10 minutes, depending on the number of modules

Carry out POWER ON.

Reset to the default settings and loading the SINAMICS parameters with macros

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




Commissioning


6FC5 397-0CP10-1BA0

Fig. 9-7 SINAMICS in 802D

Disable all drive enables. The Line Module must be disconnected from the mains (mainscontactor). Otherwise, no data will be stored (p977 remains 0).

p9 (device start-up, parameter filter) =30 (reset the CU to its default settings)

p976 (reset parameter) =1 (reset all parameters to default)

Wait until p9 is reset to 0 (checkback message “Resetting completed”).

Assign p15 a macro number.

Note

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

Macro 150111 – initialization of up to 6 axes + Active Line Module (ALM) + one/no BEROas zero mark equivalent

Macro 150112 – initialization of up to 6 axes + Active Line Module (ALM) + two BEROsas zero mark equivalent

Macro 150101 – initialization of up to 6 axes + Smart Line Module (SLM) + one/no BEROas zero mark equivalent

Macro 150102 – initialization of up to 6 axes + Smart Line Module (ALM) + two BEROsas zero mark equivalent

Wait until p977 is set to 1 (start of nonvolatile saving of parameters) and is then reset to 0again (checkback message “Nonvolatile saving of all parameters) (Attention: Resettingof parameter p977 to “1” may take up to 5 minutes depending on your particularmachine. Do not turn off the machine; otherwise, you must restart from thebeginning.)

The drive machine data are now saved to ROM. The drives will appear in the configura-tion (see Fig. 9-8).

Commissioning



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

The macro will configure terminal X20/X21 as shown in Tables 9-4 and 9-5. With the ActiveLine Module, the input PIN1 of the CU is linked with parameter p0840 of the Active LineModules; a leading contact must be connected from the main switch or from the mainscontactor.

Connect pin2 of the input to parameter p0849 for all drives. P0849 means AUS3 (rapidstop). This function realizes braking with a configurable AUS3 ramp (p1135,1136,1137);thereafter, pulse suppression and starting lockout. The drive stops controlled. The brakingbehavior of each servo drive can be set separately, also via the main switch or mains con-tactor, but should rather be connected via the PLC I/Os.

Table 9-4 Configuring terminal X20 using system macros

Pin no. Hardwarefeatures

FunctionI/O

Assignment Parameter Macrono.

1Electrically isola-ted input, 50µs,

E0/1 edge

Active Line Moduleenabled

Leading contact from main switch ormains contactor

ALM p840 = 47318016150111150112

p , µ ,smoothed

grequired

SLM hardware ready SERVO p864 = 47318016150101150102

2Electrically isola-ted input, 50µs,smoothed

E0/1 edgerequired

“OFF3 – rapid stop”

Behavior similar to terminal 64

Each SERVO

2nd OFF3, p849 =47318017

150111150112

150101150102

5 Ground for pin 1 .. 4

6 24 P

8Bidir. I/O, 1µs, smoothed

I Bero 1 – zero mark substitute” p945 = 1

150111150112

150101150102

9 Ground for pins 7, 8, 10, 11




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6FC5 397-0CP10-1BA0

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

Pin no. Macrono.

ParameterAssignmentFunctionI/O

Hardwarefeatures

10Bidir. I/O, 1µs,smoothed

ISensing probe 2, encoders 1+2 (check that MD13210 = 1!)

Each SERVO p489

Index = encoder 1,2 = 2

150111150112

150101150102

11Bidir. I/O, 1µs,smoothed

ISensing probe 1, encoders 1+2 (check that MD13210 = 1!)

Each SERVO p489

Index = encoder 1,2 = 3

150111150112

150101150102


Table 9-5 Configuring terminal X21 using system macros

Pin no. Hardwarefeatures

FunctionI/O

Assignment Parameter Macrono.

6 24 P for 802

7 Bidir. I/O, 1µs,smoothed

A Digital output $A_OUT[x] NCK

Output set p728

150111

150101

8 Bidir. I/O, 1µs, smoothed

A Digital output $A_OUT[x] NCK

Output set p728

150111150101

I Bero 2 – zero mark substitute” p945 = 4150102150112



A Digital output $A_OUT[x]

NCK

Output set p728150111150101


A Digital output $A_OUT[x]

NCK

Output set p728150111150101


Creating the message frame type in the SERVOs

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

P922 = ...

999

102

103

Message frame dependent on the encoder system

with default setting

first measuring system

second measuring system (to this end, load additonal SDB from the toolbox intothe control system)

P977 = 1 Data backup of the selected SERVO components

Commissioning



9.8.2 Starting up motors without SMI

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

P10 = 1 Check whether P10 = 1; if yes, perform the motor and encoder start-up.

P300 = ...

102

104

106

107

206

236

237

Motor type

1PH2 induction motor



1PH7 asynchronous motor

1FT6 synchronous motor

1FK6 synchronous motor

1FK7 synchronous motor

P301 = ... Motor code number (to be taken from the STARTER tool)

P400= ...

2001

2051

2002

Encoder code number

Incremental encoder: 2,048 A/B C/D R pulses (spindle)

Absolute-value encoder: EncDat 2,048 pulses

Incremental encoder: 2,048 A/B R pulses (spindle)

P922 = ...

999

102

103

Message frame dependent on the encoder system

with default setting

first measuring system

second measuring system (to this end, load additonal SDB from the toolbox intothe control system)

P3900 = 3 Parameterizing the controller parameters and completing the quick start-up

For data backup, set P977 = 1 in SINAMICS_I.

9.8.3 Faults and warnings when starting up the SINAMICS S120 drive

To be able to diagnose in detail the alarms displayed in case of faults in the header and inthe alarm buffer, the warning buffer can be read out. It is thus also possible to diagnoseProfibus alarms in detail.

The most recent warnings/alarms (max. 8) are to be found in the parameters p2122 andp2124 whereby the newer alarms have the higher indices (see Table 9-6).

Table 9-6 Meanings of the parameters for the warnings

Warning code[meaning in alarm list]

Warning value[meaning in alarm list]

Warningtime

coming

Warningtime

going

Warning 1 r2122[0] r2124[0] r2123[0] r2125[0]

Warning 2 r2122[1] r2124[1] r2123[1] r2125[1]

[...] [...] [...] [...] [...]

Warning 8 r2122[7] r2124[7] r2123[7] r2125[7]




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Note

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

9.8.4 Setpoint/actual-value assignment

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

Table 9-7

Machine data Simulation Normal mode

MD 30130 Value = 0

Simulation

Value = 1

In this case, the setpoint signals are output viaProfibus.

MD 30240 Value = 0

Simulation

Value = 1 (INCR) or 4 (EnDat)

In this case, the actual values are read in viaProfibus.

Note

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

To enable the relevant NC axis to assign its setpoint to the appropriate SINAMICS drive, en-suring that the actual values are returned from this SINAMICS drive, it is imperative to para-meterize the machine data MD 30110: CTRLOUT_MODULE_NR and MD 30220: ENC_MO-DULE_NR.

The following applies for the maximum configuration of 5 axes with Active Line Module:

Axis Drive numberMD 30110MD 30220

SINAMICS object no.

X1 2 3

Y1 3 4

Z1 4 5

SP 1 2

A1 5 6

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

Commissioning



Note

When performing the start-up with macros, the machine data MD 30110:CTRLOUT_MODULE_NR and MD 30220: ENC_MODULE_NR must be set such that theyhave the same drive number because there is a fixed assignment between measuringsystem and motor.

The assignment topology can be modified using the STARTER tool.

Example:

The machine you want to start up is a milling machine. The milling machine possesses threeaxes and one spindle.

The default data record (setup_m) has been loaded.

The bus configuration has been selected with MD 11240[2] = 5.

Now, adapt the axis machine data MD 30110: CTRLOUT_MODULE_NR and MD 30220:ENC_MODULE_NR as follows:

Axis Drive numberMD 30110MD 30220

SINAMICS object no.

X1 2 3

Y1 3 4

Z1 4 5

SP 1 2

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

9.8.5 Default settings of the axis machine data for feed axes

The following machine data list summarizes all default data or their recommended settingswith SINAMICS S120 drives connected.

Once they have been set, the axes are ready to traverse, and only a fine adjustment (refe-rence point approach, software limit switches, position controller optimization, speed feedfor-ward control, lead error compensation,...) must be performed.

Note to the reader

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




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6FC5 397-0CP10-1BA0

Note

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

MD Name Defaultvalue

Unit Remark

31030 LEADSCREW_PITCH 10 mm Leadscrew of the ballscrew

31050

31060

DRIVE_AX_RATIO_DENOM

DRIVE_AX_RATIO_NUMERA

1

1

Load gear transmission ratio

Revolutions of the ballscrew

Motor revolutions

32000 MAX_AX_VELO 10000 mm/min Maximum axis velocity

32300 MAX_AX_ACCEL 1 m/s2 Maximum axis acceleration

34200 ENC_REFP_MODE 1 1: Incremental encoderMotor order no: 1Fx6xxx-xxxxx-xAxx

0: EnDat encoderMotor order no: 1Fx6xxx-xxxxx-xExx

36200 AX_VELO_LIMIT 11500 mm/min Threshold value for velocity monitoring;setting rule: MD 36200 = 1.15 x MD 32000

Example:

Motor with incremental encoder

Gearbox transmission ratio: 1:2Spindle lead 5 mmMax. axis velocity 12 m/minMax. axis acceleration 1.5 m/s2

Machine data settings:

MD 31030 = 5MD 31050 = 1MD 31060 = 2MD 32000 = 12000MD 32300 = 1.5MD 36200 = 13800

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

Commissioning



9.8.6 Default settings of the axis machine data for the spindle

With SINUMERIK 802D sl, the spindle is a subfunction of the entire axis functionality. Themachine data of the spindle are therefore to be found amongst the axis machine data(MD 35xxx).

For this reason, data must also be entered for a spindle; this data has already beendescribed in conjunction with the start-up of feed axes.

The following variants are offered for the spindle drive:

digital spindle drive (PROFIBUS) with spindle actual-value encoder integrated into themotor

analog spindle drive with directly mounted spindle actual-value encoder

analog spindle drive with directly mounted spindle actual-value encoder

Note

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

Table 9-8


Unit Remark

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

1: spindle with speed actual-valueencoder integrated into the motor(1PH7 motor)

31050

31060

DRIVE_AX_RATIO_DENOM[1]

DRIVE_AX_RATIO_NUMERA[1]

1

1

Load gear transmission ratio

Load revolutions

Motor revolutions

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

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

35200 GEAR_STEP_SPEEDCTRL_AC-CEL[1]

30 rev/s2 Acceleration in the speed controlledmode




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Digital spindle drive with spindle actual-value encoder integrated into the motor

Parameterize the machine data listed in Table 9-8.

Example:

Motor with incremental encoder

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

Machine data settings:

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

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

Table 9-9 Additional machine data


Unit Recommendation/remark

34000 REFP_CAM_IS_ACTIVE 1 0: without reference point cam

34060 REFP_MAX_MARKER_DIST 20 degrees 720 = two spindle revolutions

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

35300 SPIND_POSCTRL_VELO 500 r.p.m.

36000 STOP_LIMIT_COARSE 0,04 degrees 0,4

36010 STOP_LIMIT_FINE 0,01 degrees 0,1

36030 STANDSTILL_POS_TOL 0,2 degrees 1

36060 STANDSTILL_VELO_TOL 0,0139 r.p.m. 1 (interface signal “Axis/spindlestopped” V390x 0001.4)

36400 CONTOUR_TOL 1 degrees 3

Digital spindle drive with directly mounted spindle actual-value encoder

The operation of a second measuring system requires changes in the message frame type.To this end, load a reloadable SDB from the toolbox, which allows message frame type 103for the appropriate drives.

In SINAMICS_I, the message frame type must also be set in P922 = 103.

For the actual-value assignment, the following machine data must be set:

Commissioning



Table 9-10 Machine data to be set

MD Name Value Recommendation/remark

13060 DRIVE_TELEGRAM_TYPE[0–5] 103

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

30230 ENC_INPUT_NR[0] 2 DRIVE-QLIQ_slot on the module to which the secondmeasuring system has been connected

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

Machine data example for 3 axes for milling with analog spindle

Output of an analog setpoint for a spindle drive for connecting a third-party converter (e. g.MICROMASTER). With software release 01.01., connection is possible via the MCPAmodule.

ALM; 1-axis module; 1-axis module; 1-axis module

Table 9-11 Machine data for the example

MD Name X Y Z SP Remark

30100 CTRLOUT_SEGMENT_NR 5 5 5 0 local bus segment for analog

30110 CTRLOUT_MODULE_NR 2 3 1 1 Module order

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

30130 CTRLOUT_TYPE 1 1 1 1 Setpoint output type

30134 IS_UNIPOLAR_OUTPUT 0 0 0 0 Setpoint output is unipolar

30200 NUM_ENCS 1 1 1 1 Number of encoders

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

connected to the axis module of the Y axis

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

30240 ENC_TYPE 4 1 1 1 Encoder type

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

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

To be able to transfer the encoder actual value, an SDB must be reloaded which reflects thehardware configuration (see Toolbox 802D_SL\V0100xx00\Special\DMSforSpindle).

Thereafter, set the following machine data:




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Table 9-12 Additional machine data


Recommendation/remark

11240[2] PROFIBUS_SDB_NUMBER 0

13060[2] DRIVE_TELEGRAM_TYPE 103 Standard message frame type forPROFIBUS DP

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

Connecting an analog spindle without spindle actual-value encoder

For an analog spindle without encoder, the same machine data apply as for an analogspindle with directly mounted encoder, but MD 30240 must be set to zero.

If an analog spindle without measuring system is used, no reloadable SDB is required.

Unipolar spindle for SINUMERIK 802D sl

MD 30134 = 1 Unidirectional D/A value type “1”

MD 32100 = 1 Positive assignment, no inversion

MD 32100 = –1 Positive assignment, inversion

Machine data Direction of spindle rotation

Voltage Setpointdisplay

VB38020004

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

Spindle CCW >0 + Bit 7 = 1

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


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

MD 32100 = 1 Positive assignment, no inversion

MD 32100 = –1 Positive assignment, inversion

Machine data Direction of spindle rotation

Voltage Setpointdisplay

VB38020004

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


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


Commissioning

9.9 STARTER start-up tool



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

Note

The screenforms of the STARTER tool, version V3.2, are shown in the following. If yourparticular version deviates from the version used here, your screenforms may deviateslightly from those shown here.

9.9.1 Explanations regarding the STARTER user interface

To create the sample project, you can use STARTER (see Fig. 9-9). To perform the indivi-dual configurations, use the user interface areas listed below:

Project navigator: This area displays the elements and objects you will insert into theproject.

Working area: Use this area to perform your task for creating the project:

– When configuring the drive, this area is assigned the wizard useful for configuring thedrive objects.

– If you configure, for example, the parameters for the speed setpoint filter.

– If you switch to the Expert list, a list of all parameters is displayed which you can viewor change.

Detailed view: This area provides detailed information, for example, on faults andwarnings.




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Project navigator: displays the elementsand objects for the STARTER project.

Working area:

Displays the wizard for configuringthe drive objects

Displays, for example, theparameters of the speed setpointfilter

Detailed view: Displays specific information, forexample, faults

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

9.9.2 Operating philosophy of the STARTER commissioning tool forSINAMICS S120

When creating a drive unit for a SINAMICS S120 system, the following operating philosophyis assumed:

The tool is used to configure objects (e.g. infeed). The name of the objects can be freelyselected.

A drive unit in the terms of the STARTER commissioning tool is always a control unit and theappropriate drives.

With controlled incoming supply, the Active Line Module is configured in STARTER. A con-trolled incoming supply is not configured in STARTER.

The appropriate drive consists, for example, of a motor (power section) and of a motor withencoder.

Fig. 9-10 shows the STARTER project navigator. You can see that a project (Project_Philo-sophy) and a drive unit (Drive_Unit_One_Motor) have been configured for a drive.

Commissioning



Fig. 9-10 Drive unit with one motor

If you want to create a second drive unit, in this case, for two motors, the drive unit will alsoconsist of a control unit and an Active Line Module (incoming supply), but this time of twodrives.

Fig. 9-11 shows the STARTER project navigator. In the same project (Project_Philosophy),a second drive unit (Device_Unit_Two_Motors), which is designed for two drives, has beenconfigured.




Commissioning


6FC5 397-0CP10-1BA0

Fig. 9-11 Drive unit with two motors

Commissioning

9.10 Start-up sequence when working with STARTER



STARTER provides two alternative procedures for creating a drive object:

OFFLINE, where you can create and parameterize your drive unit configuration using awizard;

ONLINE, where you load an existing configuration and parameterization of a drive unitinto STARTER using the wizard.

If you have created or loaded a project in STARTER, you can operate the drive using thecontrol panel of STARTER.

9.10.1 Creating a drive object OFFLINE

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

Table 9-13 OFFLINE

Step Procedure Section

1 Start the STARTER commissioning tool and use the STARTER projectWizard to create a new project.

10.1.1

2 Set up the PPI interface. 10.1.1

3 Insert the drive unit. 10.1.1

4 Use the Wizard to configure the drive unit with, for example, the infeed,drive properties, drive with power section, motor, encoder, and so on.

10.1.2

5 Save your project. 10.1.2

6 Continue with “Operating the STARTER control panel (motor rotating)”. 10.2




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9.10.2 Operating the STARTER control panel (motor rotating)

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

Table 9-14 Motor rotates


1 Open the project. 10.2.1

2 Establish a connection to the target system.

Switch to ONLINE mode.

10.2.1

3 Load the project into the drive unit. When doing so, observe the LEDs on thecontrol unit; these indicate when the project has been loaded completely.

10.2.1

4 Save the parameters in the drive unit with RAM to ROM. 10.2.1

5 Operate the STARTER control panel; the motor will rotate. 10.2.2

9.10.3 Creating a drive project ONLINE (recommended)

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

Table 9-15 ONLINE


1 Start the STARTER commissioning tool. 10.3.1

2 Create a new project. 10.3.1

3 Set up the PROFIBUS interface. 10.3.1

4 Search ONLINE for the stations (drive units) which can be reached.The drive project will be inserted into the project.

10.3.1

5 Configure and acquire the topology and configuration of the drive unitautomatically.

10.3.2

6 Configure the motor and check the acquired topology. 10.3.3

7 Save your project. 10.3.3

8 Continue with “Operating the STARTER control panel (motor rotating)”. 10.2

Commissioning

9.11 Diagnosis via STARTER



Description

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

General

Prerequisites: STARTER is in the online mode.

STARTER provides the following diagnostic functions:

PROFIBUS diagnostic buffer

The message output window shows the states of the control/status words, parametersand drive enable signals for the selected drive/device.

Fault/alarm display in the alarms output window

Faults and warnings can be displayed either for one or for several drives/units. The fault/alarm description is called up by selecting “Help –> Context” or by pressing the SHIFT+ F1 keys.

Diagnostic overview

An overview table of all drives existing in the project is displayed.

– Device: The existing devices and drives are displayed with their names; the devicestatus is displayed in the “Device diagnosis” window.

– Operating status: The operating status (e.g. OFFLINE, ONLINE, STARTUP, STOP,STOP U, RUN) of the device or of the drive is displayed; it can be controlled via themode selector switch.

Signals specified from the function generator (see Section 9.11.1)

Signal recording using the Trace function (see Section 9.11.2)

Analysis of the control behavior using the measuring function (see Section 9.11.3)

Output of voltage signals for external measuring instruments via measuring sockets (seeSection 9.11.4)




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9.11.1 Function generator

Description

The function generator can be used, for example, to perform the following tasks:

for measuring and optimizing closed-loop control circuits;

for comparing the dynamic properties of coupled drives;

for specifying a straightforward traversing profile without traversing program.

The function generator can be used to generate various signal forms.

The output signal can be supplied to the closed-loop control circuit via the BICO circuit in the“Connector output” mode.

In the Servo mode, this setpoint can additionally be supplied into the control structure inaccordance with the currently selected mode, for example, as a current setpoint, disturbingtorque or speed setpoint. Any influence of overlaid closed-loop control circuits is suppressedautomatically.

Parameterizing and operating the function generator

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

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

Commissioning



Note

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

Features

It is possible to switch to several drives simultaneously.

The following signal forms can be freely parameterized:

– square wave

– staircase

– triangle

– PRBS (pseudo random binary signal, “white noise”)

– sinusoidal

An offset is possible for each signal. The power-up to the offset can be parameterized.The signal generation starts after the power-up for the offset.

Restriction of the output signal to the minimum and maximum value settable.

Operating modes of the function generator for servo and vector only

– Connector output

Operating modes of the function generator for servo only

– Current setpoint downstream of the filter (current setpoint filter)

– Disturbing torque (downstream of the current setpoint filter)

– Speed setpoint downstream of the filter (speed setpoint filter)

– Current setpoint upstream of the filter (current setpoint filter)

– Speed setpoint upstream of the filter (speed setpoint filter)

Switching points of the function generator

funk_gen_ueber.vsd

frominterpolator

Setpointfilter

Speedcontroller

Setpointfilter

Currentcontroller

Controlled

Speed setpointupstream of the filter

Speed setpointdownstream of the filter

Disturbing torque

Current setpointupstream of the filter

Current setpointdownstream of the filter

––system

Fig. 9-13 Switching points of the function generator




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Further signal forms

Further signal forms can be produced by parameterization.

Example:

The “triangular” signal shape can be parameterized with “upper limitation” to produce atriangle with no peak.

Upper

limiting

Signal form

“Triangular”

Fig. 9-14 “Triangular” signal without peak

Starting/stopping the function generator

!Caution

With the corresponding ramp-function generator parameter settings (e.g. offset), the motorcan “drift” and travel to its end stop.

The motion of the drive is not monitored with the function generator activated.

To start the function generator, proceed as follows:

1. Provide for the prerequisites for starting the function generator.

– Activate the control panel.

Drives –> Drive_x –> Commissioning –> Control board

– Turn on the drive.

Control board –> Issue enable signals –> Switch on

2. Select the appropriate operating mode,

e.g. speed setpoint downstream of the filter.

3. Select the drive (as the control panel).

4. Set the signal form,

e.g. rectangle.

