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Description of Functions 11.

2003 Edition

sinumerik
SINUMERIK 802D
SINUMERIK 802D base line

Preface, Table of Contents


EMERGENCY STOP (N2)
Axis Monitoring (A3)
Velocities, Setpoint/Actual- Value
Systems, Closed- Loop Control
(G2)
Acceleration (B2)

SINUMERIK 802D
Description of Functions

Spindle (S1)
Rotary Axes (R2)
Transverse Axes (P1)
Reference Point Approach (R1)
Manual Traversing and Handwheel Traversing (H1)
Operating Modes, Program Mode
(K1)
Feed (V1)

2
3
4
5
6
7
8
9
10
11

Continous Path Mode, Exact Stop


and LookAhead (B1)

12

Output of Auxiliary Functions to


the PLC (H2)

13

Tool Compensation (W1)


Measuring (M5)
Compensation (K3)
Traversing to Fixed Stop (F1)
Kinematic Transformations (M1)
Various Interface Signals (A2)
PLC User Interface
Various Machine Data
11.03 Edition

Glossary, Index

14
15
16
17
18
19
20
21

3ls

SINUMERIK Documentation
Printing history
Brief details of this edition and previous edition are listed below.
The status of each edition is shown by the code in the Remarks column.
Status code in the Remarks column:
A . . . . . New documentation.
B . . . . . Unrevised reprint with new Order No.
C . . . . . Revised edition with new status.
If actual changes have been made on the page since the last edition, this is indicated by
a new edition coding in the header on that page.
Edition
11.00
10.02
11.03

Order No.
6FC5 697-2AA10-0BP0
6FC5 697-2AA10-0BP1
6FC5 697-2AA10-0BP2

Remarks
A
C
C

This Manual is included on the documentation on CD ROM (DOCONCD)


E

Trademarks
SIMATIC, SIMATIC HMI, SIMATIC NET, SIROTEC, SINUMERIK and SIMODRIVE are registered
trademarks of Siemens. Third parties using for their own purpose any other names in this document which
refer to trademarks might infringe upon the rights of trademark owners.

Other functions not described in this documentation might be


executable in the control. This does not, however, represent an
obligation to supply such functions with a new control or when
servicing.
This publication was produced with Interleaf V 7.
The reproduction, transmission or use of this document or its
contents is not permitted without express written authority.Offenders
will be made liable for damages. All rights, including rights created by
patent grant or registration of utility model or design, are reserved.

We 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 contained in this document is, however,
reviewed regularly and any necessary changes will be included in the
next edition. We welcome suggestions for improvement.

Subject to change without prior notice.

Siemens AG 2003. All rights reserved.

Order No.: 6FC5 697 - 2AA10 - 0BP2


Printed in the Federal Republic of Germany

Siemens - Aktiengesellschaft

Preface
Notes for the reader
The descriptions of functions are only valid for or up to the specified software release. When
new software releases are issued, the relevant descriptions of functions must be requested.
Old descriptions of functions can only partially be used for new software releases.

Note
Other functions not described in this documentation might be executable in the control. This
does not, however, represent an obligation to supply such functions with a new control or
when servicing.

Technical notes
Notations
The following notations and abbreviations are used in this Documentation:


PLC interface signals -> IS Signal name (signal data)


Example:
IS Feed override (VB380x 0000)
The variable byte is in the range at axis, x stands for the axis:

0 axis 1
1 aixs 2
n axis n+1.

Machine data -> MD MD_NR: MD_NAME

Setting data -> SD SD_NR: SD_NAME

The headlines of the individual chapters/sections are added by a code designation in brakkets (e.g. Chapter 1: EMERGENCY STOP (N2)). This code designation is used in references to individual Chapters/Sections.

Explanation of the code designations


In the chapters/sections of each Description of Functions, the data and/or signals are explained which are important for the function discussed. Within these explanations provided in the
form of tables, some terms and abbreviations are used, which are explained here.
Default value:
This is the default value of the machine/setting data when loading the standard machine data.
Range of values (minimum/maximum values):
specifies the input limits. If no range of values is specified, the data type defines the input limits, and the field is marked with ***.

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Preface

Activation of changes:
Changes in machine data, setting data or the like come not immediately into effect in the control system. The conditions for activation are therefore always specified. The possibilities used
are listed below by their priority:


POWER ON (po)





NEW_CONF (cf)
RESET (re)
immediately (im)

Turning off/turning on the power supply


or softkey StartUp/Normal on HMI
RESET key on the control unit
RESET key on the control unit
after input of a value

Protection level:
There are the protection levels 0 to 7 whereby the interlock for protection levels 1 to 3 can be
canceled by setting a password and the interlock for protection levels 4 to 7 via the IS Protection level (e.g.: keyswitch position). Protection level 0 cannot be accessed (see Chapter Various Interface Signals).
The operator has only access to information that corresponds to this particular protection level
and the lower protection levels. The machine data are assigned different protection levels by
default and are marked by a Write/Read value (e.g. 4/7).
Note: In this document, the machine and setting data of protection levels 2 to 7 are documented. Notes on machine data of protection level 1 are only provided in special cases (expert
mode).
Unit:
The unit refers to the default setting (see Section Velocities, Setpoint/Actual Value System,
Closed-Loop Control).
If the MD has no physical unit as the basis, the field is marked with -.
Data type:
The following data types are used in the control system:

vi

DOUBLE
Floating point value (64-bit value )
Input limits from +/-4.19*10 - 307 to +/-1.67*10308

DWORD
Integer values (32-bit value)
Input limits from -2 147 483 648 to +2 147 483 648 (decimal),
as a hexadecimal value: 0000 to FFFF

BYTE
Integer values (8-bit value)
Input limits from -128 to +127 (decimal), as a hexadecimal value: 00 to FF

BOOLEAN
Boolean value: TRUE (1) or FALSE (0)

STRING
consisting of a maximum of 16 ASCII characters (uppercase letters, digits and underscore)

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Preface

Example machine data


36210

CTRLOUT_LIMIT[0]

MD number

Maximum speed setpoint

Default: 110.0

Min. input limit: 0.0

Change valid after NEW_CONF


Data type: DOUBLE

Max. input limit: 200.0

Protection level: 2/7

Unit: %

Valid from SW release:

Meaning:

Alarms
For detailed explanations on occurring alarms, please refer to:
References:
Diagnostics Guide.

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

vii

Contents

Contents
1

viii

EMERGENCY STOP (N2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-17

1.1

Brief description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-17

1.2

EMERGENCY STOP sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-18

1.3

EMERGENCY STOP acknowlededgement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-19

1.4

Data descriptions (MD, SD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-20

1.5

Signal descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-21

1.6
1.6.1
1.6.2

Data fields, lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Interface signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-22
1-22
1-22

Axis Monitoring (A3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-23

2.1

Overview of monitoring functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-23

2.2
2.2.1
2.2.2
2.2.3
2.2.4
2.2.5
2.2.6

Motion monitoring functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Contour monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Positioning monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Zero speed monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clamping monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Speed setpoint monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Actual velocity monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-24
2-24
2-25
2-27
2-27
2-28
2-30

2.3
2.3.1
2.3.2

Encoder monitoring functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Encoder limit frequency monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Zero mark monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-31
2-31
2-32

2.4
2.4.1
2.4.2

Monitoring of static limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Limit switch monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Working area limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-33
2-33
2-35

2.5

Boundary conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-37

2.6
2.6.1
2.6.2
2.6.3

Data descriptions (MD, SD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Channel -specific machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Axis/spindle -specific machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Axis/spindle -specific setting data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-38
2-38
2-38
2-44

2.7
2.7.1

Signal description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Axis/spindle -specific signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-45
2-45

2.8
2.8.1
2.8.2
2.8.3
2.8.4

Data fields, lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Axis/spindle -specific interface signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Axis/spindle -specific machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Channel -specific machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Axis/spindle -specific setting data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-47
2-47
2-47
2-48
2-48

Velocities, Setpoint/Actual-Value Systems, Closed-Loop Control (G2) . . . . . . . . . .

3-49

3.1
3.1.1
3.1.2
3.1.3
3.1.4

Velocities, traversing ranges, accuracies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Velocities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Traversing ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Input/display resolution, computational resolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standardization of physical quantities of machine and setting data . . . . . . . . . . . . . . . . . . .

3-49
3-49
3-50
3-51
3-52

3.2
3.2.1
3.2.2

Metric/inch scaling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Conversion of the scaling system using the part program . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switching over the scaling system manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-53
3-53
3-55

3.3
3.3.1

Setpoint/actual-value system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-57
3-57

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Contents

3.3.2
3.3.3
3.3.4
3.3.5

Drives connected to Profibus DP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Speed setpoint and actual -value assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Speed setpoint output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Actual -value processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-58
3-59
3-62
3-63

3.4

Closed -loop control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-65

3.5
3.5.1
3.5.2
3.5.3

Data description (MD, SD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


General machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Channel -specific machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Axis -specific machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-68
3-68
3-70
3-71

3.6

Signal descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-76

3.7
3.7.1
3.7.2

Data fields, data lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Interface signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-77
3-77
3-77

Acceleration (B2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-79

4.1

Acceleration profiles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-79

4.2

Jerk limitation on interpolator level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-80

4.3

Jerk limitation in JOG mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-81

4.4

Percentage acceleration correction, ACC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-82

4.5

Data descriptions (MD, SD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-83

4.6

Data fields, lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-84

Spindle (S1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-85

5.1

Brief description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-85

5.2
5.2.1
5.2.2
5.2.3
5.2.4

Spindle modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spindle mode: Control mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spindle mode: Oscillation mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spindle mode: Positioning mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spindle mode: Axis mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-86
5-87
5-88
5-90
5-94

5.3

Synchronizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-95

5.4

Gear stage change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-96

5.5

Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-101

5.6
5.6.1
5.6.2
5.6.3
5.6.4
5.6.5
5.6.6

Spindle monitoring functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Axis/spindle stopped . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spindle in set range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Max. spindle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Min./max. speed of the gear stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Max. encoder limit frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Target position monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.7

2nd spindle / master spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-106

5.8

Analog spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-107

5.9
5.9.1
5.9.2
5.9.3

Data descriptions (MD, SD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-108


Channel -specific machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-108
Axis/spindle -specific machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-108
Spindle -specific setting data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-116

5.10
5.10.1

Signal descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Axis/spindle -specific signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.11
5.11.1
5.11.2

Data fields, lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-127


Interface signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-127
Machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-128

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5-102
5-102
5-103
5-103
5-103
5-104
5-105

5-118
5-118

ix

Contents

5.11.3

Setting data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-129

Rotary Axes (R2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-131

6.1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-131

6.2

Modulo 360 degrees . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-133

6.3
6.3.1
6.3.2

Programming rotary axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-134


Rotary axis with active modulo conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-134
Rotary axis without modulo conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-135

6.4
6.4.1

Data descriptions (MD, SD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-136


Axis/spindle -specific machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-136

6.5
6.5.1
6.5.2

Data fields, lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-138


Machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-138
Setting data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-138

Transverse Axes (P1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-139

7.1

Defining a transverse axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-139

7.2

Diameter programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-139

7.3

Constant cutting rate: G96 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-140

Reference Point Approach (R1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-141

8.1

Fundamentals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-141

8.2

Referencing using incremental measuring systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-143

8.3
8.3.1
8.3.2

Referencing using absolute encoders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-146


General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-146
Operator-sssisted adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-146

8.4
8.4.1

Supplementary conditions for absolute encoders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-148


Adjusting the absolute encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-148

8.5
8.5.1
8.5.2

Data descriptions (MD, SD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-149


Channel -specific machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-149
Axis/spindle -specific machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-149

8.6
8.6.1
8.6.2

Signal descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-157


Channel -specific signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-157
Axis/spindle -specific signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-158

8.7
8.7.1
8.7.2

Data fields, lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-159


Interface signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-159
Machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-159

Manual Traversing and Handwheel Traversing (H1) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-161

9.1

General features when traversing in JOG mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-161

9.2

Continuous traversing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-165

9.3

Incremental traversing (INC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-166

9.4

Handwheel traversing in JOG mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-167

9.5
9.5.1
9.5.2
9.5.3

Data descriptions (MD, SD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


General machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Axis/spindle -specific machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General setting data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-170
9-170
9-171
9-172

9.6
9.6.1
9.6.2
9.6.3

Signal descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Signals from HMI to PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NCK signals and signals in the operating mode area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Channel -specific signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-174
9-174
9-175
9-176

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Contents

10

11

9.6.4

Axis/spindle -specific signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-180

9.7
9.7.1
9.7.2
9.7.3

Data fields, lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Interface signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setting data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-183
9-183
9-184
9-184

Operating Modes, Program Mode (K1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-185


10.1

Brief description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-185

10.2
10.2.1
10.2.2
10.2.3
10.2.4

Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mode change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Possible functions in the individual operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Monitoring functions in the individual operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Interlocks in the individual operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-186
10-187
10-188
10-189
10-190

10.3
10.3.1
10.3.2
10.3.3
10.3.4
10.3.5
10.3.6
10.3.7
10.3.8
10.3.9

Execution of a part program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Program mode and part program selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting the part program or part program block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Part program interruption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RESET command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Program control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Program status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Channel status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reactions to operator or program actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Example of time diagram for a program sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-191
10-191
10-191
10-192
10-193
10-194
10-194
10-195
10-196
10-197

10.4
10.4.1
10.4.2
10.4.3
10.4.4
10.4.5
10.4.6
10.4.7

Program test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General remarks on program test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Program execution without axis movements (PRT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Program execution in single block mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Program execution with Dry Run Feed (DRY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Block search: Execution of certain program sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Skipping part program blocks (SKP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graphical simulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-198
10-198
10-198
10-199
10-200
10-201
10-203
10-204

10.5

Timer for program runtime . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-205

10.6

Workpiece counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-206

10.7
10.7.1
10.7.2
10.7.3

Data descriptions (MD, SD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Display machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Channel -specific machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Channel -specific setting data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.8
10.8.1
10.8.2

Signal descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-215


Mode signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-215
Channel -specific signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-217

10.9
10.9.1
10.9.2
10.9.3

Data fields, lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Channel machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Channel -specific setting data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Interface signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-208
10-208
10-211
10-213

10-228
10-228
10-229
10-229

Feed (V1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-233


11.1
11.1.1
11.1.2
11.1.3

Feedrate F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Feed with G33 (thread cutting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Feed with G63 (tapping with compensating chuck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Feed with G331, G332 (rigid tapping = tapping without compensating chuck) . . . . . . . . . .

11.2

Rapid traverse G0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-236

11.3
11.3.1
11.3.2

Feed override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-237


Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-237
Feed disable and feed/spindle stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-237

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

11-233
11-234
11-235
11-235

xi

Contents

12

13

xii

11.3.3

Feed override from the machine control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-238

11.4

Data descriptions (MD, SD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-240

11.5
11.5.1
11.5.2

Signal descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-241


Channel -specific signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-241
Axis/spindle -specific signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-245

11.6
11.6.1
11.6.2

Data fields, lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-248


Interface signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-248
Machine data/setting data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-248

Continuous -Path Mode, Exact Stop and LookAhead (B1) . . . . . . . . . . . . . . . . . . . . . . 12-249


12.1

Brief description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-249

12.2

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-250

12.3

Exact Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-251

12.4
12.4.1
12.4.2
12.4.3
12.4.4

Continuous path mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Velocity reduction according to the overload factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Velocity reduction for jerk limitation on the path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Machine axis -specific jerk limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12.5

LookAhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-256

12.6
12.6.1
12.6.2

Data descriptions (MD, SD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-258


Channel -specific machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-258
Axis -specific machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-258

12.7
12.7.1
12.7.2

Signal descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-259


Channel -specific signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-259
Axis -specific signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-259

12.8
12.8.1
12.8.2

Data fields, lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-260


Interface signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-260
Machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-260

12-252
12-252
12-253
12-254
12-255

Output of Auxiliary Functions to the PLC (H2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-261


13.1

Brief description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-261

13.2

Programming of auxiliary functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-262

13.3

Transfer of values and signals to the PLC interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-263

13.4

Division of auxiliary functions into groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-264

13.5

Behavior on block search . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-265

13.6
13.6.1
13.6.2
13.6.3
13.6.4
13.6.5

Description of the auxiliary functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


M function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
H function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
S function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13.7
13.7.1
13.7.2

Data descriptions (MD, SD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-268


General machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-268
Channel -specific machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-268

13.8

Signal descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-270

13.9
13.9.1
13.9.2

Data fields, lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-272


Interface signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-272
Machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-273

13-266
13-266
13-266
13-266
13-267
13-267

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6FC5 697-2AA10-0BP2 (11.03) (DF)

Contents

14

15

16

Tool: Compensation and Monitoring (W1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-275


14.1

Overview: Tool and tool compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-275

14.2

Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-276

14.3

Tool compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-277

14.4
14.4.1
14.4.2
14.4.3
14.4.4

Tool monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview: Tool monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tool life monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Workpiece count monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Examples for tool life monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14.5

Special cases of tool compensations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-284

14.6

Data descriptions (MD, SD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-287

14.7

Signal descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-289

14.8
14.8.1
14.8.2

Data fields, lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-290


Interface signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-290
Machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-290