5. Load the settings to the target system (“Download parameters” pushbutton)

6. Start the ramp-function generator (“Start FctGen” pushbutton)

To stop the function generator, proceed as follows:

“Stop FctGen” pushbutton

Commissioning



Parameterization

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

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

9.11.2 Trace function

Description

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

Parameterizing and operating the trace function

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

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




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Note


Features

Four recording channels per recorder

Two independent trace recorders per control unit

Triggering

– Without triggering (recording immediately after start)

– Triggering either to signal with edge or to level

– Trigger delay and pretrigger possible

STARTER parameterization and commissioning tool

– Automatic or settable scaling of the display axes

– Signal measurement via cursor

Settable trace cycle: integers of the base sample time

Parameterization

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

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

9.11.3 Measuring function (SERVO) (available soon)

Note

This functionality is available soon.

Commissioning



Description

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

Parameterizing and operating the measuring function

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

Fig. 9-18 “Measuring function” initial screen

Note





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Features

Measuring functions

– Current controller setpoint step change (downstream of the current setpoint filter)

– Speed controller reference frequency response (downstream of the current setpointfilter)

– Speed controller setpoint step change (downstream of the speed setpoint filter)

– Speed controller disturbance variable step change (fault downstream of the currentsetpoint filter)

– Speed controller reference frequency response (downstream of the speed setpointfilter)

– Speed controller reference frequency response (upstream of the speed setpoint filter)

– Speed controller interference frequency response (fault downstream of the currentsetpoint filter)

– Speed-controlled system (excitation downstream of the current setpoint filter)

Starting / stopping the measuring function

!Caution

With the corresponding measuring function parameter settings (e.g. offset), the motor can“drift” and travel to its end stop.

The motion of the drive is not monitored with the measuring function activated.

To start the function generator, proceed as follows:

1. Provide for the prerequisites for starting the measuring function.

– Activate the control panel.

Drives –> Drive_x –> Commissioning –> Control board

– Turn on the drive.

Control board –> Issue enable signals –> Switch on

2. Select the drive (as the control panel).

3. Set the measuring function,

e.g. current controller setpoint step change.

4. Load the settings to the target system (“Download parameters” pushbutton)

5. Start the measuring function (“Start Measuring Function” pushbutton)

To stop the function generator, proceed as follows:

“Stop Measuring Function” pushbutton

Commissioning



Parameterization

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

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

9.11.4 Measuring sockets (available soon)

Note

This functionality is available soon.



9.12 Completing the start-up

Commissioning


6FC5 397-0CP10-1BA0

9.12 Completing the start-up

After the start-up by the machine manufacturer has been completed, it is recommended tocarry out a data backup prior to delivery to the end customer:

1. Performing an internal data backup (at least protection level 3 required):

– Select the Save data softkey in the System operating area.

– To save the drive mmachine data, set parameter p977=1 in the CU (SINAMICS_I).

2. Resetting the access level:

– Select the Delete passw. softkey.

Commissioning

9.13 Service display of the axis drive behavior



Servo trace

For axis service, the SERVO trace function has been implemented in the “Diagnostic” menuto represent axis signals graphically.

The trace function is selected in the System\Service display\SERVO Trace operating area.

Note to the reader

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




Commissioning


6FC5 397-0CP10-1BA0

Notes


Creating a Drive Project

10.1 Creating a drive project OFFLINE


Creating a project

The first step is to create a new project for your example:

1. Click the STARTER icon or choose Start > Program > STARTER > STARTER from theWindows Start menu to run the STARTER commissioning tool.

When the software is started for the first time, the main screen (see Fig. 10-1) appearswith the following dialog boxes:

– “STARTER Project Wizard”

– “STARTER Getting Started Commissioning Drive”

You can call up the ProjectWizard by choosing Project > New with wizard.

If you deactivate this field,the Project Wizard will notappear any more when theSTARTER is started nexttime.

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

10






6FC5 397-0CP10-1BA0

Note

If you deactivate the “Display wizard during start” field, the Project Wizard is not displayedwhen you next start STARTER.

You can call up the Project Wizard by choosing Project > New with wizard.

Note

To deactivate the online help for “Getting started”, follow the instructions provided in Help.

You can call up the online help at any time by choosing “Help –> Getting started”.

STARTER features a detailed online help function.

2. Close the online help and follow the instructions provided by the Project WizardSTARTER.

3. Select the Configure drive units offline button, as shown in Fig. 10-2.

Fig. 10-2 Project Wizard Starter

The wizard will guide you when creating a new project.

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




Fig. 10-3 Creating a new project

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

Fig. 10-4 Setting up the interface

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






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

7. The system has determined all possible interfaces on your PC (e.g. Serial Cable (PPI)).Select an interface via the Interface parameterization used list box; thereafter, click onthe Properties button and adapt the baud rate to the settings in the 802D sl (default: 115.2 kbit/s).

Alternative: The connection can be established via the TCP/IP protocol. To this end,connect the PC/PG to the CU directly using a X Crosslink patch cable or a standardpatch cable via the corporate LAN.

The following additional steps of operation are required here:

– Use the mouse to select the drive unit in the Project Navigator.

– Open the selection menu by clicking on the right mouse button.

– Use “Target device online access” to load data into the interactive dialog box which isnow displayed (see Fig. 10-6).Slot 25 and the IP address do not comply with the default configuration. In corporate networks, the IP address assigned by the administrator must be entered;with direct connection, the SINAMICS is assigned the fixed IP address 169.254.11.22in 802D.When establishing a connection via Crosslink, the IP address of the PC/PG(169.254.11.23) must be entered in the user-defined, alternative configuration(see Fig. 10-8).

– For corporate networks with DHCP server, the password for protection level 1 must beentered via HMI. Use System > Service display > Service control system >Service network to change the DHCP entry to yes.




169.254.11.22

Fig. 10-6 Features of SINAMICS

Fig. 10-7 Connection properties






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169.254. 11. 23

255.255. 0 . 0

Fig. 10-8 Alternative configuration

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

– a new drive unit with the name Machine Tool V1_2,

– a device: SINAMICS

– a type in 802D

– version V2.2 and

– bus address 5 with PPI (with TCP/IP, the bus address can be freely selected).

To add the components and data listed above, use the relevant list boxes for selectionand click on Insert button.

Note

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




5

Fig. 10-9 Inserting the drive unit

Note

To insert other drives in the project, choose Insert.

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

Fig. 10-10 Introduction

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






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Note

To call up this tutorial, choose Sinamics tutorial.

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

5

Fig. 10-11 “Machine Tool V1_2” preview

10.Click Continue >.

5

Fig. 10-12 Summary

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




As shown in Fig. 10-13 below, the Project Wizard has created the Machine Tool V1_2project and SINAMICS_In802D drive unit with a Control_Unit on board in the projectnavigator.

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

10.1.2 Configuring a drive unit

The following components are required in the example to configure a drive unit:

Active Line Module

Motor module

Synchronous motor (e.g. 1FK6) with encoder for the servo control variant

Asynchronous motor (e.g. 1PH7) with encoder for the servo control variant

To compile the components for the drive unit, proceed as follows:

1. In the project navigator, open the SINAMICS_In 802D directory and double-click theConfigure drive unit element (see Fig. 10-13).

As you can see in Fig. 10-14, the STARTER opens a wizard for configuring the drive unitcomponents.

Note

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






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Fig. 10-14 Configuration – SINAMICS CU320 option board

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

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

Fig. 10-15 Configuration – Introduction to SINAMICS CU320

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




Note

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

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

4. First choose the appropriate Active Line Module from the Selection listbox according totype (order no.) (see rating plate), assign a name (Supply_1), and click the Line filteravailable field.

5. Click Continue > to select further data for the Active Line Module (infeed)(see Fig. 10-17).






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Fig. 10-17 Incoming supply: further data

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

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

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




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

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

Select Servo.

Fig. 10-20 Drive properties

9. The “Drive properties” dialog box (see Fig. 10-20) provides general information about thedrive.

10.Choose Servo from the “Type of operation” listbox.

11.Assign a name for the first drive, Drive_1, and enter some general comments. ClickContinue >.






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Fig. 10-21 Control structure

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

Fig. 10-22 Configuring the motor module

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




14.Click Continue >.

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

– 1FK6 synchronous motor

– 1PH7 asynchronous motor

16.Select the appropriate motor from the Motor selection list box according to type(order no.) (see rating plate) and assign a name (Drive_1_Motor).

17.Click Continue > to select the motor holding brake (see Fig. 10-23).

Synchronousmotor

Asynchronousmotor

18. Choose “Without holdingbrake”.

Fig. 10-23 Configuring the motor

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






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Synchronousmotor

Asynchronousmotor

Fig. 10-24 Configuring the encoder

19.Select the appropriate encoder from the Motor encoder selection list box according totype (order no.) (see rating plate on the motor).

20.Click Continue > to choose the control mode/setpoints (see Fig. 10-25).

Synchronousmotor

Asynchronousmotor

Select Siemens message frame 102.

Fig. 10-25 Control mode/setpoints

21.For your example with the drives, you want to select the Siemens message frame 102.Select the message frame and click Continue >.

Alternatively, you can select the Siemens message frame 103 if the axis possesses adirect measuring system. In the topology tree, this encoder must be assigned an axis.




Fig. 10-26 Summary

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

As you can see in Fig. 10-27, the configuration wizard has created the objects (includingDrive_1) for drive unit SINAMICS_In_802D in the project navigator.

Fig. 10-27 Project navigator with SINAMICS_In_802D

23.Save the project Machine Tool V1_2 using the Project > Save menu.

Once you have configured the drive unit with STARTER in OFFLINE mode, proceed with thesteps described in Chapter 10.2 “Starting the Drive Project (“Motor rotates)”. You will set theparameters of the interface with the drive and rotate the motor.



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



6FC5 397-0CP10-1BA0


This chapter shows you how to start the motor using the control panel function in theSTARTER commissioning tool. These steps include:

Load the project into the drive unit.

Operate the control panel.

Prerequisites

The following prerequisites must be fulfilled to operate the control panel in STARTER:

The components as described above are assembled.

The drive unit is turned on as prescribed.

You have established a connection from the serial PPI interface of the control unit to aPC/PG with PPI interface.

A project has been created using the STARTER commissioning tool.

10.2.1 Loading the project into the drive unit

Loading the project into the drive unit

To load the project into the drive unit, proceed as follows:

1. If you have not yet created the project “Machine Tool V1_2” (created in Section 10.1.1)in STARTER, open the project using the Project > Open menu.

2. To use the “control panel” function, you have to switch to ONLINE mode. To switch tothe ONLINE mode, click the function key Connect to target system (as shown inFig. 10-28).




2. Click on the function key Connect to target system

Fig. 10-28 Project navigator with SINAMICS_In_802D

3. An ONLINE connection will be established, and an ONLINE/OFFLINE comparison willtake place. If any differences are found, these are displayed (see illustration below).

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

4. You have changed the data OFFLINE; upload now these data into the target device. Clickthe following menu items one after the other:

– Click <–– Load to target system in the “ONLINE/OFFLINE comparison” dialog box.

– When the system asks “Are you sure?”, click Yes. The system now starts loading thedata.

– When the system informs you that the data was successfully loaded to the targetsystem, click OK.

– Click OK for “Load from RAM to ROM”.






6FC5 397-0CP10-1BA0

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

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

6. You will load the newly created data from the drive unit into the PG. Click the followingmenu items one after the other:– When the system asks “Are you sure?”, click Yes. The system now starts loading the

data.– When the system informs you that the data was successfully loaded into the PG, click

OK.

7. No further discrepancies are displayed in the ONLINE/OFFLINE comparison dialog box.Click Close (see screenshot below).

Fig. 10-31 ONLINE/OFFLINE comparison, closing

Note

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

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




10.2.2 Operating the control panel

After you have established the connection to the target system and uploaded the project, agreen connector symbol is displayed in the Project Navigator in front of the drive unit and theother components configured. This indicates that the project data in STARTER and the tar-get system is consistent (see Fig. 10-32).

The drive unit is now ready to operate.

The following steps are required to operate the control panel in the STARTER commissio-ning tool such so that the motor rotates:

Double-click Control panel in theproject navigator.

Green plug icon.

Fig. 10-32 Control panel

1. Double-click Control panel in the project navigator under Drive_1 > Commissioning(see Fig. 10-32).

The control panel is displayed in STARTER (see Fig. 10-33). You can use the controlpanel to control the drive directly from the PC/PG.






6FC5 397-0CP10-1BA0

Click Assume control priority.

Fig. 10-33 Assuming control priority

2. Click Assume control priority to connect the control panel to the drive interface.

Note the message that is then displayed in the Control priority dialog screen. This noteis very important! (see also Fig. 10-34).

!Danger

Be cautious when using control priority!

This function is intended exclusively for start-up and diagnosis or within the framework ofmaintenance work.

Make sure that the drive is in the “OFF” status and that no ON/OFF1 command has beenissued either by the control word for sequence control or another signal source (e.g. BICOinterconnection).

Once control priority has been transferred to the PC, the BICO interconnections on bit 1 tobit 6 of the control word are no longer active.




To continue with commissioning, chooseOK.

You can use the default monitoring time(e.g. 3000 ms).

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

You can enter an application monitoring. This is the time that may pass between two set-points until the sign-of-life monitoring of the drive responses (error 1910).

You can use the default monitoring time (e.g. 3000 ms).

3. Since our example concerns commissioning, confirm this dialog box for assuming controlpriority by choosing OK.

Click Display/hide diagnostics view.

Status “lamps” for the control word bits.

Fig. 10-35 Diagnostics view

4. To display, amongst other things, the status lamps for the control word bits, click Display/hide diagnostics view.

Table 4-14 lists the most important digital input signals of the control word for sequencecontrol, which are required to set a motor to motion and which are issued via the controlpanel for the control unit (CU320 in 802D).






6FC5 397-0CP10-1BA0

Table 10-1 Control word for the sequence control

Signal (controlpanel)

PROFIdrive bit no. in CTW

sequence control

Meaning

ON/OFF1 Bit 0 0 = OFF (OFF1), stop via ramp-function generator, followed by pulseblock

1 = ON, service condition

ON/OFF2 Bit 1 0 = Coast down (OFF2), pulse block, motor coasts to standstill1 = Do not coast down, operating condition

ON/OFF3 Bit 2 0 = Rapid stop (OFF3)

1 = No rapid stop, service condition

Pulse enable Bit 3 0 = Disable operation, pulse suppression

1 = Enable operation, enable pulses

Enable ramp-function gene-rator

Bit 4 0 = Set ramp-function generator to 0

1 = Enable ramp-function generator

Start/stopramp-functiongenerator

Bit 5 0 = Freeze ramp-function generator, retain current output value

1 = Re-enable ramp-function generator; will follow the input value

Setpointenable

Bit 6 1 = Enable setpoint0 = Inhibit setpoint and set to 0

Click the Enables field.

Fig. 10-36 Enables

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

Click Infeed control priority.

Fig. 10-37 Incoming supply control priority

6. Click Infeed control priority. The supply (Active Line Module) is turned on.

7. Before starting the motor by choosing Motor on (see Fig. 10-38), you have to make thefollowing settings:




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

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

!Danger

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

Speed setpoint: 50

Percentage to 0%

8. Drive ON button

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

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

ON/OFF1 “enable”command set.

10. Drive OFFbutton

9.Increase the speed slowlyfrom 0 to 100%.

Fig. 10-39 The motor starts to rotate

9. Move the slider for the speed slowly from 0 to 100% (see Fig. 10-39).

The motor is rotating.

10.When you click Stop, the motor stops. You can also trigger a fast stop by pressing thespace bar.

In the following steps, reset the master controls to disconnect the drive:

– Supply

– Control unit






6FC5 397-0CP10-1BA0

Click Infeed control priority.


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

Click Return....


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

Fig. 10-42 Returning the control priority

13.Confirm the query Return control priority? with Yes (see Fig. 10-42)

Now you are in the STARTER commissioning tool project, as shown in Fig. 10-43 below.




Fig. 10-43 Commissioning completed

Congratulations!

You have now successfully completed your first start-up of a drive with theSINAMICS S120 drive system.



10.3 Creating a drive project ONLINE



6FC5 397-0CP10-1BA0


Prerequisites

The following is required to create a drive project ONLINE using the STARTER commissio-ning tool:

The components as described above are assembled.

The drive unit is turned on as prescribed.

You have established a connection from the serial PPI interface of the control unit to aPC/PG with PPI interface.

The SINAMICS firmware is able to recognize the actual topology automatically and store it inthe appropriate parameters.


To identify the drive configuration automatically using STARTER, use STARTER to open anew project:

1. To start the STARTER commissioning tool, click the STARTER icon or choose the follo-wing menu path in the Windows start menu: Start > SIMATIC > STEP 7 > STARTER.

The Project Wizard Starter is displayed.

Fig. 10-44 The STARTER project wizard

2. Click on the Find drive units online .... button (see Fig. 10-44).

The wizard will guide you when creating a new project.




Fig. 10-45 Creating a new project

3. As shown in Fig. 10-45, enter the project name, e.g. “Machine Tool V1_2”, and if neces-sary, the author and a comment.

4. Click Continue > to set up the PC/PG interface.

Fig. 10-46 Setting up the interface

5. In this example, you require a PROFIBUS interface on the PC/PG (e.g. Serial Cable(PPI). Choose Change and test and confirm your selection with Continue >.

The Project Wizard will search for the drive unit ONLINE and will insert it into the project.Once the search process is completed, the Project Wizard will display the drive unit withits PPI address Drive_unit_Addr5 in the preview (see Fig. 10-47) (for alternative PC/PGinterface settings, see Figs. 10-6 to 10-8).






6FC5 397-0CP10-1BA0

Note

The system searches for drive units or, more precisely, control units; in other words, if morethan one control unit exists in the system, more than one drive unit is found.

The I/O components of the drive units (control unit, Active Line Module etc.) are notdisplayed here; these are displayed when performing the step “Load drive configuration intoPG/PC”.

Fig. 10-47 Inserted drive unit

6. Click Continue >.

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

Fig. 10-48 Summary




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

10.3.2 Acquiring the component topology and configuring the drive unitautomatically

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

1. Select the drive unit Drive_unit_Addr5.

2. Select Connect to target system.

Fig. 10-49 Project_1

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

2. Select Connect to target system.

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

4. Choose the Restore factory settings function key (see screenshot below).

4. Select Restore default settings.

Fig. 10-50 Restoring the default settings






6FC5 397-0CP10-1BA0

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

– Interactive screenform “Reset to default settings?”

– Interactive screenform “Default settings have been restored”

– Interactive screenform “Data have been successfully copied from RAM to ROM”

Double-click onAutomatic configuration.

Fig. 10-51 Automatic configuration

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

Click onStart automatic configuration.

Fig. 10-52 Automatic commissioning

7. Click on the Start automatic configuration button.

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




Select the Servo type.

Fig. 10-53 Automatic commissioning

8. In the “Drive object type” dialog box, choose Servo and then click Complete.

“Loading from RAM to ROM” and “Loading into the PG” will take place.

Fig. 10-54 Message

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

Note

The drives are listed with standard motors.

If a drive is equipped with a motor with a DRIVE-CLiQ interface, the motor does not need tobe configured in OFFLINE mode.






6FC5 397-0CP10-1BA0

Close

Fig. 10-55 Closing the automatic commissioning

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

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

Configuration with, for example, ControlUnit, incoming supply, and Drive.

Select Disconnect from target system.

Fig. 10-56 Automatic configuration

11.Choose Disconnect from target system.

The drive unit, all components and the drives are now integrated in the STARTERproject.

Now you must merely configure the motors of the drives and check the topology(see Section 10.3.3).




10.3.3 Configuring and checking the topology of the drives

Now that you have entered the component topology and configuration for the drive unit andintegrated these in the STARTER project automatically by carrying out the steps describedin Section 10.3.2.

Now, use the following operating sequence to configure the motor for the drive, and thencheck the topology.

Double-click on Drive navigator.

Fig. 10-57 Project_1 configuration

1. In the project navigator, choose the Drives folder and double-click Drive navigator underthe drive.

The Drive Navigator dialog box provides an overview in which you can configure themain drive functions.






6FC5 397-0CP10-1BA0

Click on Device configuration.

Fig. 10-58 Drive navigator

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

Click onCarry out drive configuration.

Fig. 10-59 Device configuration

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




Click on Continue >to run the wizard.

Fig. 10-60 Project Wizard

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

Note

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






6FC5 397-0CP10-1BA0

15. Choose the motor type.

16. Choose the motoraccording to type (order no.).

Fig. 10-61 Motor configuration

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

– 1FK6 synchronous motor

– 1PH7 asynchronous motor

6. Select the appropriate motor from the Motor selection list box according to type(order no.) (see rating plate) and assign a name (Drive_1_Motor).

7. Click on Continue > and Continue> again to proceed with the wizard until you havecome to the dialog with the summary (see Fig. 10-62 below).

Note

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




Fig. 10-62 Summary

8. Click on Finish.

Before you save the project, use STARTER to check the topology you have created.

Click on Check topology.

Fig. 10-63 Device configuration

9. Click on Check topology.






6FC5 397-0CP10-1BA0

SelectProject > Save.

Fig. 10-64 Topology tree

10.In this window, check the topology and DRIVE-CLiQ connection and compare this withthe actual topology (see Fig. 10-64).

11.Choose Project > Save and save the project under the name “Project_1”.

To start the motor, continue with the steps described in Section 10.2.


Starting Up the PLC

General

The PLC is intended to control machine-related functional sequences. It is realized as a soft-ware PLC.

The user program – a PLC cycle – is always executed in the same order of sequence.

Refresh of the process image (inputs, user interface, timers)

Processing of communication requests (operator panel, PLC 802 programming tool, ver-sion 3.0 and higher)

Editing of the user program

Evaluation of alarms

Output of the process image (outputs, user interface)

During the cycle, the PLC executes the user program from the first to the last operation.The user program accesses the hardware inputs/outputs only via the process image and notdirectly. The PLC refreshes the hardware I/Os at the beginning or end of program execution.Thus, these signals are stable over a whole PLC cycle.

The user program can only be created using the PLC 802 Programming Tool, version 3.1and higher, with the S7-200 programming language using ladder diagram. Ladder diagram isa graphical programming language for representing electric circuit diagrams.

Important

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

Note

If the stop and reset buttons on the machine control panel are not realized as normally clo-sed contacts, an open circuit cannot be detected.

Monitoring can be performed using software solutions, as shown in the example MCP_802D(SBR 34) from the subroutine library.