14-278
14-278
14-280
14-281
14-282

Measuring (M5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-291


15.1

Brief description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-291

15.2
15.2.1
15.2.2

Hardware requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-292


Probes that can be used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-292
Connecting the probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-293

15.3
15.3.1
15.3.2

Channel -specific measuring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-295


Measuring mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-295
Measurement results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-295

15.4
15.4.1
15.4.2

Measuring accuracy and testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-296


Measuring accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-296
Sensing probe function test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-296

15.5

Tool gauging in JOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-298

15.6

Supplementary conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-301

15.7

Data descriptions (MD, SD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-302

15.8

Signal descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-303

15.9
15.9.1
15.9.2

Data fields, lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-305


Interface signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-305
Machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-305

Compensation (K3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-307


16.1

Brief description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-307

16.2

Backlash compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-308

16.3
16.3.1
16.3.2
16.3.3

Interpolatory compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Leadscrew error compensation (LEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special features of interpolatory compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16.4
16.4.1
16.4.2

Following error compensation (feedforward control) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-314


General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-314
Speed feedforward control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-315

16.5

Data descriptions (MD, SD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-316

16.6
16.6.1
16.6.2

Data fields, lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-318


Interface signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-318
Machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-318

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16-309
16-309
16-310
16-313

xiii

Contents

17

18

19

20

xiv

Traversing to Fixed Stop (F1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-319


17.1

Brief description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-319

17.2

Functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-320

17.3

Behavior in case of RESET and cancellation of the function . . . . . . . . . . . . . . . . . . . . . . . . . 17-326

17.4

Behavior in the case of block search . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-327

17.5

Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-328

17.6

Data descriptions (MD, SD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-330

17.7

Signal descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-334

17.8
17.8.1
17.8.2

Data fields, lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-336


Interface signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-336
Machine data/setting data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-336

Kinematic Transformations (M1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-337


18.1

Brief description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-337

18.2
18.2.1
18.2.2

TRANSMIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-338
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-338
Configuring TRANSMIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-339

18.3
18.3.1
18.3.2
18.3.3

TRACYL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Configuring TRACYL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Programming example for TRACYL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18.4

Special features with TRANSMIT and TRACYL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-352

18.5

Data descriptions (MD, SD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-353

18.6

Signal descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-357

18.7
18.7.1
18.7.2

Data fields, lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-358


Interface signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-358
Machine data/setting data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-358

18-343
18-343
18-346
18-349

Various Interface Signals (A2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-359


19.1

Brief description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-359

19.2

Signals from PLC to NCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-360

19.3

Signals from NCK to PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-364

19.4

Signals from PLC to HMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-368

19.5

Signals from HMI to PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-370

PLC User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-371


20.1

Address ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-371

20.2
20.2.1
20.2.2
20.2.3

User data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
User data 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
User Data 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Retentive data area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20-373
20-373
20-373
20-373

20.3
20.3.1
20.3.2
20.3.3

User alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
User alarm: Enabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Variable for alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Active alarm reaction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20-374
20-374
20-374
20-375

20.4
20.4.1
20.4.2

Signals from/to HMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-375


Program control signals from HMI (retentive area) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-375
General selection/status signals from MMC (retentive area) . . . . . . . . . . . . . . . . . . . . . . . . . 20-377

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Contents

21

20.4.3

General selection/status signals to MMC (retentive area) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-377

20.5
20.5.1
20.5.2
20.5.3
20.5.4
20.5.5
20.5.6

Auxiliary function transfer from NC channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Decoded M signals (M0 - M99) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T functions transferred . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M functions transferred . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
S functions transferred . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D functions transferred . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
H functions transferred . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20.6

NCK signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-381

20.7
20.7.1
20.7.2

Channel signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-383


Signals to NC channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-383
Signals from NC channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-385

20.8
20.8.1
20.8.2
20.8.3

Axis/spindle signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transferred M/S functions, axis -specific . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Signals to axis/spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Signals from axis/spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20-387
20-387
20-387
20-389

20.9
20.9.1
20.9.2
20.9.3
20.9.4

PLC machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


INT values (MD 14510 USER_DATA_INT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HEX values (MD 14512 USER_DATA_HEX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FLOAT values (MD 14514 USER_DATA_FLOAT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
User alarm: Configuration (MD 14516 USER_DATA_PLC_ALARM) . . . . . . . . . . . . . . . . . .

20-391
20-391
20-391
20-391
20-392

20.10

Reading and writing of PLC variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-392

20.11

Tool management functions provided by the NC channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-393

20.12

Axis actual values and distances to go . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-394

20-378
20-378
20-379
20-379
20-380
20-380
20-380

Various Machine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-395


21.1

Display machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-395

21.2

General machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-396

21.3

Channel -specific machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-398

21.4

Axis -specific machine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-401

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

xv

Contents

notice

xvi

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

EMERGENCY STOP (N2)

1.1

Brief description
Important
We would like to draw the machine manufacturers attention to his duty to observe the relevant international and national standards (see notes on standards further below in the text).
The SINUMERIK 802D supports the machine manufacturer in implementing the EMERGENCY STOP function according to the specifications in this Description of Functions. The
EMERGENCY STOP function (tripping, sequence and acknowledgement) is the sole and only
responsibility of the machine manufacturer.

Note
The following standards are relevant for the EMERGENCY STOP function:






EN 292 Part 1
EN 292 Part 2
EN 418
EN 60204 Part 1:1992 Section 10.7

The VDE 0113 Part 1 is only valid for a transition period and is replaced by EN 60204.

EMERGENCY STOP in the control system


The following arrangements are provided in the control system to support the machine manufacturer in implementing the EMERGENCY STOP function:


Initiation of the EMERGENCY STOP sequence in the NC via the PLC input.

The EMERGENCY STOP sequence in the NC will decelerate all axes and spindles in the
NC as fast as possible.

The EMERGENCY STOP status cannot be canceled by unlocking the EMERGENCY


STOP button. Resetting the control device will not result in a restart.

After the EMERGENCY STOP status has been canceled, it is not necessary to reference
axes or synchronize spindles (the positions are corrected).

EMERGENCY STOP button


A mushroom button (with one normally closed and normally open contact each), further referred to as EMERGENCY STOP button, is installed in the Siemens machine control panel
(MCP) for the 802D.

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

1-17

EMERGENCY STOP (N2)


1.2

1.2

EMERGENCY STOP sequence

EMERGENCY STOP sequence

Prerequisite
The actuation of the EMERGENCY STOP button or a signal directly derived from it must be
carried to the control (PLC) as a PLC input. In the PLC user program, this PLC input must be
passed on to the NC to the IS EMERGENCY STOP (V2600 0000.1).
Resetting of the EMERGENCY STOP button or a signal directly derived from it must be carried to the control (PLC) as a PLC input. In the PLC user program, this PLC input must be
passed on the NC to the IS Acknowledge EMERGENCY STOP (V2600 0000.2).

Sequence in the NC
In the control system, the predetermined sequence (as per EN 418) of internal functions for
the EMERGENCY STOP status is as follows:
1. The part program execution is interrupted. All axes and spindles are stopped along defined
braking ramps according to MD 36610: AX_EMERGENCY_STOP_TIME.
2. The IS 802-READY (V3100 0000.3) is reset.
3. The IS EMERGENCY STOP active (V2700 0000.1) is set.
4. Alarm 3000 is set.
5. The servo enable is disabled after an axis/spindle-specific time that can be set in MD
36620: SERVO_DISABLE_DELAY_TIME (servo enable cutout delay) has been elapsed.
In this context, make sure that 36620: SERVO_DISABLE_DELAY_TIME must be specified
at least as large as MD 36610: AX_EMERGENCY_STOP_TIME.

Sequence on the machine


The EMERGENCY STOP sequence on the machine is exclusively defined by the machine
manufacturer. The following must be observed in conjunction with the sequence in the NC:


The sequence in the NC is started using the IS EMERGENCY STOP (V2600 0000.1).
After the axes and spindles have been stopped, the power supply must be interrupted acc.
to EN418.

The sequence in the NC has no influence on the PLC I/Os (digital outputs). If you wish
individual outputs to have a certain status in case of EMERGENCY STOP, the machine
manufacturer must implement the appropriate functions in the PLC program.

Important
To interrupt the power supply, is the sole and only responsibility of the machine manufacturer.
If you wish the sequence in the NC in case of EMERGENCY STOP not to be carried out as
defined, the IS EMERGENCY STOP (V2600 0000.1) may not be set until an EMERGENCY
STOP status defined by the machine manufacturer in the PLC user program is reached. Until
the IS EMERGENCY STOP is not yet set and no other alarm is pending, all IS are active in
the NC. Thus, any manufacturer-specific EMERGENCY STOP status is possible.

1-18

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

EMERGENCY STOP (N2)


1.3

1.3

EMERGENCY STOP acknowlededgement

EMERGENCY STOP acknowlededgement

Acknowledging EMERGENCY STOP


The EMERGENCY STOP status will only be reset if first the IS Acknowledge EMERGENCY
STOP (V2600 0000.2) and then the IS Reset (V3000 0000.7) is set. When doing so, make
sure that the IS Acknowledge EMERGENCY STOP and the IS Reset must be set together
at least as long as the IS EMERGENCY STOP active (V2700 0000.1) has been reset (see
Fig. 1-1).

IS EMERGENCY STOP
V2600 0000.1
IS Acknoweledge
EMERGENCY STOP
V2600 0000.2

IS EMERGENCY STOP
active
V2700 0000.1

IS RESET
V3000 0000.7
1
2
3

The IS Acknowledge EMERGENCY STOP has no effect.


The IS RESET has no effect.
The IS Acknowledge EMERGENCY STOP and RESET will reset EMERGENCY STOP active.

Fig. 1-1

Resetting EMERGENCY STOP

Resetting the EMERGENCY STOP status:




resets the IS EMERGENCY STOP active;

connect servo enable;

set the IS Position control active;

set the IS 802-READY;

clear alarm 3000;

cancel the part program execution.

PLC I/Os
The PLC I/Os must be brought again by the PLC user program to the appropriate status required to operate the machine.

Reset
It is not possible to reset the EMERGENCY STOP status with the IS Reset (V3000 0000.7)
alone (see diagram above).

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

1-19

EMERGENCY STOP (N2)


1.4

Data descriptions (MD, SD)

Power ON
Power ON (turning off/turning off the power supply) will clear the EMERGENCY STOP status,
except the IS EMERGENCY STOP (V2600 0000.1), which remains set.

1.4

Data descriptions (MD, SD)

Axis-specific machine data


36620
MD number
Default: 0.1
Change valid after
Data type: DOUBLE
Meaning:

SERVO_DISABLE_DELAY_TIME
Servo enable cutout delay
Min. input limit: 0.02
Max. input limit: ***
NEW_CONF
Protection level: 2/2
Unit: s
Valid from SW release:
Maximum time delay for cancellation of Servo enable after faults.
The speed enable (servo enable) of the drive is canceled internally in the control system at the
latest after a set delay time if the axis / spindle is moving.
The entered delay time acts due to the following events:




Application example(s)

Special cases, errors, ......

Related to ....

1-20

in case of errors resulting in immediate axis stop


if the IS Servo enable is canceled from the PLC.

Once the actual speed reaches the zero speed range (MD 36060: STANDSTILL_VELO_ TOL),
Servo enable is disabled for the drive.
The time should be set as large as the axis / spindle needs to come to a standstill from maximum
traversing velocity or speed.
If the axis / spindle is already at a standstill, Servo enable is disabled for the drive immediately.
The speed control of the drive should be maintained for this time to make sure that the axis/spindle
can come to a standstill from maximum traversing velocity or speed. For this time, the cancellation
of Servo enable should be delayed for an axis/spindle moving.
CAUTION: If the servo enable cutout delay is set too small, the Servo enable is already canceled
even if the axis/spindle is still traversing. In this case, it is suddenly stopped with setpoint 0.
The time set in this MD should therefore be greater than the time of the braking ramp in case of
error statuses (MD 36610: AX_EMERGENCY_STOP_TIME).
IS Servo enable (V380x 0002.1)
MD 36610: AX_EMERGENCY_STOP_TIME (time of braking ramp in case of error statuses)

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

EMERGENCY STOP (N2)


1.5

1.5

Signal descriptions

Signal descriptions

General signals
V2600 0000.1
Interface signal

EMERGENCY STOP
Signal(s) to NC (PLC - - -> NC)

Edge evaluation: no

Signal(s) updated: cyclically

Signal(s) valid from SW release:

Signal state 1 or edge


change 0 - ->1

The NC is set to the EMERGENCY STOP status and the EMERGENCY STOP sequence in the
NC is started.

Signal state 0 or edge


change 1 - ->0




Related to ....

IS Acknowledge EMERGENCY STOP (V2600 0000.2)


IS EMERGENCY STOP active (V2700 0000.1)

V2600 0000.2
Interface signal

Acknowledge EMERGENCY STOP


Signal(s) to NC (PLC - - -> NC)

The NC is not in the EMERGENCY STOP status.


The EMERGENCY STOP status is (still) active, but can be reset using the IS Acknowledge
EMERGENCY STOP and IS Reset.

Edge evaluation: no

Signal(s) updated: cyclically

Signal(s) valid from SW release:

Signal state 1 or edge


change 0 - ->1

The EMERGENCY STOP status will only be reset if first the IS Acknowledge EMERGENCY
STOP and then the IS Reset (V3000 0000.7) are set. When doing so, make sure that the IS
Acknowledge EMERGENCY STOP and the IS Reset must be set together at least as long
as the IS EMERGENCY STOP active (V2600 0000.1) has been reset.
Resetting the EMERGENCY STOP status:
 resets the IS EMERGENCY STOP active;
 connects Servo enable;
 sets the IS Position control;
 sets the IS 802-Ready;
 lcears alarm 3000;
 aborts the part program execution.

Related to ....

IS EMERGENCY STOP (V2600 0000.1)


IS EMERGENCY STOP active (V2700 0000.1)
IS Reset (V3000 0000.7)

V2700 0000.1
Interface signal

EMERGENCY STOP active


Signal(s) to NC (PLC - - -> NC)

Edge evaluation: no

Signal(s) updated: cyclically

Signal state 1 or edge


change 0 - ->1

The NC is in the EMERGENCY STOP status.

Related to ....

IS EMERGENCY STOP (V2600 0000.1)


IS Acknowledge EMERGENCY STOP (V2600 0000.2)

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Signal(s) valid from SW release:

1-21

EMERGENCY STOP (N2)


1.6

Data fields, lists

1.6

Data fields, lists

1.6.1

Interface signals

Number

.Bit

Name

Ref.

General
V2600 0000

.1

EMERGENCY STOP

V2600 0000

.2

Acknowledge EMERGENCY STOP

V2700 0000

.1

EMERGENCY STOP active

Mode signal range


V3000 0000

.7

1.6.2

Reset

K1

Machine data

Number

Identifier

Name

Ref.

Axis-specific
36610

AX_EMERGENCY_STOP_TIME

Duration of braking ramp in case of error statuses

36620

SERVO_DISABLE_DELAY_TIME

Servo enable cutout delay

1-22

A3

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Axis Monitoring (A3)

2.1

Overview of monitoring functions




Motion monitoring functions


-

Contour monitoring

Positioning monitoring

Zero speed monitoring

Clamping position monitoring

Speed setpoint monitoring

Actual velocity monitoring

Encoder monitoring functions

Monitoring of static limitations


-

Limit switch monitoring

Work area monitoring

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

2-23

Axis Monitoring (A3)


2.2

Motion monitoring functions

2.2

Motion monitoring functions

2.2.1

Contour monitoring

Function
The principle of functioning of the contour monitoring is based on the permanent comparison
of measured actual position value and the actual position value calculated from the NC position setpoint. To calculate the following error in advance, a model is used which simulates the
dynamic properties of the position control including feedforward control.
To make sure that the monitoring system does not respond already in the case of slight
speed variations (caused by load changes), a tolerance band is permitted for the maximum
contour deviation.
If the permissible actual value deviation entered in MD 36400: CONTOUR_TOL (contour monitoring tolerance band) is exceeded, an alarm is output, and the axes are stopped.

Activation
The contour monitoring is active for axes and a position - controlled spindle.

Effect
If the contour error is too large, the following will occur:


Alarm 25050 Contour monitoring is output.

The axis/spindle concerned is stopped with rapid stop (with open position feedback loop)
via a speed setpoint ramp.
The duration of the braking ramp is defined in the MD 36610: AX_EMERGENCY_STOP_TIME (duration of braking ramp in case of error statuses).

If the axis/spindle interpolates with other axes/spindles, these are stopped by rapid stop
with reduction of the following error (position setpoint = constant).

Increase tolerance band of monitoring function in MD 36400.

The real servo gain factor must correspond to the desired servo gain factor set in
MD 32200: POSCTRL_GAIN (servo gain factor).
With an analog spindle, check
MD 32260: RATED_VELO (rated motor speed) and
MD 32250: RATED_OUTVAL (rated output voltage).

Check optimization of speed controller.

Check smooth running of axes.

Check machine data for traversing movements (feedoverride, acceleration, max. velocities, ... )

Remedy

2-24

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

Axis Monitoring (A3)


2.2

2.2.2

Motion monitoring functions

Positioning monitoring

Function
To make sure that an axis is positioned within a specified time, the time configured in MD
36020: POSITIONING_TIME (exact stop fine time delay) is started after a motion block has
been ended (set point has reached the target), and after this time has elapsed, it is checked
whether the axis has reached its set position within the tolerance of MD 36010: STOP_LIMIT_FINE (exact stop fine).
Exact stop coarse and fine see:
References:
Chapter Continuous - Path Mode, Exact Stop and LookAhead
 active tolerance in case of zero
speed or clamping monitoring

V or s

Actual value

Interface signal
Clamping process
running (V380x
0002.3)
MD: CLAMP_POS_TOL
Setpoint

MD:
STANDSTILL_POS_T
OL
MD: STOP_LIMIT_COARSE
MD: STOP_LIMIT_FINE
Exact stop fine - interface signal

MD:
STANDSTILL_
DELAY_TIME

Exact stop coarse - interface signal

MD: POSITIONING_TIME

Fig. 2-1

Interrelation between positioning, zero speed and clamping monitoring

Enabling
The positioning monitoring is always enabled after a setpoint - dependent completion of motion blocks (setpoint has reached the target).
The positioning monitoring is active for axes and a position - controlled spindle.

Disabling
The positioning monitoring is disabled after the specified Exact stop limit fine has been reached or after output of a new setpoint position (e.g. when positioning to Exact stop coarse
followed by a block change).

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

2-25

Axis Monitoring (A3)


2.2

Motion monitoring functions

Effect
If the limit value for Exact stop fine has not yet been reached after the positioning monitoring time has elapsed, the following action is carried out:


Alarm 25080 Positioning monitoring is output.

The axis/spindle concverned is stopped with rapid stop (with open position control loop)
via a speed setpoint ramp.
The duration of the braking ramp is defined in MD 36610: AX_EMERGENCY_STOP_TIME (duration of braking ramp in case of error statuses).

If the axis/spindle interpolates with other axes/spindles, these will be stopped by rapid
stop with reduction of the following error (specification of partial position setpoint = 0).

Error cause/error elimination




Too small position controller gain - - > change machine data for position control gain
MD 32200: POSCTRL_GAIN(servo gain factor)

Positioning window (exact stop fine), positioning monitoring time and position control gain
are not matched another to one - - > change machine data:
MD 36010: STOP_LIMIT_FINE (exact stop fine),
MD 36020: POSITIONING_TIME (exact stop fine delay time),
MD 32200: POSCTRL_GAIN (servo gain factor)

General rule


Large positioning window - - > a relative short max. positioning monitoring time can be
selected

Small positioning window - - > a relatively long positioning monitoring time must be selected

Small position control gain - - > a relatively long max. positioning monitoring time must
be selected

High position control gain - - > a relatively short max. positioning monitoring time can be
selected

Note
The size of the positioning window will influence the block change time. The smaller these tolerances are chosen, the longer will last the positioning process and the longer it will last until the next
command can be executed.

2-26

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

Axis Monitoring (A3)


2.2

2.2.3

Motion monitoring functions

Zero speed monitoring

Function
After a motion block has been completed (position setpoint has reached target), it is monitored whether the axis is no more away from its setpoint position than specified in MD 36060:
STANDSTILL_POS_TOL (standstill tolerance) after the delay time that can be parameterized
in MD 36040: STANDSTILL_DELAY_TIME (standstill monitoring delay time) has elapsed.
Otherwise, an alarm is generated.
See Fig. 2-1

Activation
The zero speed monitoring is always active after the Standstill monitoring delay time has
elapsed, provided that no new traversing command is active.
The standstill monitoring is active for axes and a position - controlled spindle.

Effect
The response of the monitoring function has the following effect:


Alarm 25040 Standstill monitoring is output.

The axis/spindle concerned is stopped with rapid stop (with open position control loop) via
a speed setpoint ramp. The duration of the braking ramp is defined in MD
36610: AX_EMERGENCY_STOP_TIME (duration of braking ramp in case of error statuses).

If the axis interpolates with other axes/spindles, these will be stopped by rapid stop with
reduction of the following error (specification of partial position setpoint = 0).

Error cause/error elimination

2.2.4

Position control gain too large (vibrations of servo loop) - - >change machine data for controller gain MD 32200: POSCTRL_GAIN (servo gain factor)

Standstill window too small - - > change machine data


MD 36030: STANDSTILL_POS_TOL (standstill tolerance)

Axis is mechanically pushed off position - - > eliminate cause

Clamping monitoring

Function
If you wish the axis to be clamped at the end of the positioning process, the clamping monitoring can be activated using the IS Clamping monitoring running (V380x 0002.3).

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

2-27

Axis Monitoring (A3)


2.2

Motion monitoring functions

This can be necessary because it is possible that during the clamping process the axis has
been pushed off its setpoint position farther than permitted by the standstill tolerance. The
amount by which the setpoint position can be left is specified in MD 36050:
CLAMP_POS_TOL (clamping position tolerance at interface signal Clamping running).
See Fig. 2-1

Activation
The clamping position monitoring is activated by the interface signal Clamping process running. It replaces the standstill monitoring during the clamping process.
The clamping position monitoring is active for axes and a position - controlled spindle.

Effect
If during the clamping process the axis is pushed off its position farther than permitted by the
clamping position tolerance, the following will occur:

2.2.5

Alarm 26000 Clamping position monitoring is output.

The axis/spindle concerned is stopped with rapid stop (with open position control loop) via
a speed setpoint ramp. The duration of the braking ramp is defined in
MD 36610: AX_EMERGENCY_STOP_TIME (duration of braking ramp in case of error
statuses).

If the axis/spindle interpolates with other axes/spindles, these will also be stopped by rapid stop with reduction of the following error (specification of partial position setpoint = 0).

Speed setpoint monitoring

Function
The speed setpoint monitoring checks whether the setpoint specification does not exceed the
maximum permissible speed for the drives specified in MD 36210: CTRLOUT_LIMIT (maximum speed setpoint). If necessary, it is limited to this value, and the axis/spindle is stopped
and an alarm is output.
For the axes, the maximum speed setpoint (as a percentage) is above the speed at which the
velocity defined in MD 3200: MAX_AX_VELO is reached (100%). This also defines the control margin.
With an analog spindle, the maximum output speed cannot be greater than the speed reached at a maximum setpoint output voltage of 10V (100%).
The speed setpoint consists of the speed setpoint of the position controller and the feedforward control value (if feedforward control is active).

2-28

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

Axis Monitoring (A3)


2.2

Motion monitoring functions

Feedforward control value

KV

Following
error

Position controller

Fig. 2-2

to speed
controller
Speed setpoint
monitoring

Speed setpoint monitoring

Activation
The speed setpoint monitoring is always active for axes and for a spindle.

Effect
The following will occur if the maximum speed setpoint is exceeded:


Alarm 25060 Speed setpoint limitation is output.

The axis/spindle concerned is stopped with rapid stop (with open position control loop) via
a speed setpoint ramp.
The duration of the braking ramp is defined in MD 36610: AX_EMERGENCY_STOP_TIME (duration of braking ramp in case of error statuses).

If the axis interpolates with other axes/spindles, these will be stopped by rapid stop with
reduction of the following error (specification of partial position setpoint = 0).

Note: At the access level Expert mode (protection level 1), a delay time can be set in
MD 36220: CTRLOUT_LIMIT_TIME, after which the alarm is generated, stopping the axes.
This time is zero by default.
The beginning limitation of the speed setpoint makes this servo loop non - linear. Generally,
this results in path deviations when an axis dwells in a speed setpoint limitation. Therefore, a
control margin must be set (see Section 3.3.4 Speed setpoint output).

Error causes


A measuring error circuit or a drive error exists in the measuring circuit.

Too high setpoints specified (accelerations, velocities, reduction factors)

Obstacle in working area (e.g. coming into contact with the work table)

Tachogenerator adjustment with analog spindle has not been carried out correctly or a
measuring circuit or drive error exists.

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

2-29

Axis Monitoring (A3)


2.2

Motion monitoring functions

2.2.6

Actual velocity monitoring

Function
The actual velocity is monitored for exceeding of a permissible limit value entered in MD
36200: AX_VELO_LIMIT (threshold value for velocity monitoring).

Activation
The actual velocity monitoring is always active if the active measuring circuit that has been
activated via the iS Position measuring system 1 (V380x 0001.5) provides actual values, i.e.
is still below the imit frequency.
The actual velocity momnitoring is active for axes and for a spindle.

Effect
The following will occur if the Threshold value for velocity monitoring is exceeded:


Alarm 25030 Actual velocity alarm limit

The axis/spindle concerned is stopped with rapid stop (with open position control loop) via
a speed setpoint ramp.
The duration of the brake ramp is defined in MD 36610: AX_EMERGENCY_STOP_TIME
(duration of braking ramp in case of error statuses).

If the axis/spindle interpolates with other axes/spindles, these will also be stopped by rapid stop with reduction of the following error (specification of partial setpoint = 0).

Notes for fault finding

2-30

Check actual values.

Check position control direction.

Check MD 36200: AX_VELO_LIMIT (threshold value for velocity monitoring).

In the case of an analog spindle, check speed setpoint cable.

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

Axis Monitoring (A3)


2.3

2.3

Encoder monitoring functions

Encoder monitoring functions

2.3.1

Encoder limit frequency monitoring

Function
If the limit frequency of a measuring system, which is entered in MD 36300: ENC_FREQ_LIMIT(encoder limit frequency), is exceeded, the position synchronization (reference point) between machine and control system will be lost. A correct position control is no longer possible
in this cases. This status is signaled to the PLC.

Activation
The encoder limit frequency monitoring is always active if the encoder is turned on and is
active for axes and for a spindle.

Effect
The following will occur if the limit frequency of an encoder is exceeded:


The IS Encoder limit frequency exceeded 1 (V390x 0000.2) is set.

Spindle continues running withspeed control


If the spindle speed is reduced such that the encoder frequency falls below the value specified in MD 36302: ENC_FREQ_LIMIT_LOW (% value of MD 36300: ENC_FREQ_LIMIT), the spindle will automatically resynchronize with the reference system of the encoder.

If with an active measuring system of a position - controlled axis/spindle, the limit frequency is exceeded, alarm 21610 Frequency exceeded is output.

The axis/spindle concerned is stopped with rapid stop (with open position control loop) via
a speed setpoint ramp.
The duration of the brake ramp is defined in MD 36610: AX_EMERGENCY_STOP_TIME
(duration of braking ramp in case of error statuses).

If the axis/spindle interpolates with other axes/spindles, these will also be stopped by rapid stop with reduction of the following error (specification of partial setpoint = 0).

Error elimination


After the axes have come to a standstill, the position control will resume automatically.

Note
The axis concerned must be rereferenced.

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

2-31

Axis Monitoring (A3)


2.3

Encoder monitoring functions

2.3.2

Zero mark monitoring

Function
The zero mark monitoring checks whether pulses have been lost between two zero mark
passages of the position actual - value encoder. The number of detected zero mark errors at
which the monitoring function is to respond is entered in MD 36310: ENC_ZERO_MONITORING (zero mark monitoring).

Activation
The monitoring is activated using MD 36310: ENC_ZERO_MONITORING.
The counting of the zero mark errors starts from zero after the encoder has been turned on.

Effect
If the number of the zero mark errors entered in MD 36310: ENC_ZERO_MONITORING is
reached for a measuring system, alarm 25020 Zero mark monitoring is output.
The axis/spindle concerned is stopped with rapid stop (with open position control loop) via a
speed setpoint ramp.
The duration of the brake ramp is defined in MD 36610: AX_EMERGENCY_STOP_TIME
(duration of braking ramp in case of error statuses).
If the axis/spindle interpolates with other axes/spindles, these will also be stopped by rapid
stop with reduction of the following error (specification of partial setpoint = 0).

Error causes


MD 36300: ENC_FREQ_LIMIT (encoder limit frequency) set too high.

Encoder cable damaged.

Encoder or encoder electronics defective.

Note
In case of an error, the IS Referenced/synchronized 2 (V390x 0000.4) is canceled, i.e. the axis
must be rereferenced.

2-32

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

Axis Monitoring (A3)


2.4

2.4

Monitoring of static limitations

Monitoring of static limitations

2.4.1

Limit switch monitoring

2nd SW limit switch


(activated via PLC)

HW limit switch

1st SW limit switch

Fig. 2-3

Mechanical
traversing stop

EMERGENCY STOP

Overview of limit stops of a linear axis

Hardware limit switches


Function
For each axis, one hardware limit switch each is provided for each traversing direction to prevent the slide moving off the slide bed.
If the hardware limit switch is overtraveled, the PLC will signal it to the NC via the IS Hardware limit switch plus/minus (V380x 1000.1 or .0), and the movement of all axes is stopped.
The kind of braking can be defined via the MD 36600: BRAKE_MODE_CHOICE (braking behavior with hardware limit switch).

Activation
The hardware limit switch monitoring is active in all operating modes after the control system
has powered up.

Effect


When a hardware limit switch is overtraveled, depending on the direction, alarm 21614
Hardware limit switch + or - is output.

Depending on MD 36600: BRAKE_MODE_CHOICE (braking behavior with hardware limit


switch), the axis is stopped.

If the axis/spindle interpolates with other axes/spindles, these will also be stopped, depending on MD 36600: BRAKE_MODE_CHOICE (braking behavior with hardware limit
switch).

The direction keys in the direction of approach are disabled.

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

2-33

Axis Monitoring (A3)


2.4

Monitoring of static limitations

Remedy


Initiate Reset.

Retract in the opposite direction (in JOG mode).

Correct the program.

Software limit switches


Function
The software limit switches serve as limitations of the maximum traversing range of each individual axis.
2 software limit switch pairs are provided per axis, which are defined via the following machine data in the machine axis system:
MD 36100: POS_LIMIT_MINUS (1st software limit switch minus)
MD 36110: POS_LIMIT_PLUS (1st software limit switch plus)
MD 36120: POS_LIMIT_MINUS2 (2nd software limit switch minus)
MD 36130: POS_LIMIT_PLUS2 (2nd software limit switch plus)

Activation


The software limit switch monitoring is active in all operating modes after reference point
approach.

The position of the software limit switches can be approached.

The 2nd software limit switch can be activated from the PLC via the interface signal 2nd
software limit switch plus/minus (V380x 1000.3 or .2). The change will come into effect
immediately. The 1st software limit switch plus/minus is thus inactive.

The SW limit switch monitoring is not active with endlessly rotating rotary axes, i.e. if
MD 30310: ROT_IS_MODULO = 1. (modulo conversion for rotary axis and spindle)

Effect/reactions
Depending on the operating mode, there are different reactions if it was tried to overtravel a
software limit switch:
AUTO, MDA:
-

The block that would violate the software limit switches will not start. The previous
block is completed correctly.

The program execution is canceled.

Alarm 10720 Software limit switch + or - is output.

JOG:

2-34

The axis is stopped at the software limit switch position.

Alarm 10621 Axis has stopped on software limit switch + or - .

The direction keys in the direction of approach are disabled.

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

Axis Monitoring (A3)


2.4

Monitoring of static limitations

Special features:
-

Switching over the software limit switch:


If the current position after switching over lies after the new software limit switch, the
axis is decelerated at the maximum permissible acceleration. If the axis interpolates
with other axes, these will also be decelerated. A contour violation may result.

Remedy

2.4.2

Initiate Reset.

Retract in the opposite direction (in JOG mode).

Correct the program.

Working area limitation

Function
Working area limitations describe the range in which a machining can be carried out. In addition to the limit switches, the working area limitation is another means for the user to limit the
traversing range of the axes.
References:

Operation and Programming.

It is monitored whether the tool tip P is within the protected working area. The value entered
in the working area limitation is the last permissible position for the axis.
Using MD 21020: WORKAREA_WITH_TOOL_RADIUS (taking into account the tool radius in
the case of working area limitation), it can be determined whether the tool radius is taken into
account in the monitoring.
One pair of values (minus/plus) can be specified per axis to describe the protected working
area.

Specifying the working area limitation


The working area limitation can be specified and modified in two different ways:


via the operator panel in the Parameters operating area using the following setting data:
SD 43430: WORKAREA_LIMIT_MINUS (working area limitation minus)
SD 43420: WORKAREA_LIMIT_PLUS (working area limitation plus)
Any changes in Automatic mode are only possible in the Reset status and will then come
into effect immediately.
In Jog mode, changes are always possible, but come only into effect when a new movement starts.

in the program with G25/G26. Any changes come into effect immediately.
A programmed limitation has first priority; it will overwrite the value entered in the setting
data and is kept after RESET and program end.

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

2-35

Axis Monitoring (A3)


2.4

Monitoring of static limitations

XMachine
G26
Xmax
Tool tip

Working area
M

ZMachine

G25
Xmin

Fig. 2-4

G25
Zmin

G26
Zmax

Working area limitation shown using the example of a turning machine

Activation


Using SD 43410: WORKAREA_MINUS_ENABLE, SD 43400: WORKAREA_PLUS_ENABLE (working area limitation in the negative or positive direction active),
it is possible to activate the working area limitation; it comes into effect after reference
point approach.

During the program execution, the working area limitation can be activated using the modal G codes WALIMON and deactivated using WALIMOF.

The working area limitation is not active with endlessly rotating rotary axes, i.e. if MD
30310: ROT_IS_MODULO = 1 (modulo conversion for rotary axis and spindle).