11



11.1 Commissioning the PLC

Starting Up the PLC


6FC5 397-0CP10-1BA0

11.1 Commissioning the PLC

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

11.2 Start-up modes of the PLC

Table 11-1 Start-up modes

Selection Response

PCUSwitch-on menu

(802D)

PCUStart-up menu

(802D)

PT PLC 802(PC)

PLCprogrampreselec-

tion

Programstatus

Retentivedata

(battery bak-ked)

MD for thePLC in the

user interface

NCK start-up *

Normal booting Normal booting User pro-gram ***

Run unchanged Acceptance ofthe activePLC MD

Booting with default va-lues

Booting with default values

User pro-gram ***

Run deleted DefaultPLC MD

Booting with saved data

Booting with saved data

User pro-gram ***

Run saved

data

Saved PLC MD

PLC stopafter POWER ON

PLC stoppossible ei-ther in Runor in Stop

unchanged Stop unchanged Acceptance ofthe activePLC MD

PLC start-up **

Cold restart Run (afterStop)

User pro-gram ***

Run unchanged Acceptance ofthe activePLC MD

Cold restart

and debug mode

User pro-gram ***

Stop unchanged Acceptance ofthe activePLC MD

Overall reset User pro-gram ***

Run deleted Acceptance ofthe activePLC MD

Starting Up the PLC

11.2 Start-up modes of the PLC


Table 11-1 Start-up modes, continued

MD for thePLC in the

user interface

Retentivedata

(battery bak-ked)

Programstatus

PLCprogrampreselec-

tion

PT PLC 802(PC)

PCUStart-up menu

(802D)

PCUSwitch-on menu

(802D)

Overall reset

and debug mode

User pro-gram ***

Stop deleted Acceptanceof the activePLC MD

* “System” hardkey system/“Start-up” softkey/NC** “System” hardkey system/“Start-up” softkey/PLC*** is loaded from the permanent memory into the RAM

Thanks to the debug mode (see “Operation and Programming”, Chapter 7), the PLC remainsin PLC Stop after booting of the control system. All start-up modes set via softkey only comeinto effect when the control system is booted the next time.

The “Run” mode activates the cyclic operation.

The following actions are triggered in the “Stop” mode:

All hardware outputs are disabled.

Profibus DP is inactive.

No cyclic operation (the active user program is not executed).

The process image is no longer refreshed (it is frozen).

EMERGENCY STOP active.

Only in the “Stop” mode can the user load a corrected or new project into the control system.The user program only becomes effective when the control system is booted the next timeor if the “Run” mode is selected.



11.3 PLC alarms

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6FC5 397-0CP10-1BA0

11.3 PLC alarms

The control system displays max. 8 PLC alarms (system alarms or user alarms).

The PLC manages the alarm information per PLC cycle. It saves/cancels the alarms accor-ding to their times of occurrence. The first alarm in the list is always the alarm last occurred.

If more than 8 alarms have occurred, the first seven alarms and the newest alarm with thehighest cancel priority are displayed.

Alarm response and cancel criteria

In addition, the alarm responses are managed by the PLC. The alarm responses alwayscome into effect, irrespective of the number of active alarms. Depending on the type of thealarm response, the PLC will trigger the required action.

A cancel criterion must be defined for each alarm. The PLC uses the cancel criterion SELF-CLEARING by default (see “Configuring user alarms”).

Cancel criteria are:

POWERONCLEAR: The alarm is canceled by turning off/turning on the control system(POWER ON).

CANCELCLEAR: The alarm is canceled by pressing the Cancel key or the Reset key(analogously to the NCK alarms).

SELF-CLEARING: The alarm is canceled, since the alarm cause is no longer present.

The cancel conditions have the following priority:

POWERON CLEAR – system alarms (highest priority)

CANCEL CLEAR – system alarms

SELF–CLEARING – system alarms

POWERON CLEAR – user alarms

CANCEL CLEAR – user alarms

SELF-CLEARING – user alarm (lowest priority)

The responses to be triggered by the alarm in question in the PLC are defined for eachalarm. The PLC uses the alarm response SHOWALARM by default.

Alarm responses are:

PLC stop: The user program is not executed any more, Profibus DP is inactive, and thehardware outputs are disabled.

EMERGENCY STOP: Once the user program is executed, the PLC transmits the EMER-GENCY STOP signal to the NCK via the user interface.

Feed disable: Once the user program is executed, the PLC transmits the feed disablesignal to the NCK via the user interface.

Read-in disable: Once the user program is executed, the PLC transmits the read-in disa-ble signal to the NCK via the user interface.

Starting Up the PLC

11.3 PLC alarms


NC Start inhibited: Once the user program is executed, the PLC signals the “NC startinhibited” signal to the NCK via the user interface.

SHOWALARM: This alarm has no alarm response.

11.3.1 General PLC alarms

Note to the reader

SINUMERIK 802D sl Diagnostics Guide

11.3.2 User alarms

The user interface ‘’ 1600xxxx ‘’ provides the subareas (0, 1) for the user to define useralarms.

Subarea 0: 8 x 8 bits to set the user alarms (0 –>1 edge)Byte 0 : Bit 0 => 1st user alarm “ 700000 ”Byte 1 : Bit 0 => 9th user alarm “ 700008 ”Byte 7 : Bit 7 => 64th user alarm “ 700063 ”

A new user alarm is activated with the relevant bit (subarea 0) via a 0/1 edge.

Subarea 1: User alarm variables

Subarea 1 is intended for additional user information; it can only be read/written as a dou-bleword.

Subarea 2: Alarm responseByte 0 : Bit 0 => NC start inhibited

Bit 1 => Read-in disableBit 2 => Feed disable for all axesBit 3 => EMERGENCY STOPBit 4 => PLC STOP

By using subarea 2, the user can evaluate the active alarm responses; this subarea isread-only.

Self-clearing user alarms must be canceled by the user by resetting the appropriate bit insubarea 0 (1 –> 0 edge).

Other user alarms are canceled by the PLC after detecting the relevant cancel condition forthe appropriate user alarms. If the bit of the user alarm, however, is still present, the alarmrecurs.



11.3 PLC alarms

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6FC5 397-0CP10-1BA0

Type of action of a user alarm

User alarms have a higher priority than the appropriate signal in the user interface(e.g. NC start inhibited, read-in disable, feed disable and EMERGENCY STOP).

Example:MD 14516[0]: USER_DAT_PLC_ALARM = 8If alarm 700000 is present, in addition, alarm 3000 EMERGENCY STOP is also presenteven if the interface signal V26000000.1=0.

Configuring user alarms

A configuration byte is provided for each alarm. The user alarms can be configured by theuser in the machine data 14516: USER_DATA_PLC_ALARM.

Default setting of MD 14516[0...63]: 0 => SHOWALARM/SELF-CLEARING user alarm

Structure of a configuration byte:

Bit0 – bit5 : Alarm responses

Bit6 – bit7 : Cancel criteria

Alarm responses: Bit0 – bit 5 = 0: Showalarm (default)Bit0 = 1: NC start inhibitedBit1 = 1: Read–in disableBit2 = 1: Feed disable for all axesBit3 = 1: EMERGENCY STOPBit4 = 1: PLC stopBit5 = reserved

Cancel criteria: Bit6 + bit7 = 0: SELF-CLEARING alarm (default)Bit6 = 1 : CANCELCLEAR alarmBit7 = 1 : POWERONCLEAR alarm

The alarm response to PLC Stop always has the cancel condition POWER ON.

Alarm texts

The user are offered two options of defining his own alarm texts:

by using the System hardkey \ softkeys PLC \ Edit PLC alarm txt (see ”Operation andProgramming”, Chapter 7)

by using the toolbox: Editing and loading the alarm text file using the text manager

If no alarm text is assigned by the user, only the alarm number is displayed.

The % character in the alarm text denotes an additional variable. The variable type is theform of representation of the variable.

The following variable types are possible:

%D integer decimal number

%I integer decimal number

%U decimal number without sign

Starting Up the PLC

11.3 PLC alarms


%O integer octal number

%X integer hexadecimal number

%B binary representation of a 32-bit value

%F 4-byte floating point number

Examples of user alarm texts (Note: The text after the ”//” is a comment and is not dis-played.)

700000 ‘’ ‘’ // only the user alarm number

700001 ‘’ Hardware limit switch + of the X axis’’

700002 ‘’ %D ‘’ // only a variable as an integer decimal number

700003 ‘’ Alarm number with a fixed alarm text and the variable %X ‘’

700004 ‘’ %U Alarm number with variable and fixed alarm text ‘’

700005 ‘’Axis monitoring active : %U’’

Display: 700005 Axis monitoring active : 1or 700005 Axis monitoring active : 3



11.4 PLC programming

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6FC5 397-0CP10-1BA0


The PLC user program is created using the PLC 802 Programming Tool.

The handling of this tool for an S7-200 is described in the documentation “SIMATIC S7-200Automation System Manual”. The PLC 802 Programming Tool constitutes a subset of thisdocumentation.

Compared to the S7-200 MicroWin base system, the following is to be observed:

The user program can only be programmed in ladder diagram.

Only a subset of the S7-200 programming language is supported.

The compilation of the user program is performed offline on a PG/PC or automaticallywhen downloading into the control system.

The project can be loaded into the control system (download).

It is also possible to load the project from the control system (upload).

Indirect data addressing is not possible. Thus, no programming errors will occur duringthe runtime.

The user must manage the data and process information type-specifically.For all accesses to the data, it is imperative to use consistently the agreed data type.

Example: Information 1 T value Memory size DInt (32-bit)Information 2 Override Memory size Byte (8-bit)

User dataMemory double-word MD0 DInt (information 1)Memory byte MB4 Byte (information 2)

Furthermore, the alignment towards certain memory addresses is dependent on the datatype. This alignment is performed towards bus addresses which can be divided by thebyte length of the data type without remainder.

BOOL and BYTE can start at any byte address (0, 1, 2, 3, ...), WORD and INT must start at an even byte address (0, 2, 4, 6, ...) andDWORD, DINT, REAL must start at a byte address which can be divided by 4(0, 4, 8, 12, ...).

Example:

Memory bits MB0.1,MB3.5Memory bytes MB0,MB1,MB2Memory word MW0,MW2,MW4

MW3, MW5 ... are not permissibleMemory double words MD0,MD4,MD8

MD1,MD2,MD3, MD5 ... are not permissible

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

Data type Size Addressalignment

Range for logical operations Range for arithmetic operations

BOOL 1 Bit 1 0.1 –

BYTE 1 byte 1 00 ... FF 0 ... +255

Starting Up the PLC



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

Data type Range for arithmetic operationsRange for logical operationsAddressalignment

Size

WORD 2 bytes 2 0000 ... FFFF –32 768 ... + 32 767

DWORD(DoubleWord)

4 bytes 4 0000 0000 ... FFFF FFFF –2 147 483 648 ... +2 147 483 647

REAL 4 bytes 4 – 10–37... 1038

PLC project

The PLC 802 Programming Tool always manages one project (combinational logic, symbolsand comments). All important information of a project can be stored in the control system viaa download. The information is transmitted from the control to the PC via upload.

The control system can save max. 6,000 instructions and 1,500 symbols. The PLC memoryrequired is influenced by the following components:

number of instructions

number and length of the symbol names

number and length of the comments

S7-200 Ladder Diagram

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

11.4.1 Command overview

Table 11-3 Operand identifier

Operand identifier Description Area

V Data V1000 0000.0 to V7999 9999.7

T Timers T0 to T15 (100 ms)T16 to T39 (10 ms)

C Counter C0 to C31

I Image of digital inputs I0.0 to I17.7

Q Image of digital outputs Q0.0 to Q11.7

M Flags M0.0 to M383.7




Starting Up the PLC


6FC5 397-0CP10-1BA0

Table 11-3 Operand identifier, continued

Operand identifier AreaDescription

SM Special bit memory SM0.0 to SM 0.6 (see Table 11-6)

AC ACCU AC0 ... AC3

L Local data L0.0 to L51.7

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

Type identifi-cation (mo-

dule no.)

Area no.(channel/axis no.)

Subarea Offset Addressing

00

(10–79)

00

(00–99)

0

(0–9)

000

(000–999)

symbolic

(8-digit)

Table 11-5 802D Operand Ranges

Access Method Valid Operand Ranges for Programming 802D

Bit Access (Byte.Bit) V(1000 0000.0–7900 9999.7)

I(0.0–17.7)

Q(0.0–11.7)

M(0.0–383.7)

SM(0.0–0.7)

–

T(0–39)

C(0–31)

Byte Access VB(1000 0000–7999 9999)

IB(0–17)

QB(0–11)

MB(0–383)

AC(0–3)

SMB(0)

–

KB (Constant)

Word Access VW(1000 0000–7999 9998)

T(0–39)

C(0–31)

IW(0–16)

QW(0–10)

MW(0–382)

AC(0–3)

–

–

KW (Constant)

Starting Up the PLC



Table 11-5 802D Operand Ranges, continued

Access Method Valid Operand Ranges for Programming 802D

Double Word Access VD(1000 0000–7999 9994)

ID(0–14)

QD(0–8)

MD(0–380)

AC(0–3)

–

–

AC(0–3)

KD (Constant)

Table 11-6 Special bit memory SM Bit Definition

SM bits Description

SM 0.0 Bit memory with defined ONE signal

SM 0.1 Initial position: first PLC cycle ‘1’, subsequent cycles ‘0’

SM 0.2 Buffered data lost – only valid in the first PLC cycle(‘0’ – data o.k., ‘1’ – data lost)

SM 0.3 POWER ON: first PLC cycle ‘1’, subsequent cycles ‘0’

SM 0.4 60 s clock (alternating ‘0’ for 30 s, then ‘1’ for 30 s)

SM 0.5 1 s clock (alternating ‘0’ for 0.5 s, then ‘1’ for 0.5 s)

SM 0.6 PLC cycle clock (alternating one cycle ‘0’, then one cycle’)

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




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6FC5 397-0CP10-1BA0

11.4.2 Explanation of the stack operations

Table 11-7 INSTRUCTIONS Set

BASIC BOOLEAN INSTRUCTIONS

Instruction Ladder Symbol Valid Operands

Load

And

Or

normal open

n=1 close

n=0 open

nn: V, I, Q, M, SM, T, C, L

Load Not

And Not

Or Not

normal close

n=0 close

n=1 open

nn: V, I, Q, M, SM, T, C, L

Output prior 0, n=0

prior 1, n=1

n n: V, I, Q, M,T, C, L

Set(1 Bit)

prior 0, not set

prior 1 or

Bit

S

S_Bit: V, I, Q, M,T, C, L

n =1

Reset(1 Bit)

prior 0, no reset

prior 1 or Bit

R

S_Bit: V, I, Q, M,T, C, L

n =1

OTHER BOOLEAN INSTRUCTIONS


Edge Up prior close

(1 PLC cycle)P

Edge Down prior close

(1 PLC cycle)N

Logical Not prior 0, later 1

prior 1, later 0NOT

No operationNOP

n n = 0 ... 255

BYTE COMPARES (Unsigned)


Load Byte =

And Byte =

Or Byte =

a = b close

a b open

a

b==B

a: VB, IB, QB, MB, SMB, AC, Constant, LB

b: VB, IB, QB, MB, SMB, AC, Constant, LB

Load Byte

And Byte

Or Byte

a ≥ b close

a b opena

b> =B

LB

Load Byte

And Byte

Or Byte

a ≤ b close

a b opena

b

< =B

Starting Up the PLC



WORD COMPARES (Signed)


Load Word =

And Word =

Or Word =

a = b close

a b open

a

b

==I

a: VW, T, C, IW, QW, MW, AC, Constant, LW

b: VW, T, C, IW, QW, MW, AC, Constant,LW

Load Word

And Word

Or Word

a ≥ b close

a b open

a

b> =I

LW

Load Word

And Word

Or Word

a ≤ b close

a b open

a

b< =I

DOUBLE WORD COMPARES (Signed)


Load DWord =

And DWord =

Or DWord =

a = b close

a b open

a

b

==D

a: VD, ID, QD, MD, AC, Constant, LB

b: VD, ID, QD, MD, AC, Constant, LB

Load DWord

And DWord

Or DWord

a ≥ b close

a b open

a

b> =D

Load DWord

And DWord

Or DWord

a ≤ b close

a b open

a

b< =D

REAL WORD COMPARES (Signed)


Load RWord =

And RWord =

Or RWord =

a = b close

a b open

a

b

= =R

a: VD, ID, QD, MD, AC, Constant, LD

b: VD, ID, QD, MD, AC, Constant, LD

Load RWord

And RWord

Or RWord

a ≥ b close

a b open

a

b

> =R

Load RWord

And RWord

Or RWord

a ≤ b close

a b open

a

b< =R




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6FC5 397-0CP10-1BA0

TIMER


Timer Retentive OnDelay

EN=1, Start EN=0, Stop

If TValue ≥ PT, Tbit=1

TONR

Txxx

PT

IN

Enable: (IN)S0

Txxx: T0 – T31

Preset: (PT)VW, T, C, IW, QW, MW, AC, Constant

100 ms T0 – T1510 ms T16 – T39

Timer On Delay EN=1, Start EN=0, Stop

If TValue ≥ PT, Tbit=1

TON

Txxx

PT

IN

Enable: (IN)S0

Txxx: T0 – T31


100 ms T0 – T1510 ms T16 – T39

Timer Of Delay If TValue < PT, Tbit=1

TOF

Txxx

PT

IN

Enable: (IN)S0

Txxx: T0 – T31


100 ms T0 – T1510 ms T16 – T39

COUNTER


Count Up CU , Value+1

R=1, Reset

If CValue ≥ PV, Cbit=1

CTU

Cxxx

CU

R

PV

Cnt Up: (CU)S1

Reset: (R)S0

Cxxx: C0 – 31

Preset: (PV)VW, T, C, IW, QW, MW, AC, Constant, LW

Count Up/Down CU , Value+1CD , Value–1

R=1, Reset

If CValue ≥ PV, Cbit=1 CTUD

CD

Cxxx

CU

R

PV

Cnt Up: (CU)S2

Cnt Dn: (CD)S1

Reset: (R)S0

Cxxx: C0 – 31


Starting Up the PLC



Instruction Valid OperandsLadder Symbol

Count Down If CValue = 0,Cbit=1

CTD

LD

Cxxx

CD

PV

Cnt Down: (CD)S2

Reset: (R)S0

Cxxx: C0 – 31


MATH OPERATIONS


Word Add

Word Subtract

If EN = 1,

b = a + b

b = b – a

ADD_I

IN1

IN2 OUT

EN ENO

Enable: EN

In: VW, T, C, IW, QW, MW, AC, Constant, LW

Out: VW, T, C, IW, QW, MW, AC, LW

DWord Add

DWord Subtract

If EN = 1,

b = a + b

b = b – a

SUB_DI

IN1

IN2 OUT

EN ENO

Enable: EN

In: VD, ID, QD, MD, AC, Constant, LD

Out: VD, ID, QD, MD, AC, LD

Multiply If EN = 1,

b = a x bMUL

IN1

IN2 OUT

EN ENO

Enable: EN



Divide If EN = 1, b = b ÷ a

Out: 16 bit remainder

Out+2: 16 bit quotient

DIV

IN1

IN2 OUT

EN ENO

Enable: EN


Out: VD, ID, QD, MD, LD

Add

Subtract

Real Numbers

If EN = 1,

b = a + b

b = b – a

ADD_R

IN1

IN2 OUT

EN ENO

Enable: EN



Multiply

Divide

Real Numbers

If EN = 1,

b = a x b

b = b ÷ a

MUL_R

IN1

IN2 OUT

EN ENO

Enable: EN






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6FC5 397-0CP10-1BA0

INCREMENT, DECREMENT


Increment

Decrement

Byte

If EN = 1,

a = a + 1

a = a – 1

INC_B

IN OUT

EN ENO

Enable: EN

In: VB, IB, QB, MB, AC, Constant LB

Out: VB, IB, QB, MB, AC, LB

Increment

Decrement

Word

If EN = 1,

a = a + 1

a = a – 1

a = /a

INC_W

IN OUT

EN ENO

Enable: EN



Increment

Decrement

If EN = 1,

a = a + 1

a = a – 1

INV_DW

IN OUT

EN ENO

Enable: EN



LOGIC OPERATIONS


Byte AND

Byte OR

Byte XOR

If EN = 1,

b = a AND b

b = a OR b

b = a XOR b

WAND_B

IN1

IN2 OUT

EN ENO

Enable: EN

In: VB, IB, QB, MB, AC, Constant, LB


Word AND

Word OR

Word XOR

If EN = 1,

b = a AND b

b = a OR b

b = a XOR b

WAND_W

IN1

IN2 OUT

EN ENO

Enable: EN



DWord AND

DWord OR

DWord XOR

If EN = 1,

b = a AND b

b = a OR b

b = a XOR b

WXOR_DW

IN1

IN2 OUT

EN ENO

Enable: EN



Invert Byte If EN = 1,

a = /aINC_B

IN OUT

EN ENO

Enable: EN



Invert Word If EN = 1,

a = /aINC_W

IN OUT

EN ENO

Enable: EN



Invert DWord If EN = 1,

a = /aINV_DW

IN OUT

EN ENO

Enable: EN



Starting Up the PLC



SHIFT AND ROTATE OPERATIONS


Shift Right

Shift Left

If EN = 1,

a = a SR c bits

a = a SL c bits

SHL_R

IN

N OUT

EN ENO

Enable: EN


Out: VB, IB, QB, MB, AC

Count: VB, IB, QB, MB, AC, Constant, LB

Shift Right

Shift Left

If EN = 1,

a = a SR c bits

a = a SL c bits

SHL_W

IN

NOUT

EN ENO

Enable: EN




DWord Shift R

DWord Shift L

If EN = 1,

a = a SR c bits

a = a SL c bits

SHL_DW

IN

N OUT

EN ENO

Enable: EN




CONVERSION OPERATIONS


Convert DoubleWord Integer to aReal

If EN = 1, convert thedouble word integer ito a real number o.

DI_REAL

IN OUT

EN ENO

Enable: EN



Convert a Real to aDouble Word Integer

If EN = 1, convert thereal number i to adouble word integer o.

TRUNC

IN OUT

EN ENO

Enable: EN



PROGRAM CONTROL FUNCTIONS


Jump to Label If EN = 1, go to label n. n

JMP

Enable: EN

Label: WORD: 0–127

Label Label marker for thejump. LBL

n Label: WORD: 0–127

Conditional Returnfrom Subroutine

If EN = 1, exit the sub-routine. RET

Enable: EN

Return from Subrou-tine

Exit subroutine.RET

Conditional End If EN = 1, END termi-nates the main scan. END

Enable: EN




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6FC5 397-0CP10-1BA0

PROGRAM CONTROL FUNCTIONS


Subroutine If EN , go to subrou-tine n. SBR

x1

x2 x3

EN

n

(x... optional parameters

Label: Constant : 0–63

MOVE, FILL AND FIND OPERATIONS


Move Byte If EN = 1, copy i to o.