Effect/reaction
Depending on the operating mode, there are different reactions if it has been tried to overtreavel the work area limitation:
AUTO, MDA:
-

The block that violates the working area limitation is not started. The previous block is
still completed correctly.

The program execution is aborted.

Alarm 10730 Working area limitation + or - is set.

JOG:

2-36

The axis stops at the position of the working area limitation.

Alarm 10631 Axis stopped at working area limitation + or - is set.

The direction keys in the direction of approach are disabled.

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

Axis Monitoring (A3)


2.5

Boundary conditions

Remedy

2.5

Initiate Reset.

Check the working area limitation in the part program (G25/G26) or in the setting data.

Move away in the opposite direction (in JOG mode).

Boundary conditions
To make sure that the monitoring functions respond correctly, make especially sure that the
machine data are correct:


MD 31030: LEADSCREW_PITCH (leadscrew pitch)

Gear transmission ratio (load gear):


MD 31050: DRIVE_AX_RATIO_DENOM(load gear denominator)
MD 31060: DRIVE_AX_RATIO_NUMERA(load gear numerator)
Gear transmission ratio (encoder), also for spindle if any:
MD 31070: DRIVE_ENC_RATIO_DENOM (resolver gearbox denominator)
MD 31080: DRIVE_ENC_RATIO_NUMERA (resolver gearbox denominator)

MD 32810: EQUIV_SPEEDCTRL_TIME
(speed control loop equivalent time constant for feedforward control)

Ratio output voltage / output speed


(only applicable to analog spindle):
MD 32260: RATED_VELO (rated motor speed)
MD 32250: RATED_OUTVAL (rated output voltage)

Encoder resolution

The corresponding machine data are described in


References:

Chapter Velocities, Setpoint/Actual - Value Systems, Closed - Loop Control

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

2-37

Axis Monitoring (A3)


2.6

2.6
2.6.1

Data descriptions (MD, SD)

Data descriptions (MD, SD)


Channel - specific machine data

21020
MD number
Default: 0
Change valid after RESET
Data type: BOOLEAN
Meaning:

2.6.2

WORKAREA_WITH_TOOL_RADIUS
Taking into account the tool radius with working area limitation
Min. input limit: 0
Max. input limit: 1
Protection level: 2/2
Unit:
Valid from SW release:
0: The tool radius is not taken into account.
1: The tool radius is taken into account in the working area limitation.

Axis/spindle - specific machine data

36000
STOP_LIMIT_COARSE
MD number
Exact stop coarse
Default: 0.04
Min. input limit: 0.0
Max. input limit: ***
Change valid after NEW_CONF
Protection level: 2/2
Unit: mm, degrees
Data type: DOUBLE
Valid from SW release:
Meaning:
An NC block is considered completed if the actual position of the path axes is away from the
setpoint position by the value of the entered exact stop limit. If the actual position of a path axis
is not within this limit, the NC block is not considered completed and the part program cannot be
continued. The time when the next block is processed depends on the size of the value entered.
The larger the value is, the earlier is the block change initiated. If the specified exact stop limit is
not reached,
- the block is not considered completed;
- the axis cannot be traversed further;
- the alarm 25080 Positioning monitoring is output after the time defined in
MD 36020: POSITIONING_TIME (exact stop fine monitoring time) has elapsed;
- the direction of movement +/ - is displayed for the axis on the position display. The eaxt stop
window is also evaluated for spindles in the position - controlled mode.
Special cases, errors, ...... This MD may not be less than MD 36010: STOP_LIMIT_FINE (exact stop fine). To achieve the
same block change behavior as with the exact stop fine criterion, the exact stop coarse window
may be identical to the exact stop fine window.
This MD may not be equal to or greater than MD 36030: STANDSTILL_POS_TOL (standstill
position tolerance).
Related to ....
MD 36020: POSITIONING_TIME (exact stop fine delay time)

36010
STOP_LIMIT_FINE
MD number
Exact stop fine
Default : 0.01
Min. input limit: 0.0
Max. input limit: ***
Change valid after NEW_CONF
Protection level: 2/2
Unit: mm, degrees
Data type: DOUBLE
Valid from SW release:
Meaning:
See MD 3600: STOP_LIMIT_COARSE (exact stop coarse)
Special cases, errors, ...... This MD may not be greater than MD 36000: STOP_LIMIT_COARSE (exact stop coarse).
This MD may not be equal to or greater than MD 36030: STANDSTILL_POS_TOL (standstill
position tolerance).
Related to ....
MD 36020: POSITIONING_TIME (exact stop fine delay time)

2-38

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

Axis Monitoring (A3)


2.6

Data descriptions (MD, SD)

36020
POSITIONING_TIME
MD number
Time delay for exact stop fine
Default: 1.0
Min. input limit: 0.0
Max. input limit: ***
Change valid after NEW_CONF
Protection level: 2/2
Unit: s
Data type: DOUBLE
Valid from SW release:
Meaning:
This MD is used to specify the time after which the following error must have reached the limit
value for exact stop fine after the time for approaching the position has elapsed (partial position
set value=0 at the end of the movement). If this is not the case, the alarm 25080 Positioning
monitoring is set and the axis concerned is decelerated.
The MD should be selected so generously that the monitoring does not respond in normal mode,
since the entire traversing process (acceleration, constant traversing, braking) is monitored by
other functions continuously.
Related to ....
MD 36010: STOP_LIMIT_FINE (exact stop fine)

36030
STANDSTILL_POS_TOL
MD number
Standstill position tolerance
Default: 0.2
Min. input limit: 0.0
Max. input limit: ***
Change valid after NEW_CONF
Protection level: 2/2
Unit: mm, degrees
Data type: DOUBLE
Valid from SW release:
Meaning:
On completion of a traversing block (position setpoint has reached target), it is monitored whether the axis is no farther away from its set position than specified in
MD 36060: STANDSTILL_POS_TOL (standstill tolerance) after the parameterizable delay time
defined in MD 36040 STANDSTILL_DELAY_TIME (standstill monitoring delay time) has elapsed.

Special cases, errors, ......


Related to ....

If the standstill position tolerance exceeds or falls below the set position, alarm 25040 Standstill
monitoring is output and the axis is stopped.
The standstill tolerance must be greater than the Exact stop limit coarse.
MD 36040: STANDSTILL_DELAY_TIME (standstill monitoring delay time)

36040
STANDSTILL_DELAY_TIME
MD number
Standstill monitoring delay time
Default: 0.4
Min. input limit: 0.0
Max. input limit: ***
Change valid after NEW_CONF
Protection level: 2/2
Unit: s
Data type: DOUBLE
Valid from SW release:
Meaning:
see MD 36030: STANDSTILL_POS_TOL (standstill position tolerance)
Related to ....
MD 36030: STANDSTILL_POS_TOL (standstill position tolerance)

36050
CLAMP_POS_TOL
MD number
Clamping tolerance at interface signal Clamping active
Default: 0.5
Min. input limit: 0.0
Max. input limit: ***
Change valid after NEW_CONF
Protection level: 2/2
Unit: mm; degrees
Data type: DOUBLE
Valid from SW release:
Meaning:
The interface signal Clamping process running (V380x0002.3) activates clamping monitoring. If
the monitored axis is pushed off the set position (exact stop limit) more than specified in the
clamping tolerance, alarm 26000 Clamping monitoring is generated and the axis stopped.
Special cases, errors, ...... The clamping tolerance must be greater than the Exact stop limit coarse.
Related to ....
IS Clamping process running

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

2-39

Axis Monitoring (A3)


2.6

Data descriptions (MD, SD)

36060
MD number
Default: 5.0 mm/min,
0.0138 rpm
Change valid after

STANDSTILL_VELO_TOL
Max. velocity/speed Axis/spindle at a standstill

Data type: DOUBLE


Meaning:

Valid from SW release:


This machine date defines the standstill area for the axis velocity and/or for spindle speed.
If the current actual velocity of the axis and/or the actual speed of the spindle is less than the
value entered and if the NC does no longer deliver setpoints to the axis/spindle, the
IS Axis/spindle at a standstill (V390x0001.4) is set.

Min. input limit: 0.0


NEW_CONF

Max. input limit: ***

Protection level: 2/2

Unit:
Linear axis: mm/min
Rotary axis: rpm

Vact
MD:STANDSTILL_VELO_TOL

Vstill

t
1
IS

Spindle at a standstill

0
Application example(s)
Related to ....

In order to allow a controlled stop of the axis/spindle, the pulse enable should only be canceled if
the axis/spindle has stopped. Otherwise, the axis would coast down.
IS Axis/spindle at a standstill (V390x0001.4)

36100
POS_LIMIT_MINUS
MD number
1st software limit switch minus
Default: - 100 000 000
Min. input limit: ***
Max. input limit: ***
Change valid after Power On
Protection level: 2/7
Unit: mm; degrees
Data type: DOUBLE
Valid from SW release:
Meaning:
The same meaning as the 1st software limit switch plus, but for the traversing area limit in the
negative direction.
The MD is active after reference point approach if the PLC interface signal
2nd software limit switch minus is not set.
MD inapplicable if ......
the axis is not referenced.
Related to ....
IS 2nd software limit switch minus

36110
POS_LIMIT_PLUS
MD number
1st software limit switch plus
Default: 100 000 000
Min. input limit: ***
Max. input limit: ***
Change valid after Power On
Protection level: 2/7
Unit: mm; degrees
Data type: DOUBLE
Valid from SW release:
Meaning:
In addition to the hardware switch, it is also possible to use a software switch. The absolute position in the machine coordinate system of the positive traversing limit is entered in this MD for
each axis.
The MD is active after reference point approach if the IS 2nd software limit switch plus is not
set.
MD inapplicable if ......
the axis is not referenced.
Related to ....
IS 2nd software limit switch plus

2-40

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

Axis Monitoring (A3)


2.6

Data descriptions (MD, SD)

36120
POS_LIMIT_MINUS2
MD number
2nd software limit switch minus
Default: - 100 000 000
Min. input limit: ***
Max. input limit: ***
Change valid after Power On
Protection level: 2/7
Unit: mm; degrees
Data type: DOUBLE
Valid from SW release:
Meaning:
The same meaning as the 2nd software limit switch plus, but for the traversing area limit in the
negative direction.
Which of the two SW limit switches 1 or 2 is to be active can be selected from the PLC using the
interfrace signal.
e. g.
V380x1000 bit 2 = 0 1st software limit switch minus active for 1st axis
Bit 2 = 1 2nd software limit switch minus active for 1st axis
MD inapplicable if ......
the axis is not referenced.
Related to ....
IS 2nd software limit switch minus

36130
POS_LIMIT_PLUS2
MD number
2nd software limit switch plus
Default: 100 000 000
Min. input limit: ***
Max. input limit: ***
Change valid after Power On
Protection level: 2/7
Unit: mm; degrees
Data type: DOUBLE
Valid from SW release:
Meaning:
This machine data can be used to specify a 2nd software limit switch position in the machine
axis system in the positive direction.
Which of the two software limit switches 1 or 2 is to be active can be selected from the PLC
using the interface signal.
e. g.:
V380x1000 Bit 3 = 0 1st software limit switch plus active for the 1st axis
Bit 3 = 1 2nd software limit switch plus active for 1st axis
MD inapplicable if ......
the axis is not referenced.
Related to ....
IS 2nd software limit switch plus

36200
AX_VELO_LIMIT[0]....[5]
MD number
Threshold value for velocity monitoring
Default: 11500 mm/min,
Min. input limit: 0.0
31.944 rpm
Change valid after NEW_CONF
Protection level: 2/7
Data type: DOUBLE
Meaning:

Max. input limit: ***


Unit:

mm/min
rpm

Valid from SW release:


This MD is used to specify the threshold value of the actual - value velocity monitoring.
If the axis has at least one active encoder and this is below its limit frequency, alarm 25030 Actual velocity alarm limit is output if the threshold value is exceeded, and the axes are stopped.
Settings:
 For axes, select a value that is 10 - 15 % higher than
MD 32000: MAX_AX_VELO (max. axis velocity).
 For spindles, select a value per gear stage, which is 10 - 15 % higher than
MD 35110: GEAR_STEP_MAX_VELO_LIMIT[n] (max. gear stage speed).
The machine data index is coded as follows:
[control parameter block No.]: 0 - 5
For the activation of the control parameter records, please refer to:
References: Section Velocities, Setpoint/Actual - Value Systems, Closed - Loop Control

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

2-41

Axis Monitoring (A3)


2.6

Data descriptions (MD, SD)

36300
ENC_FREQ_LIMIT[0]
MD number
Encoder limit frequency
Default: 300000
Min. input limit: 0.0
Max. input limit: ***
Change valid after Power On
Protection level: 2/2
Unit: Hz
Data type: DOUBLE
Valid from SW release:
Meaning:
This MD is used to specify the encoder limit frequency.

Related to ....

The active encoder is defined via the IS Position measuring system 1 (V380x0001.5).
MD 36302: ENC_FREQ_LIMIT_LOW

36310
ENC_ZERO_MONITORING[0]
MD number
Zero mark monitoring
Default: 0
Min. input limit: 0
Max. input limit: ***
Change valid after NEW_CONF
Protection level: 2/2
Unit: Data type: DWORD
Valid from SW release:
Meaning:
This machine data is used to activate the zero reference mark monitoring and to define the number of illegal zero reference mark errors.
0:
Zero mark monitoring OFF, encoder HW monitoring ON
1 - 99, > 100: Number of detected zero mark errors at which the monitoring is to respond
100:
Zero mark monitoring OFF, encoder HW monitoring OFF
Examples:
MD value = 1: The monitoring will respond at the 1st error.
MD value = 2: The 1st error is tolerated. The monitoring will respond at the 2nd error.
MD value = 3: The 1st and 2nd errors are tolerated. At the 3rd error, the monitoring will respond.
After turning on the encoder, the error count will always start from zero.
Special cases, errors, ...... For absolute encoders, the zero mark monitoring must be disabled with the value = 0!

36400
CONTOUR_TOL
MD number
Contour monitoring tolerance band
Default: 1.0
Min. input limit: 0.0
Max. input limit: ***
Change valid after NEW_CONF
Protection level: 2/2
Unit: mm; degrees
Data type: DOUBLE
Valid from SW release:
Meaning:
The tolerance band for maximum contour deviation.
The admissible deviation between the real and the expected actual value is entered in this MD.
The input of a tolerance band is intended to avoid false trippings of the contour monitoring due to
slight speed variations resulting from process - related control operations (e.g. on first cut).
This MD has to be adapted to the position controller gain and, in case of feedforward control, to
the accuracy of the line motion model MD 32810: EQUIV_SPEEDCTRL_TIME (equivalent time
constant for feedforward control of speed control loop) and to the permissible accelerations and
velocities.
Further references
see Section 2.2.1

36600
BRAKE_MODE_CHOICE
MD number
Braking behavior with hardware limit switch
Default: 1
Min. input limit: 0
Max. input limit: 1
Change valid after Power On
Protection level: 2/2
Unit: Data type: BYTE
Valid from SW release:
Meaning:
If with a traversing axis a rising edge of the axis - specific hardware switch is detected, the axis is
decelerated immediately.
The deceleration mode is set in the machine data:
0:

Related to ....

2-42

Controlled braking according to the acceleration ramp defined by


MD 32300: MAX_AX_ACCEL (axis acceleration).
1:
Rapid deceleration (specification of setpoint = 0) with reduction of the following error
IS Hardware limit switch plus or minus (V380x1000.1 or V380x1000.0)

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

Axis Monitoring (A3)


2.6

36610
MD number
Default: 0.05

Data descriptions (MD, SD)

AX_EMERGENCY_STOP_TIME
Duration of brake ramp in case of errors
Min. input limit: 0.02

Max. input limit: 1000

Change valid after NEW_CONF


Protection level: 2/2
Unit: s
Data type: DOUBLE
Valid from SW release:
Meaning:
For axis: The axis concerned is stopped with rapid stop (with open position control loop) via a
brake ramp of the speed setpoint if the monitoring functions listed below respond:
 EMERGENCY STOP
 Following error monitoring
 Positioning monitoring
 Zero- speed control
 Clamping monitoring
 Set speed monitoring
 Actual velocity monitoring
 Encoder limit frequency monitoring (except for speed - controlled spindles)
 Zero mark monitoring
 Contur tunnel monitoring
If the encoder limit frequency is exceeded, the speed setpoint is displayed in the NC basic
screen as an actual value.
Enter the time needed to reduce the speed setpoint from the maximum speed setpoint to setpoint = 0 in MD 36610. The time until standstill depends on the current speed setpoint if a monitoring function responds.

Speed setpoint
MD 36210:
CTRLOUT_LIMIT
e.g. current
speed setpoint

Current time until


axis standstill

t [s]

Check MD 36610:
AX_EMERGENCY_STOP_TIME
Fig. 4 - 1 Braking ramp in case of errors

Meaning:

Related to ....

For spindle: With spindles without active position control, the speed - controlled spindle may go
on rotating if the encoder frequency monitoring responds (i.e. without valid actual value information); rapid stop is not carried out. If the encoder is turned on, the speed setpoint monitoring is
active, but the actual - velocity monitoring (MD 36200) is active. The limiting of the spindle speed
has only a limiting effect (no alarm), the setpoint is limited to the max. chuck speed (MD 35100)
and displayed in the IS Programmed speed too high.
The current speed is no longer displayed, since no valid actual value exists at this moment.
With interpolating axes, it is not guaranteed that the contour is not violated during the brake
phase.
CAUTION: If you have set the time of the brake ramp in errored states too much, servo enable
will be canceled even if the axis/spindle is still traversing/rotating. It will then suddenly be stopped with speed setpoint 0. Thats why the time in MD 36610:
AX_EMERGENCY_STOP_TIME should be less than the time in MD 36620:
SERVO_DISABLE_DELAY_TIME (servo disable delay time).
MD 36620: SERVO_DISABLE_DELAY_TIME Servo disable delay time
MD 36210: CTRLOUT_LIMIT
Max. speed setpoint

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

2-43

Axis Monitoring (A3)


2.6

2.6.3

Data descriptions (MD, SD)

Axis/spindle - specific setting data

43400
SD number
Default: 0
Change valid: immediately
Data type: BOOLEAN
Meaning:

SD inapplicable to ......

43410
SD number
Default: 0
Change valid: immediately
Data type: BOOLEAN
Meaning:

SD inapplicable to ......

43420
SD number
Default: 100 000 000
Change valid: immediately
Data type: DOUBLE
Meaning:

SD inapplicable to ......
Related to ....

43430
SD number
Default: - 100 000 000
Change valid: immediately
Data type: DOUBLE
Meaning:

SD inapplicable to ......
Related to ....

2-44

WORKAREA_PLUS_ENABLE
Working area limitation in the positive direction active
Min. input limit: 0
Max. input limit: 1
Protection level: 7/7
Unit: Valid from SW release:
0: The working area limitation of the axis in the positive direction is disabled.
1: The working area limitation of the axis in the positive direction is active.
The parameterization of the setting data is carried out from the operator panel in the Parameters operating area by enabling/disabling the working area limitation.
G code: WALIMOF

WORKAREA_MINUS_ENABLE
Working area limitation in the negative direction active
Min. input limit: 0
Max. input limit: 1
Protection level: 7/7
Unit: Valid from SW release:
0: The working area limitation of the axis in the negative direction is disabled.
1: The working area limitation of the axis in the negative direction is active.
The parameterization of the setting data is carried out from the operator panel in the Parameters operating area by enabling/disabling the working area limitation.
G code: WALIMOF

WORKAREA_LIMIT_PLUS

Working area limitation plus


Min. input limit: ***
Max. input limit: ***
Protection level: 7/7
Unit: mm, degrees
Valid from SW release:
The working area limitation can be used to limit the working area of the MCS (machine coordinate system) in the positive direction of the corresponding axis.
The setting data can be modified from the operator panel in the Parameters operating area.
The positive working area limitation can be modified in the program using G26.
G code: WALIMOF
SD 43400: WORKAREA_PLUS_ENABLE

WORKAREA_LIMIT_MINUS
Working area limiting minus
Min. input limit: ***
Max. input limit: ***
Protection level: 7/7
Unit: mm, degrees
Valid from SW release:
The working area limitation can be used to limit the working area in the MCS (machine coordinate system) in the negative direction of the corresponding axis.
The setting data can be modified from the operator panel in the Parameters operating area.
The negative working area limitation can be modified in the program using G25.
G code: WALIMOF
SD 43410: WORKAREA_MINUS_ENABLE

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

Axis Monitoring (A3)


2.7

2.7

Signal description

Signal description

2.7.1

Axis/spindle - specific signals

Signals to axis (V380x....)

x=0 - > axis 1,


x=1 - >axis 2, ...

.
Axis 3
Axis 2
Axis 1

.
Signals from axis (V390x....)

x=0 - > axis 1,


x=1 - >axis 2, ...

Clamping process running (V380x0002.3)


Hardware limit switch plus (V380x1000.1)
Hardware limit switch minus (V380x1000.0)

Axis
monitoring
functions

Encoder limit frequency


exceeded 1 (V390x0000.2)

2nd software limit switch plus


(V380x1000.3)
2nd software limit switch minus
(V380x1000.2)
Fig. 2-5

PLC interface signals for axis monitoring functions

Signals to axis/spindle
V380x0002.3

Clamping process running

Data block
Edge evaluation: no
Signal state 1 or edge
change 0 - - - > 1.
Signal state 0 or edge
change 1 - - - > 0
Related to ....
Further references

Signal(s) to axis/spindle (PLC - - - > NCK)


Signal(s) updated: cyclically
Signal(s) valid from SW release:
Clamping process running.
The clamping monitoring is activated.
Camping process completed.
The clamping monitoring is replaced by zero - speed control.
MD 36050: CLAMP_POS_TOL (clamping position tolerance)
Section 2.2.4

V380x0003.6

Velocity/spindle speed limitation

Data block
Edge evaluation: no
Signal state 1 or edge
change 0 - - - > 1
Signal state 0 or edge
change 1 - - - > 0
Related to ....

Signal(s)
Signal(s) updated: cyclically
Signal(s) valid from SW release:
The NCK limits the velocity/spindle speed to the limit value specified in MD 35160:
SPIND_EXTERN_VELO_LIMIT.
No limitation active.
MD 35100: SPIND_VELO_LIMIT (max. spindle speed)
SD 43220: SPIND_MAX_VELO_G26 (progr. spindle speed limiting G26)
SD 43230: SPIND_MAX_VELO_LIMIT (progr. spindle speed limiting G96)

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

2-45

Axis Monitoring (A3)


2.7

Signal description

V380x1000.1 and .0

Hardware limit switch plus or minus

Data block
Edge evaluation: no
Signal state 1 or edge
change 0 - - - > 1

Signal(s) to axis/spindle (PLC - - - > NCK)


Signal(s) updated: cyclically
Signal(s) valid from SW release:
One switch each can be installed at the end of both sides of the traversing range of a machine
axis, which provides a signal Hardware limit switch plus or minus to the NC via the PLC when
approaching the position.
If the signal is detected set, alarm 021614 Hardware limit switch + or - is output and the axis is
decelerated immediately. How the axis is decelerated is defined by
MD 36600: BRAKE_MODE_CHOICE (braking behavior with hardware limit switch).
Normal state, no HW limit switch responded.

Signal state 0 or edge


change 1 - - - > 0
Related to ....

MD 36600: BRAKE_MODE_CHOICE (braking behavior with hardware limit switch)

V380x1000.3 or .2

2nd software limit switch plus or minus

Data block
Edge evaluation: no
Signal state 1 or edge
change 0 - - - > 1

Signal(s) to axis/spindle (PLC - - - > NCK)


Signal(s) updated: cyclically
Signal(s) valid from SW release:
2nd software limit switch is active for the plus and/or minus direction.
1st software limit switch is inactive for the plus or minus direction.
In addition to the 1st software limit switches (plus and/or minus), 2nd software limit switches
(plus and/or minus) can be activated via the interface signals.
The position is defined by MD 36130: POS_LIMIT_PLUS, MD 36120:
POS_LIMIT_MINUS2 (2nd software limit switch plus, 2nd software limit switch minus).
1st software limit switch is active for the plus and/or minus direction
2nd software limit switch is inactive for the plus and/or minus direction.
MD 36110: POS_LIMIT_PLUS, MD 36130: POS_LIMIT_PLUS,
MD 36100: POS_LIMIT_MINUS, MD 36120: POS_LIMIT_MINUS2, (software limit switch plus,
software limit switch minus)

Signal state 0 or edge


change 1 - - - > 0
Related to ....

Signals from axis/spindle


V390x0000.2

Encoder frequency exceeded 1

Data block
Edge evaluation: no
Signal state 1 or edge
change 0 - - - > 1

Signal(s) from axis/spindle (NCK - - - > PLC)


Signal(s) updated: cyclically
Signal(s) valid from SW release:
The limit frequency set in MD 36300: ENC_FREQ_LIMIT (encoder limit frequency) has been
exceeded. The reference point for the position encoder has got lost (IS:
Referenced/synchronized has signal state 0). No position control is possible any more. The
spindles go on running with speed control.
The axes are stopped with rapid stop (with open position control loop) via a speed setpoint ramp.
The limit frequency set in MD 36300: ENC_FREQ_LIMIT is no longer exceeded (encoder
frequency).
For the edge change 1 - - > 0, the encoder frequency must have undershot the value
defined in MD 36302: ENC_FREQ_LIMIT_LOW (percentage value of MD 36300:
ENC_FREQU_LIMIT).

Signal state 0 or edge


change 1 - - - > 0

2-46

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

Axis Monitoring (A3)


2.8

2.8
2.8.1

Data fields, lists

Data fields, lists


Axis/spindle - specific interface signals

Number

.Bit

Name

Ref.

Axis/spindle- specific
V380x0001

.5

Position encoder 1

V380x0002

.3

Clamping process running

V380x0003

.6

Velocity/spindle speed limitation

V380x1000

.0 / .1

Hardware limit switch minus / hardware limit switch plus

V380x1000

.2 / .3

2nd software limit switch minus / 2nd software limit switch plus

V390x0000

.2

Encoder limit frequency exceeded 1

V390x0000

.4

Referenced/synchronized 1

2.8.2

A2

R1

Axis/spindle - specific machine data

Number

Identifier

Name

Ref.

Axis/spindle specific ($MA_ ... )


30310

ROT_IS_MODULO

Modulo conversion for rotary axis and spindle

R2

32000

MAX_AX_VELO

Maximum axis velocity

G2

32200

POSTCTRL_GAIN[n]

Servo gain factor (kv factor)

G2

32250

RATED_OUTVAL

Rated output voltage

G2

32260

RATED_VELO

Rated motor speed

G2

32300

MAX_AX_ACCEL

Axis acceleration

B2

32810

EQUIV_SPEEDCTRL_TIME[n]

Speed control loop equivalent time constant for


feedforward control

K3

35160

SPIND_EXTERN_VELO_LIMIT

Spindle speed limiting from PLC

S1

36000

STOP_LIMIT_COARSE

Exact stop coarse

36010

STOP_LIMIT_FINE

Exact stop fine

36020

POSITIONING_TIME

Exact stop fine delay time

36030

STANDSTILL_POS_TOL

Standstill position tolerance

36040

STANDSTILL_DELAY_TIME

Standstill monitoring delay time

36050

CLAMP_POS_TOL

Clamping position tolerance at IS Clamping


running

36060

STANDSTILL_VELO_TOL

Max. velocity/speed Axis/spindle at a standstill

36100

POS_LIMIT_MINUS

1st software limit switch minus

36110

POS_LIMIT_PLUS

1st software limit switch plus

36120

POS_LIMIT_MINUS

2nd software limit switch minus

36130

POS_LIMIT_PLUS

2nd software limit switch plus

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

2-47

Axis Monitoring (A3)


2.8

Data fields, lists

Number

Identifier

Name

36200

AX_VELO_LIMIT[n]

Threshold value for velocity monitoring

36210

CTRLOUT_LIMIT[n]

Max. speed setpoint

36300

ENC_FREQ_LIMIT[n]

Encoder limit frequency

36302

ENC_FREQ_LIMIT_LOW

Encoder limit frequency resynchronization

36310

ENC_ZERO_MONITORING[n]

Zero mark monitoring

36400

CONTOUR_TOL

Tolerance band for contour monitoring

36500

ENC_CHANGE_TOL

Large backlash values/


maximum tolerance at actual position value
switchover

36600

BRAKE_MODE_CHOICE

Braking behavior with hardware limit switch

36610

AX_EMERGENCY_STOP_TIME

Duration of brake ramp in case of errors

36620

SERVO_DISABLE_DELAY_TIME

Servo disable delay time

2.8.3

Ref.

G2

R1

K3

N2

Channel - specific machine data

Number

Identifier

Name

Ref.

Channel- specific ($MC_ ... )


21020

2.8.4
Number

WORKAREA_WITH_TOOL_RADIUS

Taking into account the tool radius with working


area limitation

Axis/spindle - specific setting data


Identifier

Name

Ref.

Axis/spindle- specific ($SA_ ... )


43400

WORKAREA_PLUS_ENABLE

Working area limitation in the positive direction is


active

43410

WORKAREA_MINUS_ENABLE

Working area limitation in the negative direction


is active

43420

WORKAREA_LIMIT_PLUS

Working area limitation plus

43430

WORKAREA_LIMIT_MINUS

Working area limitation minus

2-48

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

Velocities, Setpoint/Actual - Value Systems,


Closed - Loop Control (G2)

Note
The following machine data are not available with the 802D base line:

 MD 10200
 MD 10210
 MD 37600.
The machine data setting options described in the following do not apply to the 802D
base line.

3.1
3.1.1

Velocities, traversing ranges, accuracies


Velocities
The maximum path, axis velocity and spindle speed depend on the machine design, the dimensioning of the drive dynamics and the limit frequency of the actual-value acquisition (encoder limit frequency).
The maximum axis velocity is defined in MD 32000: MAX_AX_VELO (maximum axis velocity).
The maximum permissible spindle speed is preset using MD 35100: SPIND_VELO_LIMIT
(maximum spindle speed).
References:
Chapter Spindle
In addition to the limitation by MD 32000: MAX_AX_VELO, the control system limits the maximum path velocity acc. to the formula below, depending on the particular situation:
Vmax 

progr. path length in a part programblock [mm or degrees]


* 0.9
IPOcycle [s]

In case the feed is higher (resulting from a feed programmed higher or due to feed override), it
is limited to Vmax.
With programs generated using CAD programs that contain extremely short blocks, this may
result in speed/velocity reduction over several blocks.

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

3-49

Velocities, Setpoint/Actual-Value Systems, Closed-Loop Control (G2)


3.1

Velocities, traversing ranges, accuracies

Example:
IPO cycle = 12 ms
N10 G0 X0 Y0; [mm]
N20 G0 X100 Y100; [mm]
programmed path length in the block = 141.42 mm
% Vmax = (141.42 mm / 12 ms) * 0.9 = 10606.6 mm/s = 636.39 m/min

The minimum path or axis velocitiy is subject to the following limitation:


Vmin 

10 3
Computational resolution[mm orIncr.
] * IPOcycle [s]
degrees

The computational resolution is defined in MD 10200: INT_INCR_PER_MM (computational


resolution for linear positions) or MD 10210: INT_INCR_PER_DEG (computational resolution
for angle positions). It is described on the following pages in detail.
If Vmin is undershot, no traversing movement is carried out.
Example:

MD 10200: INT_INCR_PER_MM = 1000 [Incr. / mm] ;


IPO clock = 12 ms;
Vmin = 10 - 3 / (1000 Incr/mm x 12 ms) = 0.005 mm / min;

The range of feed values is dependent on the computational resolution selected. If the default
setting has been chosen for MD 10200: INT_INCR_PER_MM (computational resolution for
linear positions) (1,000 incr./mm) or MD 10210: INT_INCR_PER_DEG (computational resolution for angle positions) (1,000 incr./degree), the range of values can be programmed with the
resolution specified:
Range of values for feedrate F:
Metric system:
0.001 F 999,999.999 [mm/min, mm/rev., degrees/min, degrees/rev.]
Range of values for spindle speed S:
0.001 S 999,999.999 [rpm]
If the computational resolution is increased/reduced by factor 10, the ranges of values will
change accordingly.

3.1.2

Traversing ranges
The ranges of values of the traversing ranges is dependent on the computational resolution
selected.
If the default setting has been selected for MD 10200: INT_INCR_PER_MM (computational
resolution for linear positions) (1,000 incr./mm) and/or MD 10210: INT_INCR_PER_DEG
(computational resolution for angle positions) (1,000 incr./degree), the range of values can be
programmed with the resolution specified:

3-50

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Velocities, Setpoint/Actual-Value Systems, Closed-Loop Control (G2)


3.1

Table 3-1

Velocities, traversing ranges, accuracies

Traversing ranges of the axes


G71 [mm, degrees]

G70 [inch, degrees]

Range

Range

Linear axes X, Y, Z, ...

999,999.999

399,999.999

Rotary axes A, B, C, ...

999,999.999

999,999.999

Interpolation parameters I, J, K

999,999.999

399,999.999

Rotary axes are always specified in degrees.


If the computational resolution is increased/reduced by factor 10, the ranges of values will
change accordingly.
The traversing range can be limited using SW limit switches and work areas.
References:
Section Axis Monitoring Functions
The traversing range for rotary axes can be limited using machine data.
References:
Section Rotary Axes

3.1.3

Input/display resolution, computational resolution


The resolutions of linear and angle positions, velocities, accelerations and jerk differ by:


the input resolution, i.e. the input of data from the operator panel or via the part programs.

the display resolution, i.e. the display of data on the operator panel.

the computational resolution, i.e. the internal of the data input via the operator panel or the
part program.

The input and display resolution is determined by the operator panel used (display of machine
data), whereas the display resolution for position values/spindle speed can be modified using
MD 203: DISPLAY_RESOLUTION (display resolution, metric linear position, angle position
general) and/or MD 205: DISPLAY_RESOLUTION_SPINDLE (display resolution for spindle
speed).
MD 204: DISPLAY_RESOLUTION_INCH can be used to configure the display resolution for
linear position values with inch setting.
For programming in part programs, the input resolutions indicated in the Programming Instructions will apply.
The desired computational resolution is defined using the MD 10200: INT_INCR_PER_MM
(computational resolution for linear positions) and MD 10210: INT_INCR_PER_ DEG (computational resolution for angle positions). It is independent of the input/display resolution, but
should have at least the same resolution.
The computational resolution defines the maximum number of the active places after the decimal point for position values, speed values etc. in the part program, as well as the number of
places after the decimal point for tool compensations, zero offsets etc. (and with it the maximum accuracy that can be obtained).