MOV_B

IN OUT

EN ENO

Enable: EN



Move Word If EN = 1, copy i to o.

MOV_W

IN OUT

EN ENO

Enable: EN



Move DWord If EN = 1, copy i to o.

MOV_DW

IN OUT

EN ENO

Enable: EN



Move Real If EN = 1, copy i to o.

MOV_R

IN OUT

EN ENO

Enable: EN



Swap Bytes If EN = 1, exchange MSB andLSB of w.

SWAP

IN

EN ENO

Enable: EN

In: VW, IW, QW, MW, T, C, AC, LW

Starting Up the PLC



11.4.3 Program organization

A programmer should structure the user program into separate program sections (subrouti-nes). The S7-200 programming language offers the user the possibility to create a structureduser program. There are two program types – main program and subroutine. Eight programlevels are possible.

A PLC cycle can be a multiple of the control-internal interpolation cycle (IPO cycle). The ma-chine manufacturer must set the PLC cycle according to his particular conditions (see ma-chine data “PLC_IPO_TIME_RATIO”). An IPO/ PLC ratio of 1:1 has been proven to providethe fastest possible cyclic program execution.

Example: The programmer will write a sequence control in the main program using a cycledefined by himself. This sequence control will organize all cyclic signals in the subroutine(UP0); UP1/UP2 are called every two cycles, and UP3 controls all signals at an interval ofthree cycles.

11.4.4 Data organization

The data can be divided into three areas:

non-retentive data

retentive data

machine data for the PLC (all these machine data are active after POWER ON).

Most of the machine data, such as process image, timer and counter are non-retentive datawhich are deleted each time when the control system is powered up.

The data area 1400 0000 –1400 0127 is reserved for the retentive data. The user can herestore all data which are to remain valid after POWER OFF/ON.

The user can either load the data in his program with default data using the PLC machinedata (see “User interface”) or parameterize various program sections.

11.4.5 Interface to the control system

This interface can be selected via SYSTEM, softkeys PLC > STEP7-connect.

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




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6FC5 397-0CP10-1BA0

11.4.6 Testing and monitoring your program

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

PLC status: Display and change of called operands

Status list: Display and change of three freely selected variable fields

PLC program: Display and monitoring (status) of the whole user program including sym-bols and comments

PT PLC 802: It is possible to connect a PG/PC and to activate the PT connection via mo-dem

Starting Up the PLC

11.5 PLC applications Download/Upload/Copy/Compare



The user can save, copy or overwrite the PLC project or the PLC applications in the controlsystem.

This is possible using

PLC 802 Programming Tool

RCS802 (binary file)

CF card

The PLC project comprises the PLC user program including all important information (sym-bols, comments, ...). It is loaded by the Programming Tool via upload/download or via File >Import/Export.

The PLC application incorporates the PLC project and PLC user alarm texts. The PLC ap-plication can only be generated by the control system.

PLC project

PLC user

alarm texts

PLCmachine data

PT PLC 802

RCS802

CF card

Toolbox

PLCapplication

Series machine start-up

Series machine start-up

PLCapplication

Download/Upload/Compare

802D Permanentmemory

Export/Import

Fig. 11-1 PLC applications in the control system




Starting Up the PLC


6FC5 397-0CP10-1BA0

Download

This function writes the transmitted data to the permanent memory (load memory) of thecontrol system.

Download of a PLC project using the PLC 802 Programming Tool (Step 7 connect on)

Series machine start-up (System > Start-up files > NC/PLC start-up archive) using theRCS802 tool or CF card. For example, CF card:Copy the start-up archive from the customer CF card and paste it into the directory Start-up files > Start-up archive (NC/PLC).

– NC data

– NC directories

– Display machine data

– Leadscrew error compensation (LEC)

– PLC user program

– Drive machine data

Reading in PLC applications using the RCS802 tool or the CF card (PLC project and useralarm texts) analogously to the series machine start-up

Upload

The PLC application can be saved from the permanent memory of the control system usingthe either PLC 802 Programming Tool, RCS802 or the CF card.

Upload from the PLC project using the PLC 802 Programming Tool (Step 7 connect on)

Reading out the project from the control system and thus reconstructing the current pro-ject in the PLC 802 Programming Tool.

Series machine start-up: System > Start-up file > Start-up archive (NC/PL) usingRCS802 (PLC MD, PLC project and user alarm texts) or the CF card

Reading out the PLC application using RCS802 or copying to CF card (PLC project infor-mation and user alarm texts)

Compare

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

Version display

This function is called using the SYSTEM hardkey, softkeys Service Display > Version.

PLC applicationThe transmitted project including the user program which is active in the user memory ofthe PLC after booting of the control system.

The programmer can use the start of the first comment line in the comment of OB1 in thePLC 802 Programming Tool for his own supplementary information in the version display(see “View Properties”).

Starting Up the PLC

11.6 User interface


11.6 User interface

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

Note to the reader

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



11.6 User interface

Starting Up the PLC


6FC5 397-0CP10-1BA0

Notes


Data Backup and Series Machine Start-Up

12.1 Data backup

12.1.1 Internal data backup

The data of the limited-buffered memory must be saved via a backup copy to the permanentmemory of the control system. This backup is performed internally and is always necessaryif the control system is switched off for longer than 50 hours.

Recommendation: After changing important data, it is recommended to carry out a databackup immediately.

Note

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

Performing an internal data backup

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

Important

While the internal data backup is running, the control system must neither be operated, norbe turned off.

Loading internally backed-up data

Boot the control system in the start-up mode “Reload saved user data”.

In case of data loss of the buffered memory, the data saved in the permanent memoryare automatically reloaded into the memory with POWER ON.

Note

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

12



12.1 Data backup



6FC5 397-0CP10-1BA0

12.1.2 External data backup

In addition to an internal data backup, the user data of the control system can also be savedexternally. To do so, a PC with V24 interface and the RCS tool (included in the toolbox) or aCF card are required.

An external data backup should be performed if major data changes have been made or al-ways at the end of the start-up.

To create a complete data backup for a machine, it is sufficient to create the series machinestart-up file.

Variants of external data backup

1. Reading out the data completely: Series machine start-up

2. Files are read out/read in for each area individually. The following user data can be selec-ted from the “System” operating area as individual files:

Data in the text format

– All machine data

– Setting data

– Tool data

– R parameters

– Work offset

– Compensation data (LEC)

– GUDs

Data in the start-up archive (NC/PLC)

– NC data

– NC directories

– Display machine data

– Compensation data (LEC)

– PLC user alarm texts

– PLC project (cannot be edited with PT 802)

– Drive machine data

Data in the start-up archive (HMI)

– User cycles

– User directories

– Language file SP1

– Language file SP2

– Start screen

– Online help

– HMI screens

3. Furthermore, the following data can be saved from the “Program Manager” operatingarea:

– Manufacturer cycles

– Standard cycles


12.1 Data backup


– User cycles

– Main programs

– Subroutines

12.1.3 Data backup via V24

Important

Never connect or disconnect the V24 cable when the PCU is connected to the mains.

Make sure that the settings of the RS232 interface of the 802D and of the COM port on thePC are identical.

Creating a start-up archive in the PC (data transfer from the control system to the PC)

For the series machine start-up, please refer to Section 12.2.

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

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

Note to the reader

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

Data backup in the “Program Manager” operating area

The data from the Program Manager > NC directory operating area are output to theRS232 in the text format.

12.1.4 External data backup via CF Card

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



12.2 Series machine start-up



6FC5 397-0CP10-1BA0


Functionality

The objective of the series machine start-up is:

to bring another control system at a machine of the same type to the same condition asafter a commissioning

or

to bring a new control system to the initial state in case of servicing (after hardware repla-cement) with lowest possible expenditure.

Start-up archive (NC/PLC)

The start-up archive (NC/PLC) incorporates the following data:

Machine data

R parameters

Setting data

PLC user alarm texts

Display machine data

PLC user project

Part programs

Cycles

Work offsets

Tool offsets

Leadscrew error compensation data

Drive machine data of SINAMICS

Start-up archive (HMI)

The start-up archive (HMI) incorporates the following data:

User cycles

User directories

Language file SP1

Language file SP2

Start screen

Online help

HMI screens




Prerequisites

The prerequisite for the series machine start-up is a PC with V24 interface for data transferfrom/to the control system, or a CF card.

In the PC, the RCStool must be used.

Sequence with PC

1. Creating a start-up archive (NC/PLC) in the PC (data transfer from the control system tothe PC):

– Establish a V24 cable connection between the PC (COM port) and the SINUMERIK802D (RS232).

– Use the RCS tool to make the following settings in the RS232 Config menu in thebinary format (the settings not printed in bold correspond to the default setting whenstarting WINPCIN):

COM port Number of the PC COM to SINUMERIK 802DBaud rate 19,200 (default)Parity noneData bit 8Stop bit 1Software (XON/XOFF) OFFHardware (RTS/CTS) ONTimeout 0sSTOP with EOF no tick

– Call the Receive Data menu in the PC, enter a file name (any archive name) and start the data transfer.The PC switches to “Receive” and is awaiting data from the control system.

– The control system requires the password for protection level 2.

– Configure the interface as above (default settings) using the System > Start-upfiles > RS232 > Settings menu.

– Go back with Back and 802D Data and select the “Start-up archive (NC/PLC)” line;use Copy to paste the contents to the clipboard.

– Back again in RS232,, select the “Binary mode transmission” direction key and thenSend. The series machine start-up is output to the serial interface.

2. Reading in the series start-up file from the PC into the SINUMERIK 802D

– Make the relevant settings for the V24 interface on the PC and on the 802D as speci-fied under 1.

– In the System > Start-up files > RS232 “Binary mode transmission” menu, selectReceive. The control system will now wait for data.

– Use RCS802 on your PC to open the series machine start-up file from the Send Datamenu, starting the data transfer.

– Once reading-in has started, confirm the start of the series machine start-up in thecontrol system.

– A warm start of the NC/PLC is performed several times during the series machinestart-up. At the end of the series machine start-up, the whole control system will re-boot (warm start). After an error-free series machine start-up, the control system willbe in a fully configured operating condition.






6FC5 397-0CP10-1BA0

Sequence with CF card

1. Creating a series machine start-up file on the CF card:

– Make sure that the CF card is inserted in the slot on the device front panel.


– In the System > Start-up files > 802D data menu, select the Start-up archive (NC/PLC) line and use the Copy command to paste the contents to the clipboard. Selectthe Customer CF card softkey to display the contents of the inserted card. If you se-lect the Paste softkey and subsequently enter the name for the archive file, the seriesmachine start-up is produced on the card.

2. Reading in the series start-up file from the CF card into the SINUMERIK 802D

– Make sure that the CF card is inserted.


– In the System > Start-up files > Customer CF card menu, select the line containingthe appropriate archive and use the Copy command to paste the data to the clipbo-ard. Select the 802D data softkey and select the “Startup data (NC/PLC)” line. Selec-ting the Paste softkey will transmit the series start-up to the control system.

– Once reading-in has started, confirm the start of the series machine start-up in thecontrol system.

– A warm start of the NC/PLC is performed several times during the series machinestart-up. At the end of the series machine start-up, the whole control system will re-boot (warm start). After an error-free series machine start-up, the control system willbe in a fully configured operating condition.

Start-up archive (HMI)

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


12.3 Data backup in case of backlight failure



In case of failure of the backlight of the control system, menu-assisted operation is no longerpossible. If a backlight failure occurs on the control system, an external data backup can becarried out on a PC using a special command.

To do so, the CF card must be inserted.

After turning on the control system, wait until the boot sequence is completed and pressCTRL S. This will output the series machine start-up archives (NC/PLC and HMI) with thelatest current data.






6FC5 397-0CP10-1BA0

Notes

A-195SINUMERIK 802D sl Instruction Manual (BA), 05/2005 Edition6FC5 397-0CP10-1BA0

Machine and Setting Data 802D

Data type

BOOLEAN Boolean value: 1 (TRUE) or 0 (FALSE)

BYTE 8-bit value,as an integer value: –128 ... 127,as a hexadecimal value: 00 ... FFas a character as per ASCII character set, e.g. “a”

STRING Sequence of characters (max. 16)

WORD 16-bit value,as an INTEGER value: –32768 ... 32767,as a hexadecimal value: 0000 ... FFFF

UNSIGNED WORD 16-bit value,as an integer value: 0 ... 65535,as a hexadecimal value: 0000 ... FFFF

INTEGER 16-bit value (here defined locally),integer value: –32768 ... 32767

DWORD 32-bit value,as an integer value: –2147483648 ... 2147483647,as a hexadecimal value: 0000 0000 ... FFFF FFFF

UNSIGNED DWORD 32-bit value,as an integer value: 0 ... 4294967295,as a hexadecimal value: 0000 0000 ... FFFF FFFF

DOUBLE 64-bit value,floating point value: 4.19 10–307 bis 1.67 10308

Range of values (minimum/maximum value)

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

A



A.1 List of machine data


A-196SINUMERIK 802D sl Instruction Manual (BA), 05/2005 Edition

6FC5 397-0CP10-1BA0


A.1.1 Display machine data

Number MD identifier

Cross refe-rence to therelevant sec-tion/chapterin the Des-cription ofFunctions

Schematic view Name, miscellaneous Activation Read/write protection level

Unit Default value Minimum value Maximum value Data type

202 FIRST_LANGUAGE 19decimal Foreground language POWER ON 2/3

0 2 1 2 BYTE

203 DISPLAY_RESOLUTION 19decimal Display resolution immediately 2/3

0 3 0 5 BYTE

204 DISPLAY_RESOLUTION_INCH 19decimal Display resolution immediately 2/3

0 4 0 5 BYTE

205 DISPLAY_RESOLUTION_SPINDLE 19decimal Display resolution immediately 2/3

0 1 0 5 BYTE

208 USER_CLASS_WRITE_TOA_GEOdecimal Protection level write tool geometry immediately 3/3

0 3 0 7 BYTE

209 USER_CLASS_WRITE_TOA_WEARdecimal Protection level write tool wear data immediately 3/3

0 3 0 7 BYTE

210 USER_CLASS_WRITE_ZOAdecimal Protection level for “Write settable work offset” immediately 3/3

0 3 0 7 BYTE

212 USER_CLASS_WRITE_SEAdecimal Protection level for “Write setting data” immediately 3/3

0 7 0 7 BYTE

213 USER_CLASS_READ_PROGRAMdecimal Protection level for “Read part program” immediately 3/3

0 7 0 7 BYTE

214 USER_CLASS_WRITE_PROGRAMdecimal Protection level for “Enter part program” immediately 3/3

0 3 0 7 BYTE

215 USER_CLASS_SELECT_PROGRAMdecimal Protection level for program selection immediately 3/3

0 3 0 7 BYTE




217 USER_CLASS_WRITE_CYCLESdecimal Protection level for “Write cycles” immediately 3/3

0 3 0 7 BYTE

218 USER_CLASS_WRITE_RPAdecimal Protection level write R parameters immediately 3/3

0 3 0 7 BYTE

219 USER_CLASS_SET_V24decimal Protection level for “Set V24” immediately 3/3

0 3 0 7 BYTE

221 USER_CLASS_DIR_ACCESSdecimal Protection level for directory access immediately 3/3

0 3 0 7 BYTE

222 USER_CLASS_PLC_ACCESSdecimal Protection level for PLC project immediately 2/2

0 3 0 7 BYTE

223 USER_CLASS_WRITE_PWAdecimal Protection level for protected working area immediately 2/3

0 7 0 7 BYTE

247 V24_PG_PC_BAUDBit pattern PG: Baud rate (300, 600, 1200, 2400, 4800, 9600, 19200, 38400) immediately 3/3

0 7 0 7 BYTE

280 V24_PPI_ADDR_PLCPLCstation address POWER ON 3/3

2 0 126 BYTE

281 V24_PPI_ADDR_NCKNCKstation address POWER ON 3/3

3 0 126 BYTE

289 CTM_SIMULATION_TIME_NEW_POS 10 (K1)decimal Simulation of actual-value refresh rate immediately 3/4

0 100 0 4000 INTEGER

290 CTM_POS_COORDINATE_SYSTEM 10 (K1)decimal Position of the coordinate system immediately 3/4

0 2 0 7 BYTE

291 CTM_CROSS_AX_DIAMETER_ON 10 (K1)decimal Diameter for “Transverse axis active” immediately 3/4

0 1 0 1 BYTE

292 CTM_G91_DIAMETER_ON 10 (K1)decimal Incremental feed immediately 3/7

0 1 0 1 BYTE

305 G_GROUP1decimal User-oriented G group for position display immediately 3/7

0 1 1 1000 INTEGER






6FC5 397-0CP10-1BA0


0 2 1 1000 INTEGER


0 8 1 1000 INTEGER


0 9 1 1000 INTEGER


0 10 1 1000 INTEGER

310 FG_GROUP1decimal User-oriented G group for position display (external language) immediately 3/7

0 1 1 1000 INTEGER


0 2 1 1000 INTEGER


0 8 1 1000 INTEGER


0 9 1 1000 INTEGER


0 10 1 1000 INTEGER

330 CMM_POS_COORDINATE_SYSTEMdecimal Coordinate position of machine *) immediately 3/7

0 0 0 7 BYTE

*) Explanation:Both the position and the size of the representation are handed over during initialization. The position of the coordinate systemcan be influenced by the parameter “Axis direction” in the header of the file.The following positions are possible: Position X+ Z+

0 up to the right1 up to the left2 down to the right3 down to the left4 to the right top5 to the left up6 to the right down7 to the left down

The positions of the elements must be specified in position 4 (mathematic coordinate system). The simulation will then auto-matically convert the representation to the relevant system.

331 CONTOUR_MASKdecimal Activating the 802 contour definition programming immediately 3/7

0 1 0 1 BYTE




332 TOOL_LIST_PLACE_NOdecimal Activate location number in tool list immediately 3/3

0 0 0 1 INTEGER

343 V24_PPI_ADDR_MMCdecimal POWER ON 3/3

0 4 0 126

344 V24_PPI_MODEM_ACTIVEdecimal immediately 3/3

0 0 0 1 Byte

345 V24_PPI_MODEM_BAUDdecimal Baud rate for modem connection immediately 3/3

0 7 5 9 Byte

346 V24_PPI_MODEM_PARITYdecimal Parity for modem connection immediately 3/3

0 0 0 2 Byte

356 HMI_COL_TITLE_FOCUS_FOREdecimal Color settings title bar focus window foreground immediately 0/3

15 0 15 Byte

357 HMI_COL_TITLE_FOCUS_BACKdecimal Color settings title bar focus window background immediately 0/3

2 0 15 Byte

358 HMI_COL_SK_FOREdecimal Color settings softkey foreground POWER ON 3/3

0 0 15 Byte

359 HMI_COL_SK_BACKdecimal Color settings softkey background POWER ON 3/3

7 0 15 Byte

360 SPINDLE_LOAD_DISPL1decimal Activate utilization display for spindle 1 immediately 3/3

0 0 1 Integer

361 USER_MEAS_TOOL_CHANGEdecimal Input enable for T/D no. in the “Tool gauging” window immediately 3/3

0 0 1 Byte

362 SPINDLE_LOAD_DISPL2decimal Activate utilization display for spindle 2 immediately 3/3

1 0 1 Integer

363 SPINDLE_LOAD_BAR_LIM2decimal Activate utilization display for the spindle, limit value 2 immediately 2/2

100 0 9999999 Integer

364 SPINDLE_LOAD_BAR_LIM3decimal Activate utilization display for the spindle, limit value 3 immediately 2/2

100 0 9999999 Integer






6FC5 397-0CP10-1BA0

365 SPINDLE_LOAD_BAR_MAXdecimal Utilization display for the spindle, maximum immediately 2/2

120 0 120 Integer

366 SPINDLE_LOAD_BAR_COL1decimal Utilization display color for the spindle, range 1 immediately 3/3

10 0 15 Byte


9 0 15 Byte


9 0 15 Byte

369 PROBE_MODEdecimal Measuring system type: 1: Probe, 2: Opt. measuring technique immediately 3/3

1 0 2 Integer

370 TOOL_REF_PROBE_AXIS1decimal Absolute position of probe X immediately 2/2

0 –999999.999 999999.999 Double

371 TOOL_REF_PROBE_AXIS2decimal Absolute position of probe Y immediately 2/2

0 –999999.999 999999.999 Double

372 TOOL_REF_PROBE_AXIS3decimal Absolute position of probe Z immediately 2/2

9 –999999.999 999999.999 Double

373 MEAS_SAVE_POS_LENGTH2decimal Activate tool gauging; select “Save Pos” softkey for all values immediately 2/2

0 0 1 Byte

374 TOOL_WEAR_LIMIT_VALUEdecimal Limit value for wear control during input immediately 2/2

9.999 0 9.999 Double

375 USER_CLASS_READ_CUS_DIRdecimal Protection level for “Read user cycles” immediately 2/3

0 7 0 7 Byte

376 USER_CLASS_WRITE_CUS_DIRdecimal Protection level for “Write user cycles” immediately 2/2

0 2 0 7 Byte

377 USER_CLASS_WRITE_TO_MON_DATdecimal Protection level for “Tool monitoring” immediately 2/3

0 3 0 7 Byte

378 USER_CLASS_LADDER_VIEWdecimal Protection level for “Select user ladder view” immediately 2/2

0 2 0 7 Byte




379 SPINDLE_DISP_MODE

decimal0: Standard mode, display of spindle speed1: Constant cutting rate, display with G96 set2: Mixed display

immediately 3/3

0 0 0 2 Byte

A.1.2 General machine data

MDnumber

MD identifier

Unit Brief description ActivationDisplay filter Attributes Data typeDefault Dimension Default value Minimum value Maximum value ProtectionSystem * Dimension Default value Minimum value Maximum value Protection

* Values other than those in the standard systemNote regarding the value definition: TRUE corresponds to 1

FALSE corresponds to 0

10000 AXCONF_MACHAX_NAME_TAB– Machine axis name POWER ONN01, N11 – STRINGDefault 6 “X1”, “Y1”, “Z1”, “SP”,

“A1”, “PLCX1”– – 2/2

10008 MAXNUM_PLC_CTRL_AXES– Max. no. PLC-controlled axes POWER ONN01, N09 – BYTEDefault – 0 0 1 2/2

10074 PLC_IPO_TIME_RATIO– Factor of the PLC task for main run POWER ONN01, N05 – DWORDDefault – 1 1 50 2/2

10088 REBOOT_DELAY_TIMEs Reboot delay IMMED.EXP – DOUBLEDefault – 0.2 0.0 1.0 2/2

10200 INT_INCR_PER_MM– Computational resolution for linear positions POWER ONN01 – DOUBLEDefault – 1000.0 1.0 1.0e9 2/2

10210 INT_INCR_PER_DEG– Computational resolution for angular positions POWER ONN01 – DOUBLEDefault – 1000.0 1.0 1.0e9 2/2

10240 SCALING_SYSTEM_IS_METRIC– Metric basic system POWER ONN01 SCAL BOOLEANDefault – TRUE – – 2/2

10710 PROG_SD_RESET_SAVE_TAB– Setting data to be updated POWER ONEXP, N01 – DWORDDefault 30 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0,

0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0,0, 0, 0, 0, 0, 0, 0, 0

– – 2/2






6FC5 397-0CP10-1BA0

10713 M_NO_FCT_STOPRE– M function with preprocessing stop POWER ONEXP, N12, N07 – DWORDDefault 15 –1, –1, –1, –1, –1, –1, –1,

–1, –1, –1, –1, –1, –1, –1,–1

– – 2/2

10714 M_NO_FCT_EOP– M function active for spindle after reset POWER ONEXP, N07 – DWORDDefault – –1 – – 2/2

10715 M_NO_FCT_CYCLE– M function to be replaced by a subroutine POWER ONEXP, N12, N07 – DWORDDefault 10 –1, –1, –1, –1, –1, –1, –1,

–1, –1, –1– – 2/2

10716 M_NO_FCT_CYCLE_NAME– Subroutine name for replacement of an M function POWER ONEXP, N12, N07 – STRINGDefault 10 – – 2/2

10717 T_NO_FCT_CYCLE_NAME– Subroutine name for replacement of a T function POWER ONEXP, N12, N07 – STRINGDefault –1 – – 2/2

10718 M_NO_FCT_CYCLE_PAR– M function replacement by parameters POWER ONEXP, N12, N07 – DWORDDefault – –1 – – 2/2

10719 T_NO_FCT_CYCLE_MODE– Parameterization of the T function replacement POWER ONEXP, N12, N07 – DWORDDefault – 0 0 1 2/2

10735 JOG_MODE_MASK– Enable jogging in the AUTOMATIC mode POWER ONEXP, N01 – DWORDDefault – 0 0 0x1 2/2

10760 G53_TOOLCORR– Effect with G53, G153 and SUPA POWER ONN12 – BOOLEANDefault – FALSE – – 2/2

10810 EXTERN_MEAS_G31_P_SIGNAL– Assignment of the measuring inputs for G31 P.. POWER ONEXP, N12 – BYTEDefault 4 1, 1, 1, 1 0 3 2/2

10812 EXTERN_DOUBLE_TURRET_ON– Double–resolver head with G68 POWER ONEXP, N12 – BOOLEANDefault – FALSE – – 2/2

10820 EXTERN_INTERRUPT_NUM_RETRAC– Interrupt number f. rapid retraction (G10.6) POWER ONEXP, N12 – BYTEDefault – 2 1 8 2/2




10880 MM_EXTERN_CNC_SYSTEM– Def. of control system to be adapted POWER ONN01, N12 – DWORDDefault – 1 1 3 2/2

10881 MM_EXTERN_GCODE_SYSTEM– ISO_3 Mode: GCodeSystem POWER ONN01, N12 – DWORDDefault – 0 0 2 2/2

10882 NC_USER_EXTERN_GCODES_TAB– List of user–specific G commands, ext. language POWER ONN12 – STRINGDefault 60 – – 2/2

10884 EXTERN_FLOATINGPOINT_PROG– Evaluation of progr. values without decimal point POWER ONN12 – BOOLEANDefault – TRUE – – 2/2

10886 EXTERN_INCREMENT_SYSTEM– Increment system POWER ONN12 – BOOLEANDefault – FALSE – – 2/2

10888 EXTERN_DIGITS_TOOL_NO– Number of digits for T number POWER ONN12 – BYTEDefault – 2 0 8 2/2

10890 EXTERN_TOOLPROG_MODE– Tool change program with ext. language POWER ONN12 – DWORDDefault – 0 – – 2/2

11100 AUXFU_MAXNUM_GROUP_ASSIGN– Number of auxiliary functions in AuxF groups POWER ONN01, N07, N02 – DWORDplus – 1 1 255 2/2

11160 ACCESS_EXEC_CST– Right of execution for /_N_CST_DIR POWER ONN01 – BYTEDefault – 7 – – 2/2

11161 ACCESS_EXEC_CMA– Right of execution for /_N_CMA_DIR POWER ONN01 – BYTEDefault – 7 – – 2/2

11162 ACCESS_EXEC_CUS– Right of execution for /_N_CUS_DIR POWER ONN01 – BYTEDefault – 7 – – 3/3

11165 ACCESS_WRITE_CST– Right protection for /_N_CST_DIR POWER ONN01 – DWORDDefault – –1 – – 2/2

11166 ACCESS_WRITE_CMA– Right protection for directory /_N_CMA_DIR POWER ONN01 – DWORDDefault – –1 – – 2/2






6FC5 397-0CP10-1BA0

11167 ACCESS_WRITE_CUS– Right protection for directory /_N_CUS_DIR POWER ONN01 – DWORDDefault – –1 – – 3/3

11170 ACCESS_WRITE_SACCESS– Write protection for _N_SACCESS_DEF POWER ONN01 – BYTEDefault – 7 – – 2/2

11171 ACCESS_WRITE_MACCESS– Write protection for _N_MACCESS_DEF POWER ONN01 – BYTEDefault – 7 – – 2/2

11172 ACCESS_WRITE_UACCESS– Write protection for _N_UACCESS_DEF POWER ONN01 – BYTEDefault – 7 – – 3/3

11210 UPLOAD_MD_CHANGES_ONLY– MD backup only for changed MD IMMEDIATEL

YN01, N05 – BYTEDefault – 0xFF – – 7/3plus – 0x0F – – 2/2

11240 PROFIBUS_SDB_NUMBER– SDB1000 number POWER ONN01, N05 – DWORDDefault 4 –1, –1, –1, –1 –1 7 2/2plus – 0, –1, 1, –1 – 1 2/2

11250 PROFIBUS_SHUTDOWN_TYPE– Profibus Shutdown handling POWER ONEXP, N01 – BYTEDefault – 0 0 2 2/2

11310 HANDWH_REVERSE– Threshold for handwheel direction reversal POWER ONN09 – BYTEDefault – 2 – – 2/2

11320 HANDWH_IMP_PER_LATCH– Handwheel pulses per locking position POWER ONN09 – DOUBLEDefault 6 1., 1., 1., 1., 1., 1. – – 2/2

11346 HANDWH_TRUE_DISTANCE– Handwheel travel or speed specification POWER ONN01 – BYTEDefault – 0 0 3 2/2

13060 DRIVE_TELEGRAM_TYPE– Standard message frame type for Profibus DP POWER ONN04, N10 – DWORDDefault 31 102, 102, 102, 102, 102,

102, 102, 102, 102, 102,102, 102, 102, 102, 102,102, 102, 102, 102, 102,102, 102, 102, 102, 102,102, 102, 102, 102, 102,102

– – 2/2




13070 DRIVE_FUNCTION_MASK– Used DP functions POWER ONN04, N10 – DWORDDefault 31 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0,

0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0,0, 0, 0, 0, 0, 0, 0, 0, 0

– – 2/2

13080 DRIVE_TYPE_DP– Drive type with Profibus POWER ONEXP – BYTEDefault 31 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0,

0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0,0, 0, 0, 0, 0, 0, 0, 0, 0

0 4 2/2

13200 MEAS_PROBE_LOW_ACTIVE– Polarity change of the probe POWER ONN10, N09 – BOOLEANDefault 2 FALSE, FALSE – – 3/3

13220 MEAS_PROBE_DELAY_TIMEs Detection of probe deflection delay time POWER ONN10, N09 – DOUBLEDefault 2 0.0, 0.0 0 0.1 3/3

14510 USER_DATA_INT– User data (INT) POWER ONN03 – DWORDDefault 32 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0,

0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0,0, 0, 0, 0, 0, 0, 0, 0, 0, 0

–32768 32767 7/3

14512 USER_DATA_HEX– User data (HEX) POWER ONN03 – DWORDDefault 32 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0,

0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0,0, 0, 0, 0, 0, 0, 0, 0, 0, 0

0 0x0FF 7/3

14514 USER_DATA_FLOAT– User data (FLOAT) POWER ONN03 – DOUBLEDefault 8 0.0, 0.0, 0.0, 0.0, 0.0, 0.0,

0.0, 0.0–3.40e38 3.40e38 7/3

14516 USER_DATA_PLC_ALARM– User data (HEX) POWER ONN03 – BYTEDefault 64 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0,

0, 0, 0, 0, 0, 0, 0…– – 7/3

17530 TOOL_DATA_CHANGE_COUNTER– Mark tool data change for HMI POWER ONEXP, N01 – DWORDDefault – 0 0 0xF 2/2

18040 VERSION_INFO– Version and (if necessary) date of PCMCIA card POWER ONN05 READ STRINGDefault 4 – – 7/2plus – “802D–TM2” – – 2/2






6FC5 397-0CP10-1BA0

18050 INFO_FREE_MEM_DYNAMIC– Free unbuffered memory [bytes] POWER ONN01, N02, N05 READ DWORDDefault – 430080 – – 7/2plus – 1048576 – – 7/2

18060 INFO_FREE_MEM_STATIC– Free buffered memory [bytes] POWER ONN01, N02, N05 READ DWORDDefault – 262144 – – 7/2plus – – – 7/2

18080 MM_TOOL_MANAGEMENT_MASK– Reserved memory for the tool management (SRAM) POWER ONN02, N09 – DWORDDefault – 0x0 0 0xFFFF 2/2

18102 MM_TYPE_OF_CUTTING_EDGE– Type of D number programming (SRAM) POWER ONN02, N09 – DWORDDefault – 0 0 1 2/2

18120 MM_NUM_GUD_NAMES_NCK– Number of global GUD definitions (SRAM) POWER ONN02 – DWORDDefault – 50 – – 2/2

18130 MM_NUM_GUD_NAMES_CHAN– Number of channel GUD definitions (SRAM) POWER ONN02 – DWORDDefault – 100 – – 2/2

18150 MM_GUD_VALUES_MEM– Memory space for GUD values (SRAM) POWER ONN02 – DWORDDefault – 32 – – 2/2

A.1.3 Channelspecific machine data

MDnumber

MD identifier


* Values other than those in the standard system

Note regarding the value definition: TRUE corresponds to 1


20050 AXCONF_GEOAX_ASSIGN_TAB– Assignment ‘geometry/channel axis’ POWER ONC01, C10 – BYTEDefault 3 1, 2, 3 0 6 2/2

20070 AXCONF_MACHAX_USED– Machine axis number valid in channel POWER ONC01, C10 – BYTEDefault 6 1, 2, 3, 4, 5, 0, 0 6 2/2




20080 AXCONF_CHANAX_NAME_TAB– Name of channel axis in the channel POWER ONC01, C11, C10 – STRINGDefault 6 “X”, “Y”, “Z”, “SP”, “A”,

“PLCX”– – 2/2

20090 SPIND_DEF_MASTER_SPIND– Number of master spindle POWER ONC01, C03 – BYTEDefault – 1 1 2 2/2

20094 SPIND_RIGID_TAPPING_M_NR– M function for axis mode (Siemens mode) POWER ONC01, C03, C10 – DWORDDefault – 70 – – 2/2

20095 EXTERN_RIGID_TAPPING_M_NR– M function for axis mode (external mode) POWER ONC01, C11, C03, C10 – DWORDDefault – 29 – – 2/2

20106 PROG_EVENT_IGN_SINGLEBLOCK– Prog events ignore single block POWER ONN01 – DWORDDefault – 0x0 0 0x1F 2/2

20107 PROG_EVENT_IGN_INHIBIT– Prog events ignore read–in disable POWER ONN01 – DWORDDefault – 0x0 0 0x1F 2/2

20108 PROG_EVENT_MASK– Event–controlled program calls POWER ONN01 – DWORDDefault – 0x0 0 0xF 7/2plus – – – – 2/2

20140 TRAFO_RESET_VALUE– Active transformation in case of RESET RESETC03 – BYTEDefault – 0 0 2 2/2

20204 WAB_CLEARANCE_TOLERANCEmm Direction reversal with SAR POWER ONC06 – DOUBLEDefault – 0.01 – – 2/2

20310 TOOL_MANAGEMENT_MASK– Activate tool management functions POWER ONC09 – DWORDDefault – 0x0 0 0xFFFFFFF 2/2

20320 TOOL_TIME_MONITOR_MASK– Time monitoring for the tool in the toolholder POWER ONC06, C09 – DWORDDefault – 0x1 – – 2/2

20360 TOOL_PARAMETER_DEF_MASK– Definition of the tool parameters POWER ONC09 – DWORDDefault – 0x0 0 0xFFFF 2/2






6FC5 397-0CP10-1BA0

20380 TOOL_CORR_MODE_G43G44– Handling of tool length compensation G43/44 RESETC01, C08, C11 – BYTEDefault – 0 0 2 2/2

20450 LOOKAH_RELIEVE_BLOCK_CYCLE– Block cycle time relief factor POWER ONEXP, C05 – DOUBLEDefault – 0.0 – – 2/2

20460 LOOKAH_SMOOTH_FACTOR% Smoothing factor for Look Ahead NEW CONFEXP, C05 – DOUBLEDefault – 0.0 0. 500.0 2/2

20500 CONST_VELO_MIN_TIMEs Minimum time with constant velocity POWER ONEXP, C05 – DOUBLEDefault – 0.0 0.0 0.1 2/2

20550 EXACT_POS_MODE– Exact stop conditions with G00 and G01 NEW CONFEXP – BYTEDefault – 0 0 33 2/2

20552 EXACT_POS_MODE_G0_TO_G1– Exact stop conditions with the transition G00–>G01 NEW CONFEXP – BYTEDefault – 0 0 5 2/2

20700 REFP_NC_START_LOCK– NC start disable without reference point RESETC01, C03 – BOOLEANDefault – TRUE – – 2/2

20730 G0_LINEAR_MODE– Interpolation behavior with G0 POWER ONC09 – BOOLEANDefault – TRUE – – 2/2

20732 EXTERN_G0_LINEAR_MODE– Interpolation behavior with G00 POWER ONN12 – BOOLEANDefault – TRUE – – 2/2

20734 EXTERN_FUNCTION_MASK– Function mask for external language RESETN12 – DWORDDefault – 0 0 0xFFFF 2/2

21000 CIRCLE_ERROR_CONSTmm Circle end point monitoring constant POWER ONC06 – DOUBLEDefault – 0.01 – – 2/2

21010 CIRCLE_ERROR_FACTOR– Circle end point monitoring factor POWER ONC06 – DOUBLEDefault – 0.001 – – 2/2

21020 WORKAREA_WITH_TOOL_RADIUS– Tool radius with working area limitation RESETC03, C06 – BOOLEANDefault – FALSE – – 2/2




22000 AUXFU_ASSIGN_GROUP– Auxiliary function group POWER ONC04 – BYTEDefault 255 1 1 64 7/2plus 64 – – – 2/2

22010 AUXFU_ASSIGN_TYPE– Auxiliary function type POWER ONC04 – STRINGDefault 255 ”” – – 7/2plus 64 – – – 2/2

22020 AUXFU_ASSIGN_EXTENSION– Auxiliary function extension POWER ONC04 – BYTEDefault 255 0 0 99 7/2plus 64 – – – 2/2

22030 AUXFU_ASSIGN_VALUE– Auxiliary function value POWER ONC04 – DWORDDefault 255 0 – – 7/2plus 64 – – – 2/2

22035 AUXFU_ASSIGN_SPEC– Output specification POWER ONC04 – DWORDDefault 255 0 – – 7/2plus 64 – – – 2/2

22040 AUXFU_PREDEF_GROUP– Predefined auxiliary function groups POWER ONC04 – BYTEDefault 33 1, 1, 1, 1, 1, 1, 2, 2, 2, 2, 2,

4, 4, 4, 4, 4, 4, 3, 1, 1, 1, ...0 64 7/2

plus – – – – 2/2

22050 AUXFU_PREDEF_TYPE– Predefined auxiliary function type POWER ONC04 – STRINGDefault 33 “M”, “M”, “M”, “M”, “M”, “M”,

“M”, “M”, “M”, “M”, “M”, “M”,“M”...

– – 7/2

plus – – – – 2/2

22060 AUXFU_PREDEF_EXTENSION– Predefined auxiliary function extension POWER ONC04 – BYTEDefault 33 0, 0, 0, 0, 0, 1, 1, 1, 1, 1,

1, 1, 1, 1, 1, 1, 1, 1, 0, 0,0…

0 99 7/2

plus – – – – 2/2

22070 AUXFU_PREDEF_VALUE– Predefined auxiliary function value POWER ONC04 – DWORDDefault 33 0, 1, 2, 17, 30, 6, 3, 4, 5,

19, 70, 40, 41, 42, 43, 44,45, –1...

– – 7/2

plus – – – – 2/2

22254 AUXFU_ASSOC_M0_VALUE– Additional M functions for program stop POWER ONC01, C03, C10 – DWORDDefault – –1 – – 2/2






6FC5 397-0CP10-1BA0

22256 AUXFU_ASSOC_M1_VALUE– Additional M functions for conditional stop POWER ONC01, C03, C10 – DWORDDefault – –1 – – 2/2

22400 S_VALUES_ACTIVE_AFTER_RESET– S function active even after RESET POWER ONC04, C03, C05 – BOOLEANDefault – FALSE – – 2/2

22410 F_VALUES_ACTIVE_AFTER_RESET– F function active even after RESET POWER ONC04, C03, C05 – BOOLEANDefault – FALSE – – 2/2

22534 TRAFO_CHANGE_M_CODE– M code when switching the transformation type POWER ONC04 – DWORDDefault – 0 0 99999999 2/2

22550 TOOL_CHANGE_MODE– New tool offset with T or M function POWER ONC01, C11, C04, C09 – BYTEDefault – 0 0 1 2/2

22910 WEIGHTING_FACTOR_FOR_SCALE– Input resolution for scaling factor POWER ONEXP, C01, C11 – BOOLEANDefault – FALSE – – 2/2

22914 AXES_SCALE_ENABLE– Activation for axial scaling factor G51 POWER ONEXP, C01, C11 – BOOLEANDefault – FALSE – – 2/2

22920 EXTERN_FIXED_FEEDRATE_F1_ON– Activate fixed feedrate F1 – F9 POWER ONEXP, C01, C11 – BOOLEANDefault – FALSE – – 2/2

22930 EXTERN_PARALLEL_GEOAX– Assignment of parallel channel geometry axis POWER ONEXP, C01, C11 – BYTEDefault 3 0 0 6 2/2

24020 FRAME_SUPPRESS_MODE– Positions with frame suppression POWER ONC03 – DWORDDefault – 0x0 0 0x0000003 2/2

24100 TRAFO_TYPE_1– Transformation 1 in the channel NEW CONFC07 – DWORDDefault – 0 – – 2/2

24110 TRAFO_AXES_IN_1– Axis assignment for transformation 1 NEW CONFC07 – BYTEDefault 20 1, 2, 3, 4, 5, 0, 0, 0, 0, 0, 0,

0, 0, 0, 0, 0, 0, 0, 0, 0, 0...0 6 7/7

plus 6 – – – 2/2




24120 TRAFO_GEOAX_ASSIGN_TAB_1– GEO/channel axis assignment for transformation 1 NEW CONFC07 – BYTEDefault 3 0 0 6 2/2

24130 TRAFO_INCLUDES_TOOL_1– Tool handling with active 1st transformation NEW CONFC07 – BOOLEANDefault – TRUE – – 2/2

24200 TRAFO_TYPE_2– Transformation 2 in the channel NEW CONFC07 – DWORDDefault – 0 – – 2/2

24210 TRAFO_AXES_IN_2– Axis assignment for transformation 2 NEW CONFC07 – BYTEDefault 20 1, 2, 3, 4, 5, 0 0 6 7/7plus 6 – – – 2/2

24220 TRAFO_GEOAX_ASSIGN_TAB_2– GEO/channel axis assignment for transformation 2 NEW CONFC07 – BYTEDefault 3 0, 0, 0 0 6 2/2

24230 TRAFO_INCLUDES_TOOL_2– Tool handling with active 2nd transformation NEW CONFC07 – BOOLEANDefault – TRUE – – 2/2

24573 TRAFO5_AXIS3_1– Direction of 3rd rotary axis NEW CONFC07 – DOUBLEDefault 3 0.0, 0.0, 0.0 – – 7/7

24800 TRACYL_ROT_AX_OFFSET_1degrees Rotary axis offset TRACYL 1 NEW CONFC07 – DOUBLEDefault – 0.0 – – 2/2

24805 TRACYL_ROT_AX_FRAME_1– Rotary axis offset TRACYL 1 NEW CONFC07 – BYTEDefault – 0 0 2 2/2

24808 TRACYL_DEFAULT_MODE_1– Selection of the TRACYL mode NEW CONFC07 – BYTEDefault – 0 0 1 2/2

24810 TRACYL_ROT_SIGN_IS_PLUS_1– Sign of the rotary axis NEW CONFC07 – BOOLEANDefault – TRUE – – 2/2

24820 TRACYL_BASE_TOOL_1mm Base tool vector NEW CONFC07 – DOUBLEDefault 3 0.0, 0.0, 0.0 – – 2/2

24850 TRACYL_ROT_AX_OFFSET_2degrees Rotary axis offset TRACYL 2 NEW CONFC07 – DOUBLEDefault – 0.0 – – 2/2






6FC5 397-0CP10-1BA0

24855 TRACYL_ROT_AX_FRAME_2– Rotary axis offset TRACYL 2 NEW CONFC07 – BYTEDefault – 0 0 2 2/2

24858 TRACYL_DEFAULT_MODE_2– Selection of the TRACYL mode NEW CONFC07 – BYTEDefault – 0 0 1 2/2

24860 TRACYL_ROT_SIGN_IS_PLUS_2– Sign of the rotary axis NEW CONFC07 – BOOLEANDefault – TRUE – – 2/2

24870 TRACYL_BASE_TOOL_2mm Base tool vector NEW CONFC07 – DOUBLEDefault 3 0.0, 0.0, 0.0 – – 2/2

24900 TRANSMIT_ROT_AX_OFFSET_1degrees Rotary axis offset TRANSMIT 1 NEW CONFC07 – DOUBLEDefault – 0.0 – – 2/2

24905 TRANSMIT_ROT_AX_FRAME_1– Rotary axis offset TRANSMIT 1 NEW CONFC07 – BYTEDefault – 0 0 2 2/2

24910 TRANSMIT_ROT_SIGN_IS_PLUS_1– Sign of the rotary axis NEW CONFC07 – BOOLEANDefault – TRUE – – 2/2

24911 TRANSMIT_POLE_SIDE_FIX_1– Limiting of working area in front of / after the pole NEW CONFC07 – BYTEDefault – 0 0 2 2/2