SINUMERIK 802D, 802D base line


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3.1

Velocities, traversing ranges, accuracies

The input accuracy of angle and linear positions is limited to the computational resolution by
rounding the product of the programmed value with the computational resolution to an integer
number.
In order to ensure that the executed rounding can easily be traced, it is recommended to use
numbers raised to the power of 10 for the computational resolution.
Example of rounding:
Computational resolution : 1,000 increments / mm
Programmed path : 97.3786 mm
active value = 97.379 mm

3.1.4

Standardization of physical quantities of machine and setting data


Machine and setting data that have a physical quantity are interpreted by default with the following input/output units, depending on the basic scaling system used (metric/inch):
Physical unit:

3-52

Input/output
units for standard
scaling system:
Metric

Inch

Linear position

1 mm

1 inch

Angular position

1 degree

1 degree

Linear velocity

1 mm/min

1 inch/min

Angular velocity

1 rpm

1 rpm

Linear acceleration

1 m/s2

1 inch/s2

Angular acceleration

1 rev./s2

1 rev./s2

Linear jerk

m/s3

1 inch/s3

Angular jerk

1 rev./s3

1 rev./s3

Time

1s

1s

Position controller servo gain

1/s

1/s

Revolutional feed

1 mm/rev.

1 inch/rev.

Compensation value of linear position

1 mm

1 inch

Compensation value of angle position

1 degree

1 degree

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Velocities, Setpoint/Actual-Value Systems, Closed-Loop Control (G2)


3.2

3.2

Metric/inch scaling system

Metric/inch scaling system


The control system can use either the inch or the metric scaling system. The default setting is
determined using MD 10240: SCALING_SYSTEM_IS_METRIC (default scaling system: metric). Depending on this setting, all geometric values are interpreted either as metric or inch
dimensions. All manual settings, zero offset settings, tool compensation values, etc. with the
related displays also refer to this initial setting (e.g. handwheel, INC, conventional feed).
The setting MD 10260: CONVERT_SCALING_SYSTEM=1 makes the switching of the scaling
system considerably easier:

3.2.1

Availability of an MMC softkey for scaling system switchover.

Automatic conversion of NC active data in the case of scaling system switchover;

Data back-up with identification of the scaling system currently used;

MD 10240: SCALING_SYSTEM_IS_METRIC is activated by Reset.

Conversion of the scaling system using the part program


For certain workpiece-related data, it is possible to switchover between the scaling systems
using G70/G71 and G700/G710. The data that can be influenced by G70/G71/G700/G710 are
described in the Programming Instructions.
When the scaling system is switched over using the appropriate MMC softkey, these reset
positions are defaulted with G700 or G710, depending on the new scaling system.
Application:
This function can be used, e.g. with a metric scaling system to machine an inch thread in a
metric part program. Tool offsets, zero offsets and feeds remain metric.
Machine data are output on the screen in the scaling system selected using the MD 10240:
SCALING_SYSTEM_IS_METRIC (metric scaling system).
Any displays in the machine coordinate system, as well as displays of the tool data and zero
offsets are carried out in the default setting, displays in the workpiece coordinate system with
the current setting.
Note:
If programs, incl. data records (ZO, tool offset) are read in from an external source, which
have been programmed in a scaling system other from the inital system, first the inital setting
must be changed using MD 10240: SCALING_SYSTEM_IS_METRIC.
For interface signals that contain dimension-dependent information, such as feed for path and
positioning axes, the data exchange with the PLC is always carried out using the selected
default system.
G700/G710 is to be considered an extension of G70/G71 by the following functionality:
1. The feed is interpreted in the programmed scaling system:


G700: Length information [inch]; feeds [inch/min]

G710: Length information [mm]; feeds [mm/min]


The programmed feedrate acts modally, i.e. remains active beyond any following
G70/G71/G700/G710. If you wish the feedrate to become active in the new
G70/G71/G700/G710 context, it must be reprogrammed.

SINUMERIK 802D, 802D base line


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Velocities, Setpoint/Actual-Value Systems, Closed-Loop Control (G2)


3.2

Metric/inch scaling system

2. Reading and writing of length-related system variables and machine data in the part program is carried out in the scaling system programmed.
These properties can be used to realize part programs that are independent of the current
basic setting of the scaling system.
Comparison of the effects of G70 and G700 on machine data and system variables in the part
program:


G70: is used for reading and writing in the scaling system.

G70: is used for reading and writing in programmed scaling system

Comparison of G70/G71-G700/G710
Meaning:
P:
G:

Table 3-2

Reading/writing of data are carried out in the programmed scaling system


Reading/writing of data are carried out in the initial scaling system
(MD 10240: SCALING_SYSTEM_IS_METRIC) R/W:
Read/Write
Comparison
Range

3-54

G70/G71

G700/G710

Part program

Part program

Displays, digits after the comma (WCS)

P/P

P/P

Displays, digits after the comma (MCS)

G/G

G/G

Feedrates

G/G

P/P

Positional data X, Y, Z

P/P

P/P

Interpolation parameters I, J, K

P/P

P/P

Circle radius (CR)

P/P

P/P

Polar radius (RP)

P/P

P/P

Thread lead/pitch

P/P

P/P

Programmable offset rotation

P/P

P/P

Settable offset G54, G55, etc.

G/G

P/P

Working area limitations (G25/G26)

G/G

P/P

Tool offsets

G/G

P/P

Length-related machine data

G/G

P/P

Length-related setting data

G/G

P/P

Length-related system variables

G/G

P/P

R parameters

G/G

G/G

Siemens cycles

P/P

P/P

Increment weighting JOG/handwheel

G/G

G/G

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Velocities, Setpoint/Actual-Value Systems, Closed-Loop Control (G2)


3.2

3.2.2

Metric/inch scaling system

Switching over the scaling system manually

General
The scaling system switchover for the whole machine is carried out using an MMC softkey
Switch to mm > inch and Switch to inch > mm in the POSITION area.
Access to this softkey is only granted in JOG or MDA mode. The switchover will only be accepted if:


The channel is in the Reset status.

The axes are not traversed.

For the duration of the switchover operation, actions, such as part program start or mode
change, are disabled.
If no switchover can be carried out, an appropriate message will appear on the user interface.
This definition ensures that the program currently executed always finds a consistent data set
with reference to the scaling system.
The actual process of switching over to the scaling system is internally carried out by writing
of all required machine data and then activating them by RESET.
MD 10240: SCALING_SYSTEM_IS_METRIC and the corresponding settings
G70/G71/G700/G710 in MD 20150: GCODE_RESET_VALUES are switched over for all
channels configured automatically. Note: MD 20150 can only be read/written in expert mode
(protection level 1).
During this process, the value specified in MD 20150: GCODE_RESET_VALUES[12]
changes between G700 and G710, i.e. the default position of the G commands changes between G700 and G710.
This process is carried out independently of the protection level currently set.

System data
When switching over the scaling system, from the view of the operator, all length-related data
are automatically converted to the new scaling system. These data include:


Positions

Feedrates

Accelerations

Jerk

Tool offsets

Compensation values

Machine data

Jog and handwheel weightings

After switchover, all a/m data will be available in the physical quantities according to Section
3.1.4.
Data for which no unambiguous physical quantities are defined, such as:


R parameters

will not be included in the automatic conversion. This is the users task to take into account
the scaling system currently active (MD 10240: SCALING_SYSTEM_IS_METRIC).

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

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Velocities, Setpoint/Actual-Value Systems, Closed-Loop Control (G2)


3.2

Metric/inch scaling system

The scaling system setting currently active can be read from the PLC interface using the signal Inch scaling system V27000001.7.

Reference point
The reference point remains stored. Re-referencing is not necessary.

Input and computational resolution


The input/computational resolution is set in the control system using
MD 10200: INT_INCR_PER_MM. The default setting for a metric system is 1,000 (0.001 mm).
For an inch system, the setting must be 0.0001.
Example:
1 inch = 25.4 mm % 0.0001 inch = 0.00254 mm = 2.54 mm
To be able to program and display the last 40 nm, a value of 100,000 must be entered in MD
10200.
Only this setting, which must be the same for both scaling systems, scaling system switchover
actions can be carried out without substantial losses in accuracy. If you have done this setting
once, the MD 10200 need not to be changed with each scaling system switchover.

Jog and incremental weighting


The MD 31090: JOG_INCR_WEIGHT consists of two values containing the axis-specific increment weightings for each of the two unit systems. The control system automatically selects
the matching value, depending on the current setting in MD 10240: SCALING_SYSTEM_IS_METRIC.
Note: The MD 31090: JOG_INCR_WEIGHT can only be read/writtten in the Expert mode
access level (protection level 1).


Metric: MD 31090: JOG_INCR_WEIGHT[0;AX1]=0.001 mm

Inch: MD 31090: JOG_INCR_WEIGHT[1;AX1]=0.00254 mm 0.0001 inch

Data back-up
Data records that can be read from the control system separately and that have scaling system relevant data, are assigned an inch and/or metric ID on reading, which corresponds to
MD 10240: SCALING_SYSTEM_IS_METRIC. This will save from which scaling system the
data have origininally been read.
This information is used to avoid that data records with a scaling system setting other than
currently set are re-read into the control system. In such a case, an appropriate alarm is provided (15030) and the writing process is aborted.
Since the language statement is also evaluated in part programs, these can also be protected against maloperation in the above mentioned manner. Thus it can be prevented that part
programs that, e.g. contain only metric data, can be run in an inch scaling system.

3-56

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Velocities, Setpoint/Actual-Value Systems, Closed-Loop Control (G2)


3.3

3.3
3.3.1

Setpoint/actual -value system

Setpoint/actual-value system
General

Block diagram
A servo loop with the following structure can be configured for each controlled axis/spindle:

Closedloop
control

Speed setpoint
output

Motor

Speed setpoint

M
assignment

IS Position measuring system 1

MD 30130:
CTRLOUT_TYPE=0 (SIMULATION)
MD 30240:
ENC_TYPE=0 (SIMULATION)

Actual- value
processing

Fig. 3-1

Actualvalue
assignment

Encoder
G

Block diagram of a closed -loop control circuit

Setpoint output
One setpoint each per axis/spindle can be output. The setpoint output to the actuator is provided either digitally or, with an analog spindle 10 V unidirectionally/bidirectionally.

Simulation axes
For testing purposes, it is possible to simulate the speed control loop of an axis. In this case,
the axis will traverse with a following error, similar to a real axis.
A simulation axis is defined by setting the two MD 30130: CTRLOUT_TYPE[n] (setpoint output type) and MD 30240: ENC_TYPE[n] (actual-value output type) to 0.
After loading the standard machine data, the axes are set to simulation.
With reference point approach, setpoint and actual value can be set to the reference point
value.
MD 30350: SIMU_AX_VDI_OUTPUT (output of axis signals with simulation axes) can be
used to define whether the axis-specific IS are output to the PLC during the simulation.

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6FC5 697-2AA10-0BP2 (11.03) (DF)

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Velocities, Setpoint/Actual-Value Systems, Closed-Loop Control (G2)


3.3

3.3.2

Setpoint/actual -value system

Drives connected to Profibus DP

General
The I/O devices connected to Profibus DP (e.g. SIMODRIVE 611-UE drives, I/O modules) are
accessible through DP slave. A DP slave is a profibus node that has a PROFIBUS address
(PB address) and is loaded with values which is supplied by a master (in this case the SINUMERIK 802D).

SINUMERIK 802D
DP master

Profibus-DP
DP slave:
Basic
device
unit

Drive
A

PB address12
Drive
B

SIMODRIVE 611 universal E


Fig. 3-2

DP slave:

PB address 3

72E 48A

I/O module (digital)

Principle of a Profibus configuration with drive 611UE (double-axis power section: drives A and B) and
I/O module

Drive configuration for SINUMERIK 802D with Profibus DP


A ready-to-use system data block is provided for the SINUMERIK 802D. This data block allows to select a certain configuration of the SIMODRIVE 611UE drives and I/O modules using
MD 11240: PROFIBUS_SDB_NUMBER.
For the entire range of options, please refer to the detailed machine data description in the
Section Data Description.
The following numbers are assigned to the drives in accordance with the PB addresses and
the axis power section type (single- or double axis type) :
PB addr.10
->drive number 5
PB addr.12 (drive A)
->drive number 1
PB addr.12 (drive B)
->drive number 2
PB addr.13 (drive A)
->drive number 3
PB addr.13 (drive B)
->drive number 4
This drive number allows the assignment of the machine axis to the corresponding drive (refer
to the next Section Speed Setpoint and Actual-Value Assignment

Note
With double -axis power sections, both drives (A and B) must always be assigned to one axis.
Otherwise, during power -up, an error message will occur, and the entire power section will not be
ready. If you wish to connect only one axis, the drive must be reparameterized.

3-58

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Velocities, Setpoint/Actual-Value Systems, Closed-Loop Control (G2)


3.3

Setpoint/actual -value system

MD 13060: DRIVE_TELEGRAM_TYPE[n] is used to set the default message type for the
communication with any drive. When using the SIMODRIVE 611UE drive as a digital axis
drive, the required value = 102 is already set (default value).
For a drive operating as a spindle control, other settings may be required:
MD value = 0:
for an additional analog spindle control on the drive
MD value = 104: for a digital spindle with direct position encoder
For a digital sindle with motor measuring system, MD value = 102 will apply.
Example of a digital drive (axis or spindle):
Drive number 1 ->
MD 13060: DRIVE_TELEGRAM_TYPE[0] = 102
Drive number 2 ->
MD 13060: DRIVE_TELEGRAM_TYPE[1] = 102
Drive number 3 ->
MD 13060: DRIVE_TELEGRAM_TYPE[2] = 102
etc.
The drive parameterization is carried out as follows:
-

on the display and control unit at the SIMODRIVE 611-UE

using the parameterization and start-up tool SimoCom U

To do so, you will need the following documentation:


Description of Functions SIMODRIVE 611 UE

3.3.3

Speed setpoint and actual- value assignment

Prerequisites for the assignment


All NC machine data must be defined unambiguously in
MD 10000: AXCONF_MACHAX_NAME_TAB[n] (machine axis name). This name must be
defined unambiguously for the entire system.

Note
If you wish to use an analog spindle (instead of a digital one) in conjunction with the SIMODRIVE 611UE drive, some additional notes must be observed. Please refer to the Chapter
Spindle.

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

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Velocities, Setpoint/Actual-Value Systems, Closed-Loop Control (G2)


3.3

Setpoint/actual -value system

Speed setpoint assignment


The speed setpoint assignment is shown in the illustration below; the parameterization of the
corresponding machine data is described in the following:

Example:

Profibus DP

X1 axis = machine axis1:


Y1 axis = machine axis2:
Z1 axis = machine axis3:
SP spindle = machine axis5:
A1 axis = machine axis4:

CTRLOUT_MODULE_NR = 1
CTRLOUT_MODULE_NR = 2
CTRLOUT_MODULE_NR = 3
CTRLOUT_MODULE_NR = 5
CTRLOUT_MODULE_NR = 4

- >drive
- >drive
- >drive
- >drive
- >drive

number 1
number 2
number 3
number 5
number 4

Drive No. 4

(PB address 13)

Drive No. 3

Drive No.2

(PB address 12)

Drive No. 1

(PB address 10)

Drive No. 5

SINUMERIK
802D

Example:
Single- and 2x double-axis power section SIMODRIVE 611UE
(MD 11240:
PROFIBUS_SDB_NUMBER = 4)

Single-axis
power section
Fig. 3-3

Setpoint output

Double -axis
power section

Double -axis
power section

Speed setpoint assignment, example

Parameterize the following machine data of each machine axis:

3-60

MD 30110: CTRLOUT_MODULE_NR[0]: Assignment of drive number

MD 30130: CTRLOUT_TYPE[0] (setpoint output type): Enter here the type of the speed
setpoint output.

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Velocities, Setpoint/Actual-Value Systems, Closed-Loop Control (G2)


3.3

Setpoint/actual -value system

Actual -value assignment


Due to the fixed assignment of the encoder (measuring system) to the drive, the actual value
assignment must be carried out identically to the speed setpoint assignment (same drive number).
The actual-value assignment is shown in the illustration below. The parameters are described
in the corresponding machine data:

Example:

Profibus DP

X1 axis = machine axis1:


Y1 axis = machine axis2:
Z1 axis = machine axis3:
SP spindle = machine axis5:
A1 axis = machine axis4:

CTRLOUT_MODULE_NR = 1
CTRLOUT_MODULE_NR = 2
CTRLOUT_MODULE_NR = 3
CTRLOUT_MODULE_NR = 5
CTRLOUT_MODULE_NR = 4

- >drive
- >drive
- >drive
- >drive
- >drive

number 1
number 2
number 3
number 5
number 4

Drive No. 4

(PB address 13)

Drive No. 3

Drive No.2

(PB address 12)

Drive No. 1

(PB address 10)

Drive No. 5

SINUMERIK
802D

Example:
Single- and 2x double-axis power section SIMODRIVE 611UE
(MD 11240:
PROFIBUS_SDB_NUMBER = 4)

Single-axis
power section
Fig. 3-4

Setpoint output

Double -axis
power section

Double -axis
power section

Actual value assignment, example

Parameterize the following machine data of each machine axis:




MD 30220: ENC_MODULE_NR[0] :

MD 30240: ENC_TYPE[0] (actual-value acquisition mode): Enter here the encoder type
used

Assignment of drive number

Special features


MD 30110: CTRLOUT_MODULE_NR[0] and


MD 30220: ENC_MODULE_NR[0] of a machine axis must have the same drive number.