24920 TRANSMIT_BASE_TOOL_1mm Base tool vector NEW CONFC07 – DOUBLEDefault 3 0.0, 0.0, 0.0 – – 2/2

24950 TRANSMIT_ROT_AX_OFFSET_2degrees Rotary axis offset TRANSMIT 2 NEW CONFC07 – DOUBLEDefault – 0.0 – – 2/2

24955 TRANSMIT_ROT_AX_FRAME_2– Rotary axis offset TRANSMIT 2 NEW CONFC07 – BYTEDefault – 0 0 2 2/2

24960 TRANSMIT_ROT_SIGN_IS_PLUS_2– Sign of the rotary axis NEW CONFC07 – BOOLEANDefault – TRUE – – 2/2

24961 TRANSMIT_POLE_SIDE_FIX_2– Limitation of the working area in front of/after the pole NEW CONFC07 – BYTEDefault – 0 0 2 2/2




24970 TRANSMIT_BASE_TOOL_2mm Base tool vector NEW CONFC07 – DOUBLEDefault 3 0.0, 0.0, 0.0 – – 2/2

27100 ABSBLOCK_FUNCTION_MASK– Block display parameterized with absolute values POWER ONN01 – DWORDDefault – 0x0 0 0x1 2/2

27800 TECHNOLOGY_MODE– Technology in the channel NEW CONFC09 – BYTEDefault – 0 – – 7/2plus – 0 – – 2/2

27860 PROCESSTIMER_MODE– Activating the program runtime measurement RESETC09 – DWORDDefault – 0x00 0 0x0FF 7/2plus – 0x07 – – 2/2

27880 PART_COUNTER– Activate workpiece counter RESETC09 – DWORDDefault – 0x0 0 0x0FFFF 3/2

27882 PART_COUNTER_MCODE– Workpiece counting using a user–defined M command POWER ONC09 – BYTEDefault 3 2, 2, 2 0 99 3/2

28400 MM_ABSBLOCK– Activate block display with absolute values POWER ONEXP, C02 – DWORDDefault – 0 – – 2/2

28402 MM_ABSBLOCK_BUFFER_CONF– Dimension size of upload buffer POWER ONEXP, C02 – DWORDDefault 2 0, 0 – – 2/2






6FC5 397-0CP10-1BA0

A.1.4 Axisspecific machine data

MDnumber

MD identifier





30110 CTRLOUT_MODULE_NR– Setpoint: Drive no./module no. POWER ON–, – – BYTEDefault 1 1, 2, 3, 4, 5, 6, 7, 8, 9, 10,

11, 12, 13, 14, 15, 16, 17,18, 19, 20, 21, 22, 23, 24,25, 26, 27, 28, 29, 30, 31

1 31 2/2

30120 CTRLOUT_NR– Setpoint: Output to module POWER ONEXP, – – BYTEDefault 1 1 1 3 2/2

30130 CTRLOUT_TYPE– Setpoint output type POWER ON–, – – BYTEDefault 1 0 0 3 2/2

30134 IS_UNIPOLAR_OUTPUT– Setpoint output is unipolar POWER ON– – BYTEDefault 1 0 0 2 2/2

30200 NUM_ENCS– Number of encoders POWER ON–, – – BYTEDefault – 1 0 1 2/2

30220 ENC_MODULE_NR– Actual value: Drive no./measuring circuit no. POWER ON–, –, – – BYTEDefault 1 1 1 31 7/2

30230 ENC_INPUT_NR– Actual value: Input number on module/measuring circuit board POWER ON–, –, – – BYTEDefault 1 1 1 3 2/2

30240 ENC_TYPE– Actual value: Encoder type POWER ON–, –, – – BYTEDefault 1 0 0 5 2/2

30270 ENC_ABS_BUFFERING– Absolute encoder: Traversing range extension POWER ONEXP, –, – – BYTEDefault 1 0 0 1 2/2




30300 IS_ROT_AX– Rotary axis/spindle POWER ON–, –, – SCAL, CTEQ BOOLEANDefault – FALSE – – 2/2

30310 ROT_IS_MODULO– Modulo conversion for rotary axis/spindle POWER ON–, –, – CTEQ BOOLEANDefault – FALSE – – 2/2

30320 DISPLAY_IS_MODULO– Display modulo 360 degrees for rotary axis POWER ON–, –, – CTEQ BOOLEANDefault – FALSE – – 2/2

30350 SIMU_AX_VDI_OUTPUT– Axis signals for simulation axis POWER ON–, – CTEQ BOOLEANDefault – FALSE – – 2/2

30465 AXIS_LANG_SUB_MASK– Substitution of NC language commands POWER ONN01 – DWORDDefault – 0 0 3 2/2

30600 FIX_POINT_POSmm,degrees

Axis position with G75 POWER ON

–, – – DOUBLEDefault 2 0.0, 0.0 – – 2/2

31000 ENC_IS_LINEAR– Linear scale POWER ON–, – – BOOLEANDefault 1 FALSE – – 2/2

31010 ENC_GRID_POINT_DISTmm Scale division with linear scales POWER ON–, – – DOUBLEDefault 1 0.01 – – 2/2

31020 ENC_RESOL– Encoder lines per revolution POWER ON–, – – DWORDDefault 1 2048 – – 2/2

31030 LEADSCREW_PITCHmm Lead of the ballscrew POWER ON–, – – DOUBLEDefault – 10.0 – – 2/2

31040 ENC_IS_DIRECT– Encoder mounted directly on the machine POWER ON–, – – BOOLEANDefault 1 FALSE – – 2/2

31044 ENC_IS_DIRECT2– Encoders installed at the attached gearbox NEW CONF– – BOOLEANDefault 1 FALSE – – 2/2

31050 DRIVE_AX_RATIO_DENOM– Load gearbox denominator POWER ON–, – – DWORDDefault 6 1, 1, 1, 1, 1, 1 1 2147000000 2/2






6FC5 397-0CP10-1BA0

31060 DRIVE_AX_RATIO_NUMERA– Load gearbox numerator POWER ON–, – – DWORDDefault 6 1, 1, 1, 1, 1, 1 –2147000000 2147000000 2/2

31064 DRIVE_AX_RATIO2_DENOM– Denominator of attached gearbox NEW CONF– – DWORDDefault – 1 1 2147000000 2/2

31066 DRIVE_AX_RATIO2_NUMERA– Numerator of attached gearbox NEW CONF– – DWORDDefault – 1 –2147000000 2147000000 2/2

31070 DRIVE_ENC_RATIO_DENOM– Measuring gearbox denominator POWER ON–, – – DWORDDefault 1 1 1 2147000000 2/2

31080 DRIVE_ENC_RATIO_NUMERA– Measuring gearbox numerator POWER ON–, – – DWORDDefault 1 1 1 2147000000 2/2

31122 BERO_DELAY_TIME_PLUSs BERO delay time NEW CONF–, – – DOUBLEDefault 1 0.000110 – – 2/2

31123 BERO_DELAY_TIME_MINUSs BERO delay time NEW CONF–, – – DOUBLEDefault 1 0.000078 – – 2/2

32000 MAX_AX_VELOmm/min,rev/min

Maximum axis velocity NEW CONF

–, – CTEQ DOUBLEDefault – 10000. – – 7/2

32010 JOG_VELO_RAPIDmm/min,rev/min

Rapid traverse in the JOG mode RESET


32020 JOG_VELOmm/min,rev/min

JOG axis velocity RESET


32100 AX_MOTION_DIR– Traversing direction (not control direction) POWER ON–, –, – – DWORDDefault – 1 –1 1 2/2

32110 ENC_FEEDBACK_POL– Sign of actual value (control direction) POWER ON–, –, – – DWORDDefault 1 1 –1 1 2/2




32200 POSCTRL_GAIN1,000 r.p.m. Servo gain factor NEW CONF–, – CTEQ DOUBLEDefault 6 16.66666667,

16.66666667,16.66666667,16.66666667,16.66666667,16.66666667

0 2000. 7/2

32210 POSCTRL_INTEGR_TIMEs Integral action time of the position controller NEW CONF– – DOUBLEDefault – 1.0 0 10000.0 2/2

32220 POSCTRL_INTEGR_ENABLE– Activation of the integral portion of the position controller POWER ON– – BOOLEANDefault – FALSE – – 2/2

32230 POSCTRL_CONFIG– Configuration of the position controller structure POWER ON– – BYTEDefault – 0 0 17 7/2

32300 MAX_AX_ACCELm/s, rev/s Axis acceleration NEW CONF–, – CTEQ DOUBLEDefault 1.0 1.0e–3 – 7/2

32420 JOG_AND_POS_JERK_ENABLE– Enable axial jerk limitation RESET– CTEQ BOOLEANDefault – FALSE – – 2/2

32430 JOG_AND_POS_MAX_JERKm/s,deg/s

Axial jerk RESET

– CTEQ DOUBLEDefault – 1000.0 1.e–9 – 2/2

32431 MAX_AX_JERKm/s,deg/s

Maximum axial jerk when traveling along the path NEW CONF

– – DOUBLEDefault 1.e6 1.e–9 – 3/3plus – 1000 – – 3/3

32432 PATH_TRANS_JERK_LIMm/s,deg/s

Max. axial jerk when traveling along the path with block transition NEW CONF

– CTEQ DOUBLEDefault 1.e6 – – 3/3plus – 1.e3 – – /

32440 LOOKAH_FREQUENCY– Smoothing frequency with LookAhead NEW CONFEXP, – – DOUBLEDefault – 10. – – 2/2

32450 BACKLASHmm,degrees

Backlash on reversal NEW CONF

– – DOUBLEDefault 1 0.0, 0.0 – – 2/2






6FC5 397-0CP10-1BA0

32510 FRICT_COMP_ADAPT_ENABLE– Friction compensation adaptation active NEW CONFEXP, – – BOOLEANDefault 1 FALSE – – 2/2

32520 FRICT_COMP_CONST_MAXmm/min,rev/min

Maximum friction compensation value NEW CONF

EXP, – – DOUBLEDefault 1 0.0 – – 2/2

32530 FRICT_COMP_CONST_MINmm/min,rev/min

Minimum friction compensation value NEW CONF

EXP, – – DOUBLEDefault 1 0.0 – – 2/2

32540 FRICT_COMP_TIMEs Friction compensation time constant NEW CONFEXP, – – DOUBLEDefault 1 0.015 – – 2/2

32630 FFW_ACTIVATION_MODE– Feedforward control can be activated from the program RESET–, – CTEQ BYTEDefault – 1 – – 2/2

32640 STIFFNESS_CONTROL_ENABLE– Dynamic stiffness control NEW CONF–, – CTEQ BOOLEANDefault 1 FALSE – – 2/2

32642 STIFFNESS_CONTROL_CONFIG– Configure dynamic stiffness control POWER ON–, – CTEQ BYTEDefault 1 0 0 1 2/2

32644 STIFFNESS_DELAY_TIMEs Dyn. stiffness control: Delay POWER ON–, – CTEQ DOUBLEDefault 1 0.0 –0.02 0.02 7/2plus – –0.0015 – – 2/2

32700 ENC_COMP_ENABLE– Encoder/lead error compensation NEW CONF– – BOOLEANDefault 1 FALSE – – 2/2

32810 EQUIV_SPEEDCTRL_TIMEs Equivalent time constant for the speed control loop NEW CONF–, – – DOUBLEDefault 6 0.008, 0.008, 0.008, 0.008,

0.008, 0.008– – 7/2

plus – 0.003, 0.003, 0.003, 0.003,0.003, 0.003

– – 2/2

33050 LUBRICATION_DISTmm, degr. Travel for the lubrication pulse PLC signal NEW CONF–, – – DOUBLEDefault – 1.0e8 – – 3/3

34000 REFP_CAM_IS_ACTIVE– Axis with reference point cam RESET–, – – BOOLEANDefault – TRUE – – 2/2




34010 REFP_CAM_DIR_IS_MINUS– Reference point approach in the negative direction RESET–, – – BOOLEANDefault – FALSE – – 2/2

34020 REFP_VELO_SEARCH_CAMmm/min,rev/min

Cam approach velocity RESET

–, –, – – DOUBLEDefault – 5000.00 – – 2/2

34030 REFP_MAX_CAM_DISTmm,degrees

Max. distance to reference cam RESET

–, – – DOUBLEDefault – 10000.0 – – 2/2

34040 REFP_VELO_SEARCH_MARKERmm/min,rev/min

Velocity when searching for the reference mark RESET

–, –, – – DOUBLEDefault 1 300.00 – – 2/2

34050 REFP_SEARCH_MARKER_REVERSE– Direction reversal on reference cam RESET–, – – BOOLEANDefault 1 FALSE – – 2/2

34060 REFP_MAX_MARKER_DISTmm,degrees

Max. distance to reference mark RESET

–, – – DOUBLEDefault 1 20.0 – – 2/2

34070 REFP_VELO_POSmm/min,rev/min

Reference point approach velocity RESET

–, –, – – DOUBLEDefault – 10000.00 – – 7/2plus – 1000.00 – – 2/2

34080 REFP_MOVE_DISTmm,degrees

Reference point distance NEW CONF

–, – – DOUBLEDefault 1 –2.0 – – 2/2

34090 REFP_MOVE_DIST_CORRmm,degrees

Reference point offset NEW CONF

–, –, –, – – DOUBLEDefault 1 0.0 – – 2/2

34100 REFP_SET_POSmm,degrees

Reference point position RESET

–, – – DOUBLEDefault 4 0.0, 0.0, 0.0, 0.0 –45000000 45000000 2/2






6FC5 397-0CP10-1BA0

34110 REFP_CYCLE_NR– Order of axes when referencing POWER ON– – DWORDDefault – 1, 2, 3, 4, 5, 6, 7, 8, 9, 10,

11, 12, 13, 14, 15, 16, 17,18, 19, 20, 21, 22, 23, 24,25, 26, 27, 28, 29, 30, 31,32, 33, 34, 35, 36, 37, 38,39, 40, 41, 42, 43, 44, 45,46, 47, 48, 49, 50, 51, 52,53, 54, 55, 56, 57, 58, 59,60, 61, 62, 63, 64

–1 31 7/2

plus – 1 – – 2/2

34120 REFP_BERO_LOW_ACTIVE– Polarity change of the BERO cam POWER ON– – BOOLEANDefault – FALSE – – 2/2

34200 ENC_REFP_MODE– Referencing mode POWER ON–, – – BYTEDefault 1 1 0 8 2/2

34210 ENC_REFP_STATE– Absolute encoder adjusting status IMMED.–, –, – – BYTEDefault 1 0 0 2 2/2

34220 ENC_ABS_TURNS_MODULO– Modulo range of the rotary absolute encoder POWER ON–, – – DWORDDefault 1 4096 1 100000 2/2

34990 ENC_ACTVAL_SMOOTH_TIMEs Smoothing time constant for actual values RESET– – DOUBLEDefault 1 0.0 0.0 0.5 3/3

35000 SPIND_ASSIGN_TO_MACHAX– Assignment ‘spindle – machine axis’ POWER ON–, –, – – BYTEDefault – 0 0 2/2

35010 GEAR_STEP_CHANGE_ENABLE– Gear stage change possible RESET–, – CTEQ DWORDDefault – 0 0 12 2/2

35012 GEAR_STEP_CHANGE_POSITIONmm,degrees

Gear stage change position NEW CONF

–, – CTEQ DOUBLEDefault 6 0.0, 0.0, 0.0, 0.0, 0.0, 0.0 – – 2/2

35014 GEAR_STEP_USED_IN_AXISMODE– Gear stage for axis mode with M70 NEW CONF–, –, – CTEQ DWORDDefault – 0 0 5 2/2

35020 SPIND_DEFAULT_MODE– Spindle park position RESET–, – CTEQ BYTEDefault – 0 0 3 2/2




35030 SPIND_DEFAULT_ACT_MASK– Activate spindle park position RESET–, – CTEQ BYTEDefault – 0x00 0 0x03 2/2

35040 SPIND_ACTIVE_AFTER_RESET– Own spindle RESET POWER ON–, – CTEQ BYTEDefault – 0 0 2 2/2

35100 SPIND_VELO_LIMITrev/min Maximum spindle speed POWER ON–, –, – CTEQ DOUBLEDefault – 10000.0 1.0e–3 – 7/2

35110 GEAR_STEP_MAX_VELOrev/min Maximum speed for gear stage change NEW CONF–, –, – CTEQ DOUBLEDefault 6 500.0, 500.0, 1000.0,

2000.0, 4000.0, 8000.0– – 2/2

35120 GEAR_STEP_MIN_VELOrev/min Minimum speed for gear stage change NEW CONF–, –, – CTEQ DOUBLEDefault 6 50.0, 50.0, 400.0, 800.0,

1500.0, 3000.0– – 2/2

35130 GEAR_STEP_MAX_VELO_LIMITrev/min Maximum speed of gear stage NEW CONF–, –, – CTEQ DOUBLEDefault 6 500.0, 500.0, 1000.0,

2000.0, 4000.0, 8000.01.0e–3 – 2/2

35140 GEAR_STEP_MIN_VELO_LIMITrev/min Minimum speed of gear stage NEW CONF–, –, – CTEQ DOUBLEDefault 6 5.0, 5.0, 10.0, 20.0, 40.0,

80.0– – 2/2

35150 SPIND_DES_VELO_TOL– Spindle speed tolerance RESET–, –, –, –, – – DOUBLEDefault – 0.1 0.0 1.0 2/2

35160 SPIND_EXTERN_VELO_LIMITrev/min Spindle speed limitation from PLC NEW CONF–, – CTEQ DOUBLEDefault – 1000.0 1.0e–3 – 2/2

35200 GEAR_STEP_SPEEDCTRL_ACCELrev/s Acceleration in the control mode NEW CONF–, –, – CTEQ DOUBLEDefault 6 30.0, 30.0, 25.0, 20.0,

15.0, 10.01.0e–3 – 2/2

35210 GEAR_STEP_POSCTRL_ACCELrev/s Acceleration in the position–controlled mode NEW CONF–, –, – CTEQ DOUBLEDefault 6 30.0, 30.0, 25.0, 20.0,

15.0, 10.01.0e–3 – 2/2

35300 SPIND_POSCTRL_VELOrev/min Position controller starting speed NEW CONF–, – CTEQ DOUBLEDefault – 500.0 – – 2/2






6FC5 397-0CP10-1BA0

35310 SPIND_POSIT_DELAY_TIMEs Positioning delay time NEW CONF–, – CTEQ DOUBLEDefault 6 0.0, 0.05, 0.1, 0.2, 0.4, 0.8 – – 2/2

35350 SPIND_POSITIONING_DIR– Direction of rotation when positioning RESET– CTEQ BYTEDefault – 3 3 4 2/2

35400 SPIND_OSCILL_DES_VELOrev/min Reciprocating speed NEW CONF–, – CTEQ DOUBLEDefault – 500.0 – – 2/2

35410 SPIND_OSCILL_ACCELrev/s Acceleration when reciprocating NEW CONF–, – CTEQ DOUBLEDefault – 16.0 1.0e–3 – 2/2

35430 SPIND_OSCILL_START_DIR– Starting direction when reciprocating RESET– CTEQ BYTEDefault – 0 0 4 2/2

35440 SPIND_OSCILL_TIME_CWs Reciprocation time for M3 direction NEW CONF– CTEQ DOUBLEDefault – 1.0 – – 2/2

35450 SPIND_OSCILL_TIME_CCWs Reciprocation time for M4 direction NEW CONF– CTEQ DOUBLEDefault – 0.5 – – 2/2

35500 SPIND_ON_SPEED_AT_IPO_START– Feed enable with spindle in setpoint range RESET–, –, – CTEQ BYTEDefault – 1 0 2 2/2

35510 SPIND_STOPPED_AT_IPO_START– Feed enable with the spindle stopped RESET–, –, – CTEQ BOOLEANDefault – FALSE – – 2/2

35550 DRILL_VELO_LIMITrev/min Maximum speeds for tapping NEW CONF–, –, – CTEQ DOUBLEDefault 6 10000.0, 10000.0,

10000.0, 10000.0,10000.0, 10000.0

1 – 2/2

36000 STOP_LIMIT_COARSEmm,degrees

Exact stop coarse NEW CONF

– – DOUBLEDefault – 0.04 – – 2/2

36010 STOP_LIMIT_FINEmm,degrees

Exact stop fine NEW CONF





36020 POSITIONING_TIMEs Exact stop fine delay time NEW CONF– – DOUBLEDefault – 1.0 – – 2/2

36030 STANDSTILL_POS_TOLmm,degrees

Standstill tolerance NEW CONF


36040 STANDSTILL_DELAY_TIMEs Standstill monitoring delay time NEW CONF– – DOUBLEDefault – 0.4 – – 2/2

36050 CLAMP_POS_TOLmm, degr. Clamping tolerance NEW CONF– – DOUBLEDefault – 0.5 – – 2/2

36060 STANDSTILL_VELO_TOLmm/min,rev/min

Threshold velocity for axis stopped NEW CONF

–, – – DOUBLEDefault – 5.00 – – 2/2

36100 POS_LIMIT_MINUSmm, degr. 1st software limit switch minus NEW CONF–, –, – CTEQ DOUBLEDefault – –1.0e8 – – 2/2

36110 POS_LIMIT_PLUSmm, degr. 1st software limit switch, plus NEW CONF–, –, – CTEQ DOUBLEDefault – 1.0e8 – – 2/2

36120 POS_LIMIT_MINUS2mm, degr. 2nd software limit switch minus NEW CONF–, – CTEQ DOUBLEDefault – –1.0e8 – – 2/2

36130 POS_LIMIT_PLUS2mm, degr. 2nd software limit switch, plus NEW CONF–, – CTEQ DOUBLEDefault – 1.0e8 – – 2/2

36200 AX_VELO_LIMITmm/min,rev/min

Velocity monitoring threshold value NEW CONF

–, –, – CTEQ DOUBLEDefault 6 11500.0, 11500.0,

11500.0, 11500.0,11500.0, 11500.0

– – 2/2

36210 CTRLOUT_LIMIT% Maximum speed setpoint NEW CONFEXP, – CTEQ DOUBLEDefault 1 110.0 0 200 7/2

36300 ENC_FREQ_LIMIT– Encoder limit frequency POWER ONEXP, –, –, – – DOUBLEDefault 1 3.0e5, 3.0e5 – – 2/2






6FC5 397-0CP10-1BA0

36302 ENC_FREQ_LIMIT_LOW% Encoder limit frequency resynchronization NEW CONFEXP, –, –, – – DOUBLEDefault 1 99.9, 99.9 0 100 2/2

36310 ENC_ZERO_MONITORING– Zero mark monitoring NEW CONFEXP, –, – – DWORDDefault 1 0, 0 – – 2/2

36400 CONTOUR_TOLmm,degrees

Contour monitoring tolerance band NEW CONF

–, – – DOUBLEDefault – 1.0 – – 2/2

36500 ENC_CHANGE_TOLmm,degrees

Position actual–value switching tolerance NEW CONF

–, – – DOUBLEDefault – 0.1 – – 2/2

36600 BRAKE_MODE_CHOICE– Brake behavior at hardware limit switch POWER ONEXP, – CTEQ BYTEDefault – 1 0 1 7/2plus – 0 – – 2/2

36610 AX_EMERGENCY_STOP_TIMEs Time of braking ramp in case of errors NEW CONF– – DOUBLEDefault – 0.05 – – 2/2

36620 SERVO_DISABLE_DELAY_TIMEs Cutout delay controller enable NEW CONF– – DOUBLEDefault – 0.1 – – 2/2

36710 DRIFT_LIMIT% Limit value for automatic drift compensation NEW CONFEXP, –, – – DOUBLEDefault 1 0.0 0 1.e9 1/1plus – 1.0 – 5 3/3

36720 DRIFT_VALUE% Drift base value NEW CONFEXP, –, – – DOUBLEDefault 1 0.0 – – 2/2

37000 FIXED_STOP_MODE– Mode “Traversing to fixed stop” POWER ON– CTEQ BYTEDefault – 0 0 3 2/2

37002 FIXED_STOP_CONTROL– Sequence control when traveling to fixed stop POWER ON– – BYTEDefault – 0 0 3 2/2

37010 FIXED_STOP_TORQUE_DEF% Fixed stop clamping torque default setting POWER ON– CTEQ DOUBLEDefault – 5.0 0.0 100.0 2/2




37012 FIXED_STOP_TORQUE_RAMP_TIMEs Time until the changed torque limit is reached NEW CONF– – DOUBLEDefault – 0.0 – – 2/2

37014 FIXED_STOP_TORQUE_FACTOR– Torque limit adaptation factor NEW CONF– – DOUBLEDefault – 1.0 – – 2/2

37020 FIXED_STOP_WINDOW_DEFmm,degrees

Fixed stop monitoring window default setting POWER ON

–, – CTEQ DOUBLEDefault – 1.0 – – 2/2

37030 FIXED_STOP_THRESHOLDmm,degrees

Threshold for fixed stop detection NEW CONF


37040 FIXED_STOP_BY_SENSOR– Fixed stop detection via sensor IMMED.– CTEQ BYTEDefault – 0 0 3 2/2

37050 FIXED_STOP_ALARM_MASK– Enabling of the fixed–stop alarms NEW CONF–, – – BYTEDefault – 1 0 15 2/2

37060 FIXED_STOP_ACKN_MASK– Masking of PLC acknowledgments POWER ON– CTEQ BYTEDefault – 0 0 3 2/2

37610 PROFIBUS_CTRL_CONFIG– Profibus control bit configuration POWER ONEXP, – – BYTEDefault – 0 0 2 7/2plus – – – – 2/2

37620 PROFIBUS_TORQUE_RED_RESOL% Resolution of Profibus torque reduction NEW CONFEXP, – – DOUBLEDefault – 1.0 0.01 10.0 2/2

38000 MM_ENC_COMP_MAX_POINTS– Intermediate points for encoder/spindle compensation POWER ON–, –, – – DWORDDefault 1 125 0 5000 7/0



A.2 Setting data



6FC5 397-0CP10-1BA0

A.2 Setting data

MDnumber

SD identifier as of version





41010 JOG_VAR_INCR_SIZE– JOG mode: Size of variable increment IMMED.– – DOUBLEDefault – 0. – – 7/7

41110 JOG_SET_VELOmm/min Axis velocity in the JOG mode IMMED.– – DOUBLEDefault – 0.0 – – 7/7

41130 JOG_ROT_AX_SET_VELOrev/min Axis velocity of the rotary axes in the JOG mode IMMED.– – DOUBLEDefault – 0.0 – – 7/7

41200 JOG_SPIND_SET_VELOrev/min Speed for spindle jog mode IMMED.– – DOUBLEDefault – 0.0 – – 7/7

42000 THREAD_START_ANGLEdegrees Thread start angle [deg] IMMED.– – DOUBLEDefault – 0 – – 3/3

42010 THREAD_RAMP_DISPmm Acceleration pattern of the axis when thread cutting IMMED.– – DOUBLEDefault 2 –1.0, –1.0 –1.0 999999. 3/3

42100 DRY_RUN_FEEDmm/min At least the programmed velocity with active dry run IMMED.– – DOUBLEDefault – 5000 – – 7/7

42101 DRY_RUN_FEED_MODE– Mode for dry run velocity IMMED.– – BYTEDefault – 0 0 12 7/7

42110 DEFAULT_FEEDmm/min Default value for path feedrate IMMED.– – DOUBLEDefault – 0 – – 7/7

42120 APPROACH_FEEDmm/min Path feed in approach blocks IMMED.– – DOUBLEDefault – 0 – – 2/2


A.2 Setting data


42125 SERUPRO_SYNC_MASK– Synchronization in approach blocks IMMED.– – DWORDDefault – 0 – – 2/2

42140 DEFAULT_SCALE_FACTOR_P– Default scaling factor for address P IMMED.– – DWORDDefault – 1 – – 7/7

42150 DEFAULT_ROT_FACTOR_R– Default rotation factor for address R IMMED.– – DOUBLEDefault – 0. – – 7/7

42160 EXTERN_FIXED_FEEDRATE_F1_F9– Fixed feedrates F1 – F9 IMMED.– – DOUBLEDefault 10 0.0, 0.0, 0.0, 0.0, 0.0, 0.0,

0.0, 0.0, 0.0, 0.0– – 7/7

42162 EXTERN_DOUBLE_TURRET_DIST– Tool distance of dual resolver head IMMED.– – DOUBLEDefault – 0. – – 7/7

42200 SINGLEBLOCK2_STOPRE– Activate debug mode for SBL2 IMMED.– – BOOLEANDefault – FALSE – – 7/7

42440 FRAME_OFFSET_INCR_PROG– Work offset in frames IMMED.– – BOOLEANDefault – TRUE – – 7/7

42442 TOOL_OFFSET_INCR_PROG– Tool length compensations IMMED.– – BOOLEANDefault – TRUE – – 7/7

42444 TARGET_BLOCK_INCR_PROG– Incremental programming with block search IMMED.– – BOOLEANDefault – TRUE – – 7/7

42480 STOP_CUTCOM_STOPRE– Alarm response with TRC and preprocessing stop IMMED.– – BOOLEANDefault – TRUE – – 3/3

42490 CUTCOM_G40_STOPRE– Retraction behavior of TRC with preprocessing stop IMMED.– – BOOLEANDefault – FALSE – – 3/3

42494 CUTCOM_ACT_DEACT_CTRL– Approach/retraction behavior with 2–1/2D TRC IMMED.– – DWORDDefault – 2222 – – 3/3

42496 CUTCOM_CLSD_CONT– Behavior of the TRC with closed contour IMMED.– – BOOLEANDefault – FALSE – – 3/3



A.2 Setting data



6FC5 397-0CP10-1BA0

42528 CUTCOM_DECEL_LIMIT– Feedrate reduction at circles with TRC IMMED.– – DOUBLEDefault – 0. 0. 1. 7/7

42940 TOOL_LENGTH_CONST 0– Tool length component when changing the plane IMMED.– – DWORDDefault – 0 – – 3/3

42950 TOOL_LENGTH_TYPE– Tool length component not depending on tool type IMMED.– – DWORDDefault – 0 – – 3/3

42990 MAX_BLOCKS_IN_IPOBUFFER– Max. number of blocks in the IPO buffer IMMED.– – DWORDDefault – –1 – – 2/2

43120 DEFAULT_SCALE_FACTOR_AXIS– Default scaling factor with active G51 IMMED.– – DWORDDefault – 1 – – 7/7

43200 SPIND_Srev/min Speed for spindle start through virtual interface IMMED.– – DOUBLEDefault – 0.0 – – 7/7

43202 SPIND_CONSTCUT_Sm/min Cutting rate for spindle start through virtual interface IMMED.– – DOUBLEDefault – 0.0 – – 7/7

43210 SPIND_MIN_VELO_G25rev/min Limits the spindle speed to the specified minimum value IMMED.– – DOUBLEDefault – 0.0 – – 7/7

43220 SPIND_MAX_VELO_G26rev/min Limits the spindle speed to the specified maximum value IMMED.– – DOUBLEDefault – 1000.0 – – 7/7

43230 SPIND_MAX_VELO_LIMSrev/min Limits the spindle speed to the specified maximum value with G96, G691, G97 IMMED.– – DOUBLEDefault – 100.0 – – 7/7

43240 M19_SPOSdegrees Spindle position with M19 IMMED.–, – – DOUBLEDefault – 0.0 –10000000.0 10000000.0 7/7

43250 M19_SPOSMODE– Approach mode for spindle position with M19 IMMED.–, – – DWORDDefault – 0 0 5 7/7

43340 EXTERN_REF_POSITION_G30_1– Reference point position for G30.1 IMMED.–, – – DOUBLEDefault – 0.0 – – 7/7


A.2 Setting data


43400 WORKAREA_PLUS_ENABLE– Working area limitation active in the positive direction IMMED.– CTEQ BOOLEANDefault – FALSE – – 7/7

43410 WORKAREA_MINUS_ENABLE– Working area limitation active in the negative direction IMMED.– CTEQ BOOLEANDefault – FALSE – – 7/7

43420 WORKAREA_LIMIT_PLUSmm,degrees

Axial working area limitation active in the positive direction IMMED.

– – DOUBLEDefault – 1.0e+8 – – 7/7

43430 WORKAREA_LIMIT_MINUSmm,degrees

Axial working area limitation active in the negative direction IMMED.

– – DOUBLEDefault – –1.0e+8 – – 7/7

43500 FIXED_STOP_SWITCH– Selection “Travel to fixed stop” IMMED.– – BYTEDefault – 0 0 1 2/2

43510 FIXED_STOP_TORQUE% Fixed stop clamping torque IMMED.– – DOUBLEDefault – 5.0 0.0 800.0 2/2



A.3 SINAMICS parameters



6FC5 397-0CP10-1BA0

A.3 SINAMICS parameters

Note to the reader

SINAMICS S parameter list

B-231SINUMERIK 802D sl Instruction Manual (BA), 05/2005 Edition6FC5 397-0CP10-1BA0

Standards and Approvals

IEC 1131

The control system meets the requirements and criteria of the IEC 1131 Standard, Part 2.

CE designation

Our products meet the general and safety-related requirements of the following EC guide-lines and conform to the uniform standards (EN) for programmable controllers published inthe official gazettes of the European Union:

89/336/EEC “Electromagnetic Compatibility” (EMC Directive)

EMC guideline

SINUMERIK products are designed for use in industry.

Range of application Requirements in respect of

interference emission interference immunity

Industry EN 50081-2: 1993 EN 61000-6-2: 1999

B



B.1 Electromagnetic compatibility


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Definition

Electromagnetic compatibility is the ability of equipment or systems to be used in their inten-ded environment within designed efficiency levels without causing or receiving degradationdue to unintentional electromagnetic interference.

The D4xx also satisfies the requirements of the EMC regulations of the internal Europeanmarket.

Information on interference immunity and EMC conformance are provided in the following.

Pulse-shaped interference

The table below illustrates the electromagnetic compatibility of modules when exposed tofast transients.

Fast transient Tested with Corresponds to thedegree of severity

Electrostatic dischargetested in accordance with DIN EN 61000-4-2

8 kV4 kV

3 (air discharge) 2 (contact discharge)

Burst pulses (fast transient interference)complying to DIN 61000-4-4

2 kV (supply cable)1 kV (signal cable)

3

Surgecomplying to DIN EN 61000-4-5

Asymmetric coupling

Symmetric coupling

0.5 kV (supply line)1 kV (signal line/data line)

0.5 kV (supply line)

12

1




Sinusoidal interference

HF radiation on the device in accordance with EN 61000-6-2 requirements:

Electromagnetic HF field, amplitude-modulated

– between 80 and 1,000 MHz

– 10 V/m

– 80 % AM (1 kHz)

Electromagnetic HF field, pulse-modulated

– 900 5 MHz

– 10 V/m

– 50 % duty cycle

– 200 Hz repetition frequency

HF coupling on signal and data cables, etc., in accordance with EN 61000-6-2 require-ments, high frequency, asymmetric, amplitude modulated

– between 0.15 and 80 MHz

– 10 V r.m.s. value, unmodulated

– 80 % AM (1 kHz)

– 150 source impedance

Radio interference emission

Interference emission of electromagnetic fields to EN 55011: Limit value class A, group 1.

between 20 and 230 MHz < 30 dB (V/m)Q

between 230 and 1,000 MHz < 37 dB (V/m)Q

measured at a distance of 30 m

Interference emission via network alternating current supply in accordance with EN 55011:Limit value class A, group 1.

between 0.15 and 0.5 MHz < 79 dB (V)Q

< 66 dB (V)M

between 0.5 and 5 MHz < 73 dB (V)Q

< 60 dB (V)M

between 5 and 30 MHz < 73 dB (V)Q

< 60 dB (V)M



B.2 Transport and storage conditions



6FC5 397-0CP10-1BA0

Extension of the range of application

If you intend to use the control system in residential areas, you must ensure that the controlsystem meets the requirements of limit value class B to EN 55011 in respect of interferenceemission.

Recommendation: Install the control system in grounded metal cabinets, such as 8MC cabi-nets (see NV 21 Catalog). Connect filters to the supply lines.

B.2 Transport and storage conditions

With regard to transportation and storage conditions, the D4xx surpasses the requirementsspecified in IEC 60068-2. The following conditions apply to modules that are transported andstored in the original packaging.

Type of condition Permissible range

Free fall 1m

Temperature From – 20 C to + 60C

Air pressure 1,060 ... 700 hPa (corresponds to an altitude of 3,000)

Relative humidity from 5 to 95 %, without condensation

B.3 Mechanical and climatic ambient conditions for operation

Operating conditions

The control system is intended for use as a stationary equipment in a sheltered environment.The conditions of use are compliant with requirements to DIN IEC 68-2-2:

The control system satisfies the operating conditions of the 3C3 class in accordance withDIN EN 60721 3-3 (operating locations with high traffic densities and in the immediate vici-nity of industrial plants with chemical emissions).

The control system must not be operated in the following locations without additionalmeasures being taken:

at sites where a high volume of ionizing radiation occurs

Locations with severe operating conditions, e.g., due to:

– the formation of dust

– caustic vapor or gases.

in plants which require special supervision, e.g.

– lifts

– electrical equipment in especially hazardous rooms.

An additional measure for use of the control system may be, for example, the installationincabinets.


B.3 Mechanical and climatic ambient conditions for operation


Climatic ambient conditions

The control system can be used under the following climatic ambient conditions:

Ambient conditions Fields of application Remarks

Temperature From 0 to 50 C With a simultaneity of 50 %

Relative humidity 5 to 95%, Without condensation, corres-ponds to relative humidity (RH)severity level 2 in accordancewith IEC 1131-2

Air pressure 1,080 ... 795 hPa –

Pollutant concentration

SO2: < 0.5 ppm;

Relative humidity < 60%, withoutcondensation

H2S: < 0.1 ppm;

Relative humidity < 60%, withoutcondensation

Tested:

10 ppm; 4 days

1 ppm; 4 days

Mechanical ambient conditions

The mechanical ambient conditions for the control system are specified in the table below inthe form of sinusoidal waves.

Mechanical ambient conditions Operation Transport (in packaging)

Vibration tested in accordancewith DIN EN 60068-2-68

10 to 58 Hz: 0.35 mm58 to 200 Hz: 50 m/s2

5...9 Hz: 3.5 mm9 to 200 Hz: 10 m/s2

Shock resistance tested in accor-dance with DIN EN 60068-2-27

10 g peak value, 6 ms duration100 shocks in each of the 3axes vertical to one another

10 g peak value, 6 ms duration100 shocks in each of the3 axes vertical to one another

Vibration reduction

If the control system is subjected to major impacts or vibration, appropriate measures mustbe taken to reduce the acceleration or the amplitude of the vibration.

We recommend mounting the control system on shock-absorbing material (e.g. vibration-absorbing metal).



B.4 Information on insulation tests, safety class, and degree of protection



6FC5 397-0CP10-1BA0

B.4 Information on insulation tests, safety class, and degree ofprotection

Test voltages

The insulation resistance is tested in a routine test using the following test voltage toIEC 1131, Part 2:

Circuits with a rated voltage of Ue to othercircuits or ground

Test voltage

0 V < Ue 50 V 500 V DC

Class of protection

Class of protection I to IEC 536 (VDE 0106, Part 1), i.e. connection to protective conductorrequired!

Protection against ingress of solid foreign bodies and water

Degree of protection to IEC 529:

CNC operator panel (PCU) IP65 (front)IP00 (rear)

Machine control panel (MCP) IP54 (front)IP00 (rear)

PP 72/48 I/O module IP00


B.5 Safety of electronic control systems



Introduction

The information provided here is mainly of general nature and applies irrespective of thetype of the electronic control system and its manufacturer.

Reliability

Comprehensive and cost-effective measures have been taken during development and pro-duction to increase the reliability of the devices and components as far as possible.

These include

the selection of high-quality components;

worst-case design of all circuits;

systematic and computer-controlled testing of all components delivered;

burning in of all LSI circuits (e.g. processors, memories, etc.)

measures preventing static charge when handling MOS ICs;

visual checks and inspections at various stages of production;

continuous heat testing at increased ambient temperature over several days;

careful computer-controlled final testing;

statistic evaluation of all returned goods for immediate introduction of correctivemeasures;

monitoring of the most important control parts by way of online tests (watch dog, etc.).

In terms of safety technology, these measures are called basic measures; they avoid or con-trol most possible errors.

The risk

Special safety standards must be applied to any system – and therefore to the situation aswell – whenever, if a fault occurs, it may cause injury to persons or damage to property. Forthese applications, special, plant-specific regulations exist which must be observed whendesigning the control system (e.g. VDE 0116 for furnaces).

For electronic control systems with safety relevance, the measures to be taken to avoid orcontrol errors depend on the risk resulting from the plant. In this conjunction, the basic mea-sures mentioned above are not sufficient any more for a certain hazard potential. Additionalmeasures (e.g. channel redundance, tests, checksums, etc.) must be implemented and cer-tified for the control system (DIN VDE 0801).






6FC5 397-0CP10-1BA0

Division into safe and non-safe areas

Nearly all systems contain parts that perform safety-related tasks (e.g. emergency stopswitch, protective grating, two-hand controls). To avoid having to apply safety-related criteriato the entire controller, it is customary to divide the controller into two areas – one that iscritical to safety and one that is not critical to safety. In the non-safe area of the controlsystem, no special demands are made, since a failure of the electronics will have no effecton the safety of the plant. In the safe area, however, only controls and circuits which complywith the relevant standards and regulations must be used.

Important note

If even a maximum degree of conceptional safety has been achieved when configuring anelectronic control system, e.g. through multichannel design, it is nevertheless imperative toobserve the instructions provided in the relevant instruction manuals exactly; otherwise, im-proper or incorrect handling could put precautions intended to prevent hazardous errors outof service or even create additional hazards.

C-239SINUMERIK 802D sl Instruction Manual (BA), 05/2005 Edition6FC5 397-0CP10-1BA0

Directive for handling electrostatically sensitivedevices (ESD)

C.1 What does ESD mean?

Definition

All electronic modules are equipped with large-scale integrated chips or components. Due totechnological reasons, these electronic components can be damaged easily by overvoltageand thus discharge from static electricity.

The acronym ESD has become the established designation for such ElectrostaticallySensitive Devices. The ESD designation is used internationally to refer to electrostaticallysensitive devices.

Electrostatically sensitive devices are marked with the following symbol:

!Caution

Electrostatically sensitive devices can be destroyed even by voltages which are far belowthe human perceptive limit. These voltages already occur when you touch a component orelectrical connections of a module, without being electrostatically discharged. The damageresulting at a module due to an overvoltage is in most cases not detected immediately, butonly noticed after a longer period of operation.

C



C.2 Electrostatic charging of persons

Directive for handling electrostatically sensitive devices (ESD)

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C.2 Electrostatic charging of persons

Charging

Any person connected to the electrical potential of the environment through a non-conduc-tive connection can be charged electrostatically.

Figure C-1 indicates the maximum electrostatic voltages that can accumulate in a personwho is operating equipment when he/she comes into contact with the materials shown in thefigure. These values correspond with specifications to IEC 801-2.

Voltage in kV

123456789

10111213141516

(kV)

5 10 20 30 40 50 60 70 80 90 100 Relative humidity in %

1

3

1 synthetic material

2 wool

3 antistatic material such as woodor concrete

2

Fig. C-1 Electrostatic voltages to which an operator can be charged


C.3 Basic protective measures against discharge of static electricity

C-241SINUMERIK 802D sl Instruction Manual (BA), 05/2005 Edition6FC5 397-0CP10-1BA0


Ensure proper grounding

When handling electrostatically sensitive devices, ensure that human, workplace and packa-ging are grounded properly to avoid static charging.

Avoid direct contact

Electrostatically sensitive devices should only be touched if this cannot be avoided (e.g.when performing maintenance work). When you touch modules, make sure that you do nottouch either the pins on the modules or the printed conductors. In this way, the dischargeenergy cannot reach and thus damage sensitive devices.

If you must perform measurements at a module, discharge your body first before performingthe work. To do so, touch a grounded metal object. To do so, touch grounded metal objects.Use only grounded measuring and test equipment.