To operate a digital spindle with a direct position encoder, set


MD 30230: ENC_INPUT_NR[0] = 2 for the corresponding machine axis, and, if necessary,
correct the direction using
MD 32110: ENC_FEEDBACK_POL[0] = -1.
Set the message type for the appropriate drive n to:
MD 13060: DRIVE_TELEGRAM_TYPE[n-1] = 104
In addition, parameterize the drive (via SimoComU).

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

3-61

Velocities, Setpoint/Actual-Value Systems, Closed-Loop Control (G2)


3.3

3.3.4

Setpoint/actual -value system

Speed setpoint output

MD 32100: AX_MOTION_DIR
nMotor
Controller

M
Load
gear

nSpindle

MD 31030: LEADSCREW_PITCH
Ball screw

only for linear axes

MD 31060: DRIVE_AX_RATIO_NUMERA[n] Number of motor revs


=
Number of load revolutions (spindle)
MD 31050: DRIVE_AX_RATIO_DENOM[n]

Fig. 3-5

Speed setpoint output

Traversing direction
MD 32100: AX_MOTION_DIR (traversing direction) can be used to revert the traversing direction of the axis (without effect on the control direction of the position control).

Maximum speed setpoint


The maximum speed setpoint is defined using MD 36210: CTRLOUT_LIMIT. The value as a
percentage refers to the speed (100 %) at which the axis velocity of MD 32000:
MAX_AX_VELO is reached. A value greater than 100 % contains the required control margin
for the position control of axes.
n set = speed setpoint
5-25%

Max. speed setpoint


MD 36210: CTRLOUT_LIMIT
Speed at:
Max. axis velocity
MD 32000: MAX_AX_VELO

t [sec]

Fig. 3-6

Speed setpoint output

If values above the limit are specified, the value is limited to the value defined in MD 36210,
the axes are stopped, and an alarm is output. For detailed information, see Section Axis monitoring functions.
In the case of an analog spindle, the maximum output speed is limited by the maximum setpoint output voltage of 10 V. The value of MD 36210: CTRLOUT_LIMIT should not be above the
speed setpoint reached at this voltage (100 %).

Note
For special features regarding the control of a spindle, please refer to the Chapter Spindle.

3-62

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Velocities, Setpoint/Actual-Value Systems, Closed-Loop Control (G2)


3.3

3.3.5

Setpoint/actual -value system

Actual - value processing

Actual -value resolution


To create a position control loop that is connected correctly, it is necessary to convey the actual-value resolution to the control system.
Parameterize the following machine data for the main applications depending on the axis type
(linear axis, rotary axis/spindle, analog spindle) and depending on the type of actual value
acquisition (direct, indirect) to calculate the actual value resolution:
Machine Data

Linear Axis

Rotary Axis

Spindle

Encoder on
motor

Encoder on
motor

Encoder on
motor

Encoder on
machine

without
measuring
system

MD 30200: NUM_ENCS
(number of encoders)

MD 30300: IS_ROT_AX
(rotary axis)

MD 31040: ENC_IS_DIRECT[0]
(encoder is installed directly on the machine)

MD 31020: ENC_RESOL[0]
(encoder increments per revolution)

incr./rev.

incr./rev.

incr./rev.

incr./rev.

MD 31030: LEADSCREW_PITCH
(leadscrew pitch)

mm/rev.

MD 31080:
DRIVE_ENC_RATIO_NUMERA[n]
(measuring gear numerator)

load revs

MD 31070:
DRIVE_ENC_RATIO_DENOM[n]
(resolver gearbox denominator)

encoder
revs

MD 31060:
DRIVE_AX_RATIO_NUMERA[n]
(load gear numerator)

motor revs

motor revs

motor revs

see
note *)

MD 31050:
DRIVE_AX_RATIO_DENOM[n]
(load gear denominator)

ball screw
spindle
revs

load revs

load revs

see
note *)

- = not applicable to this combination


The index [n] of the machine data is coded as follows:
MD: DRIVE_AX_...[servo parameter set no.] : 0-5

Note
*) These MD are not required for the encoder adaptation (path evaluation). For setpoint calculation,
however, they must be entered correctly! Otherwise, the desired loop gain factor will not be set.

Variants of actual-value sensing


The appropriate machine data for the individual variants of actual value sensing are decribed
in the following.

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

3-63

Velocities, Setpoint/Actual-Value Systems, Closed-Loop Control (G2)


3.3

Setpoint/actual -value system

Linear axis with rotatory encoder installed on the motor


MD: IS_ROT_AX = 0
nEncoder

MD: ENC_IS_DIRECT=0

Table

MD:
ENC_RESOL

Fig. 3-7

nMotor

Load
gear

nSpindle

Ball screw

LEADSCREW_PITCH

MD: DRIVE_AX_RATIO_NUMERA No. of motor revs


=
MD: DRIVE_AX_RATIO_DENOM
No. of spindle revs

Linear axis with rotary encoder installed on the motor

Rotary axis with rotary encoder installed on the motor

MD:
MD:
ENC_IS_DIRECT=0 n
IS_ROT_AX=1
n
Encoder
Load
G

Rotary table

Load
gear
MD:
ENC_RESOL

Fig. 3-8

MD: DRIVE_AX_RATIO_NUMERA No. of motor revs


=
No. of load revs
MD: DRIVE_AX_RATIO_DENOM

Motor

Rotary axis with rotary encoder installed on the motor

Spindle with rotary encoder installed on the machine


n Load
Spindle chuck

MD:
ENC_IS_DIRECT=1
n Encoder
L

MD:
IS_ROT_AX=1
Load
gear

Fig. 3-9

MD:
ENC_RESOL

MD: DRIVE_ENC_RATIO_NUMERA No. of load revs


=
No. of load revs
MD: DRIVE_ENC_RATIO_DENOM
Resolver
gear

Spindle with rotarory encoder installed on the the machine

Note:
MD 32110: ENC_FEEDBACK_POL (sign of actual value) can be used to change the sign of
the actual-value sensing and thus also the control direction of the position control.

3-64

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Velocities, Setpoint/Actual-Value Systems, Closed-Loop Control (G2)


3.4

3.4

Closed-loop control

Closed-loop control

General
The closed-loop control of an axis consists of the current and of the speed control loop of the
drive and of a higher-livel position-control loop in the NC.
The speed and current control are explained in:
References:
Description of Functions SIMODRIVE 611 UE
MD 32400: AX_JERK_ENABLE
MD 32410: AX_JERK_TIME

Interpolator/
jerk limitation

MD 32200: POSCTRL_GAIN

Feedforward
control

Closed-loop
control

Speed
setpoint
processing

MD 32100: AX_MOTION_DIR

IS: Position encoder 1


MD 32620: FFW_MODE
MD 32630: FFW_ACTIVATION_MODE
MD 32610: VELO_FFW_WEIGHT
MD 32810: EQUIV_SPEEDCTRL_TIME

Fig. 3-10

Actual-value
value
processing
MD 32110: ENC_FEEDBACK_POL
MD 32700: ENC_COMP_ENABLE
MD 32450: BACKLASH

Principle of the position control of an axis/spindle

For the description of the jerk limitation, see:


References:
Section Acceleration
For the description of feedforward control, backlash and backlash error compensation, see:
References:
Section Compensations

Servo gain factor


To ensure that there are only small contour deviations in continuous-path mode, a high servo
gain factor MD 32200: POSCTRL_GAIN[n] (position controller-loop gain) is required.
The index[n] of the machine data is coded as follows:
[control parameter set No.]: 0 - 5
If the loop gain factor is too high, however, overshot and (in some cases) inadmissible high
loads on the machine may be the consequence.

SINUMERIK 802D, 802D base line


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3.4

Closed-loop control

The maximum permissible servo gain depends on:




dimensioning and dynamic properties of the drive


(rise time, acceleration and brake properties)

quality of machine (elasticity, vibration dampening)

position-control clock

KV 

[mmin]
Speed
;
Followingerror
[mm]

Unit of servo gain factor acc. to the VDI standard

Parameter sets of the position controller


The position control can use up to 6 different parameter sets. These serve for


quick accomodation of the position controller to modified properties of the machine during
operation, e.g. when switching over the spindle gearbox.

accomodation of the dynamic properties of an axis to another axis, e.g. on tapping.

The following machine data can jointly be changed by parameter set switchover during operation.
MD 31050: DRIVE_AX_RATIO_DENOM[n]

(load gear denominator)

MD 31060: DRIVE_AX_RATIO_NUMERA[n] (load gear numerator)


MD 32200: POSCTRL_GAIN[n]

(servo gain factor)

MD 32810: EQUIV_SPEEDCTRL_TIME[n]

(equivalent time constant of speed control loop for


feedforward control)

MD 36200: AX_VELO_LIMIT[n]

(threshold value for velocity monitoring)

The index [n] of the machine data is coded as follows:


[control parameter set No.]: 0-5
Parameter sets for spindle:
With the spindle, each gear stage is assigned its own parameter set. Depending on the IS
Actual gear stage (V380x2000.0 to .2), the appropriate parameter set is activated.
Note: For the machine data required to switchover the gear stage of the spindle, please refer
to the Chapter Spindle.
IS Actual Gear Stage

3-66

Active Parameter Set

000

(Index=1)

001

(Index=1)

010

(Index=2)

011

(Index=3)

100

(Index=4)

101

(Index=5)

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6FC5 697-2AA10-0BP2 (11.03) (DF)

Velocities, Setpoint/Actual-Value Systems, Closed-Loop Control (G2)


3.4

Closed-loop control

Parameter sets for axes


-

For axes not involved in tapping or thread cutting, parameter set 1 (index=0) is activated in any case.

For axes involved in tapping or thread cutting, the same parameter set number is activated as for the current gear stage of a spindle.

Note
For example, if a load gear is active for an axis, then this transmission ratio (numerator, denominator) must also be entered in all of the remaining sets of parameters used for threads, in
addition to the parameter set with the index =0.

The current parameter set is displayed in the operating area Diagnosis in the display Service of axis.

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3.5

3.5
3.5.1

Data description (MD, SD)

Data description (MD, SD)


General machine data

10200 **
INT_INCR_PER_MM
MD number
Computational resolution for linear positions
Default: 1000
Min. input limit: 1.0
Max. input limit: ***
Change valid after Power On
Protection level: 2/2
Unit: Data type: DOUBLE
Valid from SW release:
Meaning:
This MD is used to define the number of internal increments per millimiter.
The input accuracy of linear positions is limited to the computational resolution by rounding the
product of the programmed value with the computational resolution to an integer number.
To be able to trace the rounding easily, numbers raised to the power of 10 should be used for the
computational resolution.
Application example(s)
In the case of high demands on the accuracy of linear axes, the computational resolution can be
increased to values greater than 1,000 incr./mm.

** This machine data is not available with the 802D base line.
10210 **
INT_INCR_PER_DEG
MD number
Computational resolution for angular positions
Default: 1000
Min. input limit: 1.0
Max. input limit: ***
Change valid after Power On
Protection level: 2/2
Unit: Data type: DOUBLE
Valid from SW release:
Meaning:
This MD is used to define the number of internal increments per degree.
The input accuracy of angular positions is limited to the computational resolution by rounding the
product of the programmed value with the computational resolution to an integer number.
To be able to trace the rounding easily, numbers raised to the power of 10 should be used for the
computational resolution.
Application example(s)
For a high-resolution rotary axis, the computational resolution can be changed to < 1,000 incr./degrees.

** This machine data is not available with the 802D base line.
10240
SCALING_SYSTEM_IS_METRIC
MD number
Metric scaling system
Default: 1
Min. input limit: 0
Max. input limit: 1
Change valid after Power On
Protection level: 2/2
Unit: Data type: BOOLEAN
Valid from SW release:
Meaning:
The MD defines the scaling system used by the control system for the scaling of length-dependent
physical quantities for data I/O.
Internally, all data are stored in the basic units 1 mm, 1 degree and 1 sec.
When accessing from the part program, the operator panel or via external communication, the
following units are used for scaling:
SCALING_SYSTEM_IS_METRIC = 1: scaled in:
mm, mm/min, m/s2, m/s3, mm/rev.
SCALING_SYSTEM_IS_METRIC = 0: scaled in:
inch, inch/min, inch/s2, inch/s3, inch/rev.
The selection of the scaling system also defines the interpretation of the F value programmed for
linear axes:
metric
inch
G94
mm/min
inch/min
G95
mm/rev.
inch/rev.
After the machine data have been modified, the control system must be rebooted; otherwise, the
machine data with physical units will not be scaled correctly.
Observe the following procedure:
 MD change by manual input
Reboot the control system and then enter the appropriate machine data with their
physical units
 MD change is carried out using a machine data file
Reboot the control system and then reload the machine data file so that the physical
units come into effect.
Application example(s)

3-68

If the machine data are modified, the alarm 4070 Scaled machine data changed is output.
Start-up in the metric system and then conversion to the inch system

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Velocities, Setpoint/Actual-Value Systems, Closed-Loop Control (G2)


3.5

11240
MD number

PROFIBUS_SDB_NUMBER
SDB1000 number

Default: 0
Change valid after Power On
Data type: BYTE
Meaning:

Data description (MD, SD)

Min. input limit: 0


Max. input limit: 6
Protection level: 2/2
Unit: Valid from SW release: 2
Number of the system data block (SDB1000) used for configuring the Profibus I/Os. With
SINUMERIK 802D, the following possibilities are offered:
0: I/O module: 1st PP (DP addr.9 ), 2nd PP (DP addr.8) = digital inputs/outputs
Drives: none (axes in simulation)
1, 2:

reserved

3: I/O module: 1st PP (DP addr.9 ), 2nd PP (DP addr.8) = digital inputs/outputs
Drives:
Double-axis power section (DP addr.12: Drive A = drive no. 1, drive B = drive no. 2)
+ Single-axis power section (DP addr.10 = drive no. 5)
+ Single-axis
Single axis power section (DP addr
addr.11
11 = drive no.
no 6)
4: I/O module: 1st PP (DP addr.9 ), 2nd PP (DP addr.8) = digital inputs/outputs
Drives:
Double-axis power section (DP addr.12: Drive A = drive no. 1, Antrieb B = drive no. 2)
+ Double-axis power section (DP addr.13: Drive A = drive no. 3, Antrieb B = drive no. 4)
+ Single-axis power section (DP addr.10 = drive no. 5)
5: I/O module: 1st PP (DP addr.9 ), 2nd PP (DP addr.8) = digital inputs/outputs
Drives:
Single-axis power section (DP addr.20 = drive no. 1)
+ Single-axis power section (DP addr.21 = drive no. 2)
+ Double-axis power section (DP addr.13: Drive A = drive no. 3, drive B = drive no. 4)
+ Single-axis power section (DP addr.10 = drive no. 5)
6: I/O module: 1st PP (DP addr.9 ), 2nd PP (DP addr.8) = digital inputs/outputs
Drives:
Einachs-Leistungsteil (DP-Adr.20 = drive no. 1)
+ Single-axis power section (DP addr.21 = drive no. 2)
+ Single-axis power section (DP addr.22 = drive no. 3)
+ Single-axis power section (DP addr.10 = drive no. 5)
Note:
The assignment of a drive to the relevant machine axis is provided via the axis-specific machine
data CTRLOUT_MODULE_NR = ENC_MODULE_NR = drive number.

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3.5

Data description (MD, SD)

13060
DRIVE_TELEGRAM_TYPE[n]
MD number
Default message type for drives at Profibus DP
Default:
Min. input limit: 0
Max. input limit: ***
(102, 102, 102, 102, 102)
Change valid after Power On
Protection level: 2/2
Unit: Data type: DWORD
Valid from SW release:
Meaning:
Specify the message type for each drive at Profibus DP:
0: for additional analog spindle control on the drive
102: SIMODRIVE 611UE - digital axis/spindle
104: SIMODRIVE 611UE - spindle with direct measuring system
Index [n] of the machine data is coded as follows: [drive index]:
n=0: drive 1
n=1: drive 2, etc.