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Notes

D-243SINUMERIK 802D sl Instruction Manual (BA), 05/2005 Edition6FC5 397-0CP10-1BA0

SINUMERIK 802D sl License Agreement

License Agreement for the Sinumerik 802D sl Software – in the following referred to as“Software”

D.1 General Terms and Conditions for the Use of Software forSinumerik and Drive Technology

This Software is protected by national and international copyright and treaties. Unauthorizedcopying and illegal distribution of the Software or parts thereof is liable to prosecution bothunder criminal and under civil law and will result in severe penalty and/or damage compen-sation.

Prior to installation and use of the Software, please read the Terms and Conditions of thisLicense Agreement. An extract can be found in the Section D.2.

If you have received this software on a CD with the notice “Trial version” or together withanother software licensed for you, you are only permitted to use the software for test andvalidation purposes according to the attached trial licensing regulations. To this end, it isimperative to install certain programs, software libraries etc. on your computer.

We therefore strictly recommend you to install the Software either on a single-userworkstation or on a computer which is not integrated into the production processand required for storing or managing vital data, since it cannot fully be ruled out thatexisting files are modified or overwritten. We will therefore not assume any liabilityfor damage and/or data loss resulting from installing the program or not observingthis warning notice.

Any use of this Software other than that as prescribed by the present Terms andConditions is only permitted with a valid license from Siemens. If you do not possessa valid license which can be proven by submitting an appropriate Certificate ofLicense/Software Product Form, please cancel the installation immediately andcontact a Siemens branch office immediately to avoid claims for damages.

If the Software contains Free Software, an appropriate note can be found in the readme filefor the Software under License. The Customer is entitled to use the Free Software accordingto the relevant terms and conditions of licensing applying to the Free Software. These areincluded on the data carrier on which the software is supplied to the Customer. If there areany provisions in the terms and conditions of licensing for the Free Software which are incontradiction to these General Terms and Conditions, the terms and conditions of licensingfor the Free Software shall prevail. The Customer shall be entitled to request the sourcecode of the Free Software against payment of the shipping costs at least for a time of threeyears after acquiring the Software from Siemens.

D



D.2 General Terms and Conditions for the Use of Software for Sinumerik and Drive Technology


D-244SINUMERIK 802D sl Instruction Manual (BA), 05/2005 Edition

6FC5 397-0CP10-1BA0

D.2 General Terms and Conditions for the Use of Software forSinumerik and Drive Technology

D.2.1 Delivery of the Software to licensees and granting of rights of use in theSoftware

1. The delivery of the Software for automation and drive technology to the Licensee is sub-ject to the applicable mutual written declarations. Any general terms and conditions of theLicensee, however, shall only be valid if we have expressly agreed to them.

We grant the Licensee rights to use the Software mentioned either in the Order Confir-mation or – if the Licensee has not received an Order Confirmation – in the Certificate ofLicense, or – if the Licensee has received a Software Product Form instead of the Certifi-cate of License – in the Software Product Form. The Certificate of License and the Soft-ware Product Form will be referred to in the following as “CoL”. The Licensee will receivethe CoL together with the delivery of the Software or the delivery note.

The form of delivery of the Software also results either directly from the Order Confirma-tion or the Order Number of the Software specified in the Order Confirmation in conjunc-tion with the relevant order data specified in the Catalog valid at the time of order confir-mation (in the following referred to as “Order Data”), or from the CoL. If the Licensee hasnot received a data carrier, he shall be entitled to make copies of the Software he hasalready in his possession to the extent required to use the Software within the rights touse granted to him. This shall apply analogously if the Software is delivered electronically(via download).

If in these Terms and Conditions reference is made to the Order data or the CoL, the re-ference to the CoL will only be relevant if the Licensee has not received an Order Confir-mation. In any case, the data contained in the Order Data are also contained in the CoL.

2. The documentation that belongs to the software is to be acquired separately, unless it isspecified in the order data or the CoL that the documentation is included in the scope ofsupply. If the Licensee is entitled to make copies of the software as it is mentioned inPoint D.2.1, Clause 1 above, this shall also pertain to the documentation so far as inclu-ded in the scope of supply.

3. If the Licensee has received a license key for the software, this must also be installed.

4. The rights granted to the Licensee in the software result from the license type(see Point D.2.2) and the software type (see Point D.2.3). License type and software typeresult from the order data or the CoL.

If the Software is delivered electronically or by granting multi-user license rights, theseshall refer to the rights and duties in the legally created copies mentioned in these Gene-ral Terms and Conditions.

5. If the Licensee is in the legal possession of a previous version/release of the Software(in the following referred to as “Previous Version” ), the Licensee shall be granted theright to exercise the right to use the Software either for the Software itself or – if this istechnically feasible – for the Previous Version (downgrading). If the Software is anupgrade or a PowerPack as mentioned in Point D.2.4 below, Point D.2.4 shall apply inaddition.




6. If the Licensee is to receive only the data carrier, and not a license according to the provi-sions in the Order Data or resulting from the CoL, the Licensee shall only be entitled touse the Software if he acquires a license as mentioned in Point D.2.2 below. The Licen-see shall only be entitled to pass on the Software to third parties if he has acquired thelicense.

D.2.2 License type

Depending on the license type, the Software Licensee is granted the following rights:

1. Single License (One-Off License, Copy License)

The term “One-Off License” or “Copy License” used in the Software Product Form cor-responds to the Single License. The following regulation shall apply to the One-Off Li-cense/Copy License to its full extent:

The Licensee is granted the non-exclusive right unlimited in time and assignable in accor-dance with Point D.2.5, Clause 3 below to install the Software on one (1) device and touse the installed Software as specified in the Order Data or the CoL (see “Type of use”).

2. Floating License

The Licensee is granted the non-exclusive right unlimited in time and assignable in accor-dance with Point D.2.5, Clause 3, to install the Software on any number of devices of theLicensee. The number of persons who are permitted to use the software simultaneously(“users”) results from the order data or the CoL (see

3. Rental License

The Licensee is granted the non-exclusive right limited in time as specified in the OrderData or the CoL (see “Type of Use”) to Point D.2.5, Clause 3, to install and use the Soft-ware on one (1) device. If the time of use is specified in hours, the time used to calculatethe limitation in time shall commence at the time when the Software was started first andend at the time when the use of the Software is finally completed. If the time of use isspecified in days, weeks or months, the specified period shall commence from the timewhen the software was started first, irrespective of whether or not the software is in factused.

4. Trial License

The Licensee is granted the non-exclusive, nontransferable right to install the Softwareon one (1) device and to use the installed Software for validation purposes in the manneras specified in the Order Data or in the CoL (see The time of use shall be limited to14 days, commencing at the time when the Software was started first, unless anothertime of use is specified in the Order Data or in the CoL.






6FC5 397-0CP10-1BA0

D.2.3 Software type

If the software type is specified neither in the Order Data, nor in the CoL, the Software shallbe subject to the rights specified in Point D.2.3, Clause 2 (Runtime Software).

1. Engineering Software

If the Licensee uses the Engineering Software to create his own programs or data whichcontain parts of the Engineering Software, the Licensee shall have the license-free rightto make copies of these parts of the Engineering Software as a part of his own programsor data, to use them or to deliver them third parties for their use. When delivering to thirdparties, these must be bound in writing to the regulations of Point D.2.5, Clauses 1 and 2in respect of the parts of the Engineering Software mentioned above.

2. Runtime Software

If the Licensee embeds the Runtime Software or parts thereof into his own programs ordata, the Licensee shall acquire a license in the Runtime Software according to the inten-ded type of use in accordance with the Siemens Catalog valid at this time each timewhen installing the Software or making copies, whichever is earlier. If the Licensee deli-vers the programs or data mentioned above for use by third parties, these must be boundin writing to the regulations of Point D.2.5 in respect of the embedded parts of the Run-time Software. This does not affect the obligation for the Licensee to acquire a license inthe Runtime Software,if this software is to be copied in its original form.

If the Runtime Software contains tools for parameterization/configuration and if extendedrights are granted for these tools, this can be derived from the readme file of the RuntimeSoftware.

D.2.4 Upgrade and PowerPack

If it is to be understood from the Order Data or the CoL, for example through appending ofthe suffix “PowerPack” or “Upgrade” to the name of the Software, that the Software servesto upgrade another software (in the following referred to as “Original License”), the rightsgranted to the Licensee in the Software are acquired also in respect of the original softwareas soon as the original software is upgraded with the Upgrade/PowerPack. The rights of useoriginally granted to the Licensee with the Original License are terminated with the upgrade.The Licensee is however entitled to reverse the upgrade at any time (downgrading) – insofaras this is technically feasible – and to exercise the rights of use in the software granted withthe Original License in accordance with Point D.2.1, Clause 5.




D.2.5 Further rights and duties of the Licensee

1. Unless a note to the contrary with specification of a certain number of copies is made onthe data carrier or in the readme file of the Software, the Licensee is permitted to make areasonable number of copies of each copy of the Software which he is entitled to use inaccordance with these Terms and Conditions exclusively for data backup purposes.Furthermore, the Licensee is only permitted to duplicate the Software if and insofar as wehave granted rights of duplication in writing.

2. The Licensee is not permitted to modify, reverse engineer or recompile the Software, noris he permitted to segregate individual parts of the software, except where this is ex-pressly permitted by the provisions of the laws on copyright. The Licensee is furthermorenot permitted to remove alphanumerical IDs, trademarks or copyright notes from the soft-ware or data carrier and undertakes to duplicate such markings and notes unchangedinsofar as he is entitled to duplicate the Software. This provision applies analogously alsoto the documentation provided in accordance with Section D.1.

3. The Licensee is entitled to transfer his rights of use in the Software to a third party, provi-ded a written agreement is reached with this third party to the effect of all provisions ofthis Section D.5 and provided he retains no copies of the Software.

If the Licensee has received a license key for the Software, this key must be passed onto the third party together with the Software. Furthermore, the CoL is to be handed overto the third party, together with these Terms and Conditions.

If requested by us, the Licensee is to be prepared to present the CoL received for theSoftware at any time.

4. If the Software is a PowerPack or an Upgrade, the Licensee is to keep the Certificate ofLicense or the Software Product Form of the Original License and, if requested by us, isto be prepared to present it together with the CoL received for the Software at any time. Ifthe Licensee transfers his rights of use in the PowerPack Software or the Upgrade Soft-ware in accordance with Point D.2.5, Clause 3, the Certificate of License or the SoftwareProduct Form of the Original License is also to be handed over to the third party.

5. If the Licensee receives a data carrier which contains further enabled software productsbesides the Software, he is granted a right limited in time and without fees to use theseenabled software products exclusively for validation purposes. The time of use shall belimited to 14 days, commencing at the time when the Software was started first, unlessanother time of use is specified in the readme file of the software product concerned.

The provisions of these Terms and Conditions apply analogously to these software pro-ducts provided exclusively for validation purposes. The Licensee is not entitled to transferthese software products to a third party separately, i.e. without the Software.

Otherwise, the provisions of the purchase contract shall apply, unless contraryprovisions are specified expressly hereinafter for the Free Software.



D.3 License Provisions for Free Software Components



6FC5 397-0CP10-1BA0

D.3 License Provisions for Free Software Components

In the “Sinumerik 802D sl” software, the following free software components (in the followingreferred to as “Free Software”) are used either in unmodified form or after modification byus:

Name License

Linux-Kernel GPL (see gpl.txt)Grub GPL (see gpl.txt)devices GPL (see gpl.txt)glibc LGPL (see lgpl.txt)libstdc++ LGPL (see lgpl.txt)libz Zlib license (see zlib.txt)libgmp LGPL (see lgpl.txt)liboop LGPL (see lgpl.txt)busybox GPL (see gpl.txt)lsh GPL (see gpl.txt)tsort BSD (see bsd.txt)udhcp-server GPL (see gpl.txt)ipledd GPL (see gpl.txt)betaftpd GPL (see gpl.txt)tftpd BSD (see bsd.txt)iptables GPL (see gpl.txt)hotplug GPL (see gpl.txt)ntpd BSD (see bsd.txt)samba-mount GPL (see gpl.txt)

The Free Software is made available without fees. You are entitled to use the Free Softwarein accordance with the corresponding license provisions. These provisions are to be foundunder Point D.2.5 ff. above.BIn case of discrepancies between these license provisions andthe license provisions in accordance with Points D.2.1 and D.2.2, the license provisions inaccordance with Point D.2.5 shall prevail in respect of the Free Software. In case of violationof these license provisions, the named licenser is entitled, alongside us, to assert resultantclaims and rights in his own name.

Where permitted by the relevant license provisions in accordance with Clause 5ff, you areentitled to request the source code of the Free Software from your Siemens sales represen-tative against payment of the shipping costs at least for a period of three years after acqui-ring the Software.

D.4 Liability for Free Software

We assume liability for the Software, including the Free Software contained therein, in accor-dance with the license provisions valid for the Software. All liability is excluded in respect ofuse of the Free Software beyond the program sequences we have designated for the Soft-ware, as well as in respect of defects attributable to modification of the Free Software.

No technical support is provided for the Software if it has been modified.


D.5 see gpl.txt on the Toolbox CD under /licenses


D.5 see gpl.txt on the Toolbox CD under /licenses

D.6 see bsd.txt on the Toolbox CD under /licenses

D.7 see zlip.txt on the Toolbox CD under /licenses

D.8 see lgpl.txt on the Toolbox CD under /licenses



D.8 see lgpl.txt on the Toolbox CD under /licenses



6FC5 397-0CP10-1BA0

Notes

E-251SINUMERIK 802D sl Instruction Manual (BA), 05/2005 Edition6FC5 397-0CP10-1BA0

Abbreviations

CF Compact Flash

CNC Computerized numerical control

COM Communication module

CU Control Unit

DC Direct current

DI Digital input

DIN Deutsche Industrienorm (German industrial standard)

DI/DO Digital input/output, bidirectional

DO Digital output

DP Distributed I/O

ESD Electrostatically sensitive devices

EMC Electromagnetic compatibility

EN Europäische Norm (European Standard)

HMI Human Machine Interface

IEC International Electrotechnical Commission

ISO International Standardization Organization

LED Light Emitting Diode

GND Ground

MCP Machine control panel

NC Numerical control

NCK Numerical Control Kernel

PC/PG Personal computer, programming device

PCU Panel Control Unit

PELV Protective extra-low voltage

PLC Programmable Logic Control

PNO PROFIBUS Nutzer-Organisation (PROFIBUS user organization)

RJ45 Interface standard; describes an 8-pin plug connection for twisted-pair Ethernet

RS232 Serial interface

RS485 Interface standard; describes the physical properties of a digital serial interface

SDB System data block

E



Abbreviations

E-252SINUMERIK 802D sl Instruction Manual (BA), 05/2005 Edition

6FC5 397-0CP10-1BA0

TB 30 Terminal Board 30

UL Underwriters Laboratories Inc.

USB Universal Serial Bus

Index

Index-253SINUMERIK 802D sl Instruction Manual (BA), 05/2005 Edition6FC5 397-0CP10-1BA0

IndexNumbers802D machine data802D machine data

Axis-specific, A-214Channel-specific, A-206Display, A-196General, A-201

AAccess levels, 9-80Ambient conditions, B-234

Mechanical, B-235Analog output, Assignment, 4-31Analog spindle, Connecting, 7-60Assuming control priority, 10-144Automatic configuration, 10-154

BBERO, 7-71Bus connector, Setting the terminator, 7-67

CCable clamp, 7-74CE, Identification, B-231Check topology, 10-161Class of protection, B-236CNC full keyboard (installed beneath to the PCU), Dril-

ling pattern, 5-47CNC full keyboard (installed next to the PCU)

Dimension drawing, 5-44, 5-46Drilling pattern, 5-45

CNC full keyboard connection, 2-15CNC operator panel (PCU)

Dimension drawing, 5-40Drilling pattern, 5-41

COM port connection, 7-65Commissioning using predefined macros, 9-93Compact flash card (CF card) slot, 2-15, 4-19Components, 1-11Configuring a drive unit, 10-131Configuring SINAMICS S120, 9-93Connect to target system, 10-140Connected loads, 8-75Connecting, 7-51

Bus connector, 7-67

Connecting the digital inputs/outputs, 7-71, 7-72to the CNC operator panel, 7-71to the I/O module, 7-72

Connecting the Ethernet interface, 7-64Connecting the I/O module, 7-66Connecting the machine control, 7-73Connecting the SINAMICS S drive, 7-70Connection cables, 7-71Connection for the CNC-full keyboard, 7-63Connection overview, 7-56Connection to PROFIBUS DP, 7-66Control panel, 10-140, 10-143Control powerup, 9-83Control word CTW1, 10-146Creating a drive project, 10-123

OFFLINE, 10-123ONLINE, 10-150

DData backup, 12-187Data organization, 11-181Data types, L-195Degree of protection, B-236Description, 2-13Description of the PP 72/48 I/O module

Interfaces, 4-33Operator controls, 4-33

Design, Electrical, Configuring, 7-52Detailed view, 9-105Device configuration, 10-158Diagnosis via STARTER, 9-111Diagnostics function, 9-111

Function generator, 9-112Trace, 9-115

Dielectric strength test, B-236Digital inputs, 4-25

Assignment, 4-26, 4-30, 4-34Description, 4-27, 4-34Technical Specifications, 8-76

Digital inputs/outputs (CPU), 2-15Digital outputs, 4-25

Assignment, 4-26, 4-30, 4-34Description, 4-27, 4-34Technical Specifications, 8-77

Dimension drawings, 5-39, 5-40, 5-42, 5-44, 5-46, 5-48Dimensions, 8-75Drilling patterns, 5-39, 5-41, 5-43, 5-45, 5-47DRIVE CLiQ interface, 2-15, 4-23



Index

Index-254SINUMERIK 802D sl Instruction Manual (BA), 05/2005 Edition

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Drive configuration, 10-158Drive Navigator, 10-157Drive on, 10-147Drive, 10-135

EElectrical design, Configuring, 7-52Electromagnetic compatibility, B-232EMC Directives, 7-51EMC Guidelines, B-231EMERGENCY STOP strategy, 7-51Entering the machine data, 9-90Error displays, 3-18ESD Guideline, C-239Ethernet interface, 2-15, 4-20

Assignment, 4-20External electrical interference, Protection, 7-52

FFast transients, B-232Faults and Alarms, 9-97Feed axes, Initial setting, 9-99File Management, 9-84Find drive units online...., 10-150Function generator, Features, 9-113

GGenerator for signals, 9-112Guideline, ESD, C-239

HHandwheel, 1-10Handwheel connection, 2-15, 4-24

Assignment, 4-24

II/O interface, 4-33, 4-34IEC 1131, B-231Inserting a drive unit, 10-128Installation, 6-49Interfaces, 4-19

CNC operator panel (PCU), 4-19PP 72/48 I/O module, 4-32

Interference sizesPulse-shaped, B-232Sinusoidal, B-233

LLanguage setting, 9-84LEDs on the PP 72/48 I/O module, 3-18

MMachine control, 7-73Machine control panel (MCP)

Dimension drawing, 5-42Drilling pattern, 5-43

Machine data, setting dataActivation, 9-81Structure, 9-81

Macros, 9-95MCPA module, 4-28

Connecting, 7-59Measuring function, 9-116, 9-117Measuring socket, 9-119Modules, Transport and storage conditions, B-234Motor rotates, 10-140Mounting the CNC operator panel (PCU), Interfaces,

2-15Mounting the shield connection, 7-74

OOperating conditions, B-234Operating type, 10-135Operator Controls and Display, 3-17Optional interface, 2-15

PPCU interfaces, 2-15

Compact flash card (CF card) slot, 4-19Digital inputs/outputs, 4-25Ethernet interface, 4-20Handwheel connection, 4-24PROFIBUS DP1 interface, 4-22RS232 COM interface, 4-21USB interface, 4-20

PLC alarms, 11-166PLC command overview, 11-171PLC programming, 11-170Power supply connection, 2-15, 4-33, 7-61PP 72/48 I/O module, 4-32PP 72/48 interfaces, 4-33

I/O interface, 4-34PP72/48 I/O module, Dimension drawing, 5-48Probe, 7-71Product overview, 1-9

Index

Index-255SINUMERIK 802D sl Instruction Manual (BA), 05/2005 Edition6FC5 397-0CP10-1BA0

PROFIBUS address, 9-91PROFIBUS DP interface, 4-33PROFIBUS DP1 interface, 2-15, 4-22Programm organization, 11-181Project navigator, 9-105Protection against external electrical interference, 7-52Protection levels, 9-80Protective conductor, 7-55

RRadio interferences, Emission of, B-233RCS802D Tool, 9-82Recorder, 9-115Returning the control priority, 10-148RS232 COM interface, 2-15, 4-21RS232 COM port, assignment, 4-21

SSafety of electronic control systems, B-237Safety rules, 7-51

EMERGENCY STOP devices, 7-51Servo, 10-135Servo Control, 10-135Setpoint/actual-value assignment, 9-98Setting data, L-226Setting the technology, 9-88Setting the terminator on the bus connector, 7-67Shield connection, 7-74Shielded lines, 7-74Signal recording with the trace function, 9-111Sinusoidal interference, B-233Spindle

Analog, 9-103Initial setting, 9-101Unipolar, 9-104

Spindle actual-value encoderintegrated into the motor, 9-102mounted directly, 9-102

Start automatic configuration, 10-154

Start-up, 9-79Close, 9-120PLC, 11-163Prerequisites, 9-79Sequence, 9-79Series start-up, 12-190

Start-up modes of the PLC, 11-164STARTER start-up tool, 9-105Status displays, 3-18Stop, 10-147Supply, 10-133Switch on, 9-83System overview, 1-9System software, 1-11

TTechnical Specifications, 8-75

Digital inputs, 8-76Digital outputs, 8-77

Terminal strip converter, 4-34Test voltages, B-236Toolbox, 1-12Trace, 9-115Trace function, Signal recording, 9-111

UUSB interface, 4-20USB port, 2-15User alarms, 11-167User interface, 9-105Using the STARTER control panel, 10-140

VVibrations, B-235

WWeight, 8-75Working range, 9-105



Index

Index-256SINUMERIK 802D sl Instruction Manual (BA), 05/2005 Edition

6FC5 397-0CP10-1BA0

Notes

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SINUMERIK 802D sl

Manufacturer Documentation

Instruction Manual

Order No.: 6FC5397-0CP10-1BA005/2005 Edition

Should you come across any printingerrors when reading this publication,please notify us on this sheet.Suggestions for improvement arealso welcome.

To SIEMENS AGA&D MC BMSPostfach 3180

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Siemens AGAutomation & DrivesMotion Control SystemsPostfach 3180, D–91050 ErlangenFederal Republic of Germany

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Siemens AG 2005Subject to change without prior notice

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