3.5.2

Channel - specific machine data

20150
MD number
Default: see below
Change valid after RESET
Data type: BYTE
Meaning:

Further references

3-70

GCODE_RESET_VALUES[n]
Erase position of the G groups [G group no.]: 0...59
Min. input limit: 0
Max. input limit: 14
Protection level: 1/1
Unit: Valid from SW release:
Definition of the G codes that become active during start-up and reset or at the end of the part
program and when starting the part program.
As a default value, the index of the G codes must be specified in the appropriate groups.
Designation
Group
Standard Value
GCODE_RESET_VALUES[0]
1
2 (G01)
GCODE_RESET_VALUES[1]
2
0 (inactive)
GCODE_RESET_VALUES[2]
3
0 (inactive)
GCODE_RESET_VALUES[3]
4
1 (START FIFO)
GCODE_RESET_VALUES[4]
5
0 (inactive)
GCODE_RESET_VALUES[5]
6
1 (G17) for milling
GCODE_RESET_VALUES[6]
7
1 (G40)
GCODE_RESET_VALUES[7]
8
1 (G500)
GCODE_RESET_VALUES[8]
9
0 (inactive)
GCODE_RESET_VALUES[9]
10
1 (G60)
GCODE_RESET_VALUES[10]
11
0 (inactive)
GCODE_RESET_VALUES[11]
12
1 (G601)
GCODE_RESET_VALUES[12]
13
2 (G71)
GCODE_RESET_VALUES[13]
14
1 (G90)
GCODE_RESET_VALUES[14]
15
2 (G94)
GCODE_RESET_VALUES[15]
16
1 (CFC)
...
For a list of the G groups and the functions assigned to them, please refere to:
References:
Operation and Programming

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Velocities, Setpoint/Actual-Value Systems, Closed-Loop Control (G2)


3.5

3.5.3

Data description (MD, SD)

Axis - specific machine data

30110
CTRLOUT_MODULE_NR[n]
MD number
Setpoint: Drive number/module number
Default: 1
Min. input limit: 1
Max. input limit: 9
Change valid after Power On
Protection level: 2/2
Unit: Data type: BYTE
Valid from SW release:
Meaning:
Enter the drive number for a standard axis.
For an analog spindle:
Enter the transferring drive number used to address the output for the analog spindle.
Index [n] of the machine data is coded as follows: [Setpoint branch]: 0
30120
CTRLOUT_NR[n]
MD number
Setpoint: Output on the module
Default: 1
Min. input limit: 1
Max. input limit: 2
Change valid after Power On
Protection level: 2/2
Unit: Data type: BYTE
Valid from SW release:
Meaning:
Number of output on a module used to address the setpoint output.
Index [n] of the machine data is coded as follows: [setpoint branch]: 0

30130
CTRLOUT_TYPE[n]
MD number
Setpoint output type
Default: 0
Min. input limit: 0
Max. input limit: 1
Change valid after Power On
Protection level: 2/2
Unit: Data type: BYTE
Valid from SW release:
Meaning:
In this MD, the type of the speed setpoint output is entered:
0: Simulation (no hardware required)
1: Setpoint output active
Index [n] of the machine data is coded as follows: [setpoint branch]: 0
Application example(s)
Simulation: Machine functions can also be simulated without a drive connected.

30200
NUM_ENCS
MD number
Number of encoders
Default: 1
Min. input limit: 0
Max. input limit: 1
Change valid after Power On
Protection level: 2/2
Unit: Data type: BYTE
Valid from SW release:
Meaning:
1: Spindle/axis with direct measuring system (integrated in the motor or direct)
0: without measuring system (possible with spindle)

30220
ENC_MODULE_NR[n]
MD number
Actual value: Drive number/measuring circuit number
Default: 1
Min. input limit: 1
Max. input limit: 9
Change valid after Power On
Protection level: 2/7
Unit: Data type: BYTE
Valid from SW release:
Meaning:
Enter the drive number for a standard axis/spindle.
For an analog spindle:
Enter the transferring drive number used to address the output for the analog spindle.
Index [n] of the machine data is coded as follows: [encoder no.]: 0

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

3-71

Velocities, Setpoint/Actual-Value Systems, Closed-Loop Control (G2)


3.5

Data description (MD, SD)

30230
ENC_INPUT_NR[n]
MD number
Actual value: Input number on module/measuring circuit card
Default: 0
Min. input limit: 0
Max. input limit: 5
Change valid after Power On
Protection level: 2/2
Unit: Data type: BYTE
Valid from SW release:
Meaning:
Number of the input on a module, which is used to address the encoder.

Application example(s)

The index[n] of the machine data is coded as follows: [encoder no.]: 0


Simulation:
Machine functions can be simulated even without a measuring system connected.

30240
ENC_TYPE[n]
MD number
Actual value: Encoder type
Default: 0
Min. input limit: 0
Max. input limit: 4
Change valid after Power On
Protection level: 2/2
Unit: Data type: BYTE
Valid from SW release:
Meaning:
In this MD, the type of the encoder used is entered:
0: Simulation
1: Signal generator (1VSS, sin, cos)
4: Absolute encoder with EnDat interface
2, 3, 5: reserved
Index [n] of the machine data is coded as follows: [encoder No.]: 0
Application example(s)
Simulation:
Machine functions can also be simulated without measuring system connected.

30350
SIMU_AX_VDI_OUTPUT
MD number
Output of axis signals with simulation axes
Default: 0
Min. input limit: 0
Max. input limit: 1
Change valid after Power On
Protection level: 2/2
Unit: Data type: BOOLEAN
Valid from SW release:
Meaning:
This machine data is used to define whether during the simulation of an axis axis-specific interface
signals are output to the PLC.
1: The axis-specific IS (interface signals) of a simulated axis are output to the PLC.
It is thus possible to test the PLC user program without the need to connect drives.
0: The axis-specific interface signals of a simulated axis are not output to the PLC.
All axis-specific interface signals are set to 0.
MD inapplicable ......
MD 30130: CTRLOUT_TYPE (setpoint output type) = 1
Application example(s)
MD: SIMU_AX_VDI_OUTPUT = 0
This prevents, e.g. that during the simulation of an axis the brake is released.
31000
ENC_IS_LINEAR
MD number
Direct measuring system (linear scale)
Default: 0
Min. input limit: ***
Max. input limit: ***
Change valid after Power On
Protection level: 2/2
Unit:
Data type: BOOLEAN
Valid from SW release: 1.1
Meaning:
Value 1: Encoder is a linear scale
Further references

31010
ENC_GRID_POINT_DIST
MD number
Scale division with linear scales
Default: 0.01
Min. input limit: 0.0
Max. input limit: ***
Change valid after Power On
Protection level: 2/2
Unit: mm
Data type: DOUBLE
Valid from SW release: 1.1
Meaning:
Distance of increments with linear encoders
Further references

3-72

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Velocities, Setpoint/Actual-Value Systems, Closed-Loop Control (G2)


3.5

Data description (MD, SD)

31020
ENC_RESOL[n]
MD number
Increments per revolution
Default: 2048
Min. input limit: 0
Max. input limit: ***
Change valid after Power On
Protection level: 2/2
Unit: Data type: DWORD
Valid from SW release:
Meaning:
In this MD, the increments per encoder revolution are entered.
The index [n] of the machine data is coded as follows: [encoder No.]: 0

31030
LEADSCREW_PITCH
MD number
Leadscrew pitch
Default: 10.0
Min. input limit: 0.0
Max. input limit: ***
Change valid after Power On
Protection level: 2/2
Unit: mm/rev.
Data type: DOUBLE
Valid from SW release:
Meaning:
In this MD, the leadscrew pitch is entered.

31040
ENC_IS_DIRECT[n]
MD number
The encoder is directly mounted on the machine.
Default: 0
Min. input limit: 0
Max. input limit: 1
Change valid after Power On
Protection level: 2/2
Unit: Data type: BOOLEAN
Valid from SW release:
Meaning:
1: Encoder for actual position sensing is mounted directly on the machine.
0: Encoder for actual position sensing is mounted on the motor.
Index [n] of the machine data is coded as follows: [encoder No.]: 0
Special cases, errors, ......
A wrong entry may result in wrong encoder resolution, since, e.g. the wrong gear transmission
ratios are calculated.
31050
DRIVE_AX_RATIO_DENOM[n]
MD number
Load gear denominator
Default: 1
Min. input limit: 1
Max. input limit: 2 147 000 000
Change valid after Power On
Protection level: 2/2
Unit: Data type: DWORD
Valid from SW release:
Meaning:
In this MD, the denominator of the load gear must be entered.
Index [n] of the machine data is coded as follows: [control parameter set No.]: 0-5
Further references

31060
DRIVE_AX_RATIO_NUMERA[n]
MD number
Load gear numerator
Default: 1
Min. input limit: -2 147 000 000
Max. input limit: 2 147 000 000
Change valid after Power On
Protection level: 2/2
Unit: Data type: DWORD
Valid from SW release:
Meaning:
In this MD, the numerator of the load gear is entered.
Index [n] of the machine data is coded as follows: [control parameter set No.]: 0-5

31070
DRIVE_ENC_RATIO_DENOM[n]
MD number
Resolver gearbox denominator
Default: 1
Min. input limit: 1
Max. input limit: 21 47 000 000
Change valid after Power On
Protection level: 2/2
Unit: Data type: DWORD
Valid from SW release:
Meaning:
In this MD, the name of the resolver gearbox is entered.
Index [n] of the machine data is coded as follows: [encoder No.]: 0

31080
DRIVE_ENC_RATIO_NUMERA[n]
MD number
Resolver gearbox numerator
Default: 1
Min. input limit: 1
Max. input limit: 2 147 000 000
Change valid after Power On
Protection level: 2/2
Unit: Data type: DWORD
Valid from SW release:
Meaning:
In this MD, the numerator of the resolver gearbox is entered.
The index [n] of the machine data is coded as follows: [encoder No.]: 0

SINUMERIK 802D, 802D base line


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3.5

Data description (MD, SD)

32000
MAX_AX_VELO
MD number
Maximum axis velocity
Default: 10 000 mm/min,
Min. input limit: 0.0
27.77 rpm
Change valid after NEW_CONF
Protection level: 2/7
Data type: DOUBLE
Meaning:

Max. input limit: ***


Unit: mm/min,
rpm

Valid from SW release:


In this MD, enter the limit velocity up to which the axis can accelerate (rapid traverse limitation).
If rapid traverse G0 is programmed, this speed is used for traversing. Depending on
MD: IS_ROT_AX, enter the maximum linear ond/or rotary axis speed in the MD.
The max. permissible axis velocity depends on the machine and axis dynamics and the limit frequency of actual-value sensing.

32100
AX_MOTION_DIR
MD number
Traversing direction
Default: 1
Min. input limit: -1
Max. input limit: 1
Change valid after Power On
Protection level: 2/2
Unit: Data type: BYTE
Valid from SW release:
Meaning:
This MD can be used to revert the direction of rotation of the machine axis. The control direction,
however, is not reverted, i.e. the closed-loop control remains stable.
0 or 1:
no direction reversal
-1:
direction reversal

32110
ENC_FEEDBACK_POL[n]
MD number
Sign of actual value (control direction)
Default: 1
Min. input limit: - 1
Max. input limit: 1
Change valid after Power On
Protection level: 2/2
Unit: Data type:BYTE
Valid from SW release:
Meaning:
In this MD, the direction of evaluation of the encoder signals is entered.
0 or 1:
no direction reversal
-1:
direction reversal
In the case of direction reversal, the control direction is also reverted if the encoder is used for the
position control.
Index [n] of the machine data is coded as follows: [encoder No.]: 0
Special cases, errors, ......
If a wrong control direction is entered, the axis may run away.
Depending on the setting of the corresponding limit values, one of the following alarms may occur:
Alarm 25040 Zero-speed control
Alarm 25050 Contour monitoring
Alarm 25060 Speed setpoint limitation
The corresponding limit values are described in:
References:
Section Axis Monitoring Functions
If there is an uncontrolled, sudden setpoint change when connecting a drive, a wrong control direction may have been set.

3-74

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6FC5 697-2AA10-0BP2 (11.03) (DF)

Velocities, Setpoint/Actual-Value Systems, Closed-Loop Control (G2)


3.5

Data description (MD, SD)

32200
POSCTRL_GAIN[n]
MD number
Servo gain factor
Default: 1.0
Min. input limit: 0.0
Max. input limit: 2000
Change valid after NEW_CONF
Protection level: 2/7
Unit: (m/min)/mm
Data type: DOUBLE
Valid from SW release:
Meaning:
Position controller gain, so-called servo gain factor.
The input/output unit for the user is [ (m/min)/mm].
i.e. POSCTRL_GAIN[n] = 1 corresponds to 1 mm following error at V = 1 m/min.
If 0 is entered, the position controller is disconnected.
When entering the servo gain factor, take into account that the gain factor of the entire position
control loop is also dependent on other parameters of the controlled system. A distinction must
therefore be made between a desired servo gain factor (MD: POSCTRL_GAIN) and a real servo
gain factor (resulting on the machine). Only if all parameters of the control loop are matched another to one correctly, these servo gain factors are identical.
Note:
The axes which interpolate another to one and have to carry out a machining process, must have
the same gain (i.e. the same following error at the same velocity).
The real servo gain factor can be checked by means of the following error in the service displays.
Index [n] of the machine data is coded as follows: [control parameter set No.]: 0-5

36210
CTRLOUT_LIMIT[n]
MD number
Max. speed setpoint
Default: 110.0
Min. input limit: 0.0
Max. input limit: 200
Change valid after NEW_CONF
Protection level: 2/7
Unit: %
Data type: DOUBLE
Valid from SW release:
Meaning:
This MD is used to define the maximum speed setpoint value in per cent.
This specification refers to the speed (100 %) at which the velocity defined in MD 32000:
MAX_AX_VELO is reached. A value greater than 100 % contains the required control margin with
digital drives.
If values above the limit are specified, the value is limited to the MD value, the axes are stopped
and an alarm is generated.

Further references

With an analog spindle, the maximum output speed is limited by the maximum setpoint output
voltage of 10 V. The value in this MD should not be above the speed setpoint reached at this voltage (100 %).
Index[n] of the machine data is coded as follows: [setpoint branch]: 0
see Section Axis monitoring functions

37600 **
PROFIBUS_ACTVAL_LEAD_TIME
MD number
Actual-value sensing time (Profibus Ti)
Default: 0.000125
Min. input limit: 0.0
Max. input limit: 0.032
Change valid after Power On
Protection level: 2/7
Unit: s
Data type: DOUBLE
Valid from SW release: 1.1
Meaning:
Data for setting the actual-value acceptance time (Ti) of the encoder at Profibus (Ti).
Note:
The real Ti value is read either directly from the Profibus configuration or from the drive (if possible). In this case, the value of the machine data is set to the read value and only serves for displaying.
Further references

** This machine data is not available with the 802D base line.

SINUMERIK 802D, 802D base line


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3.6

3.6

Signal descriptions

Signal descriptions

V2700 0001.7
Interface signal
Edge evaluation: no

System inch unit


Signal(s) to NC (PLC - - -> NC)
Signal(s) updated: cyclically

Signal state 1

The NC uses the inch scaling system.

Signal state 0

The NC uses the metric scaling system.

3-76

Signal(s) valid from SW release:

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Velocities, Setpoint/Actual-Value Systems, Closed-Loop Control (G2)


3.7

3.7

Data fields, data lists

Data fields, data lists

3.7.1

Interface signals

Number

.Bit

Name

Ref.

General
V27000001

.7

System inch unit

.0 to .2

Actual gear stage of spindle

Axis-specific
V380x 2000

3.7.2

S1

Machine data

Number

Identifier

Name

Ref.

Operator-panel specific
203

DISPLAY_RESOLUTION

Display resolution

Chapter 19

204

DISPLAY_RESOLUTION_INCH

Display resolution for INCH scaling system

Chapter 19

205

DISPLAY_RESOLUTION_SPINDLE

Display resolution for spindle

Chapter 19

10000

AXCONF_MACHAX_NAME_TAB[n]

Machine axis name

Chapter 19

10200**

INT_INCR_PER_MM

Computational resolution for linear positions

10210**

INT_INCR_PER_DEG

Computational resolution for angle positions

10240

SCALING_SYSTEM_IS_METRIC

Metric scaling system

11240

PROFIBUS_SDB_NUMBER

SDB1000 number

13060

DRIVE_TELEGRAM_TYPE[n]

Default message type for drives at Profibus DP

General

(Profibus DP)

Channel-specific
20150

GCODE_RESET_VALUES[n]

Reset position of G groups

Axis-specific
30110

CTRLOUT_MODULE_NR[n]

Setpoint assignment: Drive number/module number


(analog spindle)

30120

CTRLOUT_NR[0]

Setpoint: Output on module

30130

CTRLOUT_TYPE[n]

Setpoint output type

30134

IS_UNIPOLAR_OUTPUT

Setpoint output is unipolar (analog spindle)

30200

NUM_ENCS

Number of encoders =1 (spindle without encoder


value =0)

30220

ENC_MODULE_NR[n]

Actual-value: Drive module no./measuring circuit no.

30230

ENC_INPUT_NR[0]

Actual value: Input number on module/measuring circuit card

30240

ENC_TYPE[n]

Actual-value sensing mode (actual position)

30300

IS_ROT_AX

Rotary axis

30350

SIMU_AX_VDI_OUTPUT

Output of axis signals with simulation axes

31000

ENC_IS_LINEAR

Direct measuring system (linear scale)

31010

ENC_GRID_POINT_DIST

Scaling division with linear scales

31020

ENC_RESOL[n]

Increments per revolution

31030

LEADSCREW_PITCH

Leadscrew pitch

31040

ENC_IS_DIRECT[n]

Encoder is mounted directly on the machine

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

S1

R2

3-77

Velocities, Setpoint/Actual-Value Systems, Closed-Loop Control (G2)


3.7

Data fields, data lists

Number

Identifier

Name

Ref.

31050

* DRIVE_AX_RATIO_DENOM[n]

Load gear denominator

31060

* DRIVE_AX_RATIO_NUMERA[n]

Load gear numerator

31070

DRIVE_ENC_RATIO_DENOM[n]

Resolver gearbox denominator

31080

DRIVE_ENC_RATIO_NUMERA[n]

Resolver gearbox numerator

32000

MAX_AX_VELO

Maximum axis velocity

32100

AX_MOTION_DIR

Traversing direction

ENC_FEEDBACK_POL[n]

Sign of actual value (control direction)

32110
32200

* POSCTRL_GAIN[n]

Servo gain factor

32450

BACKLASH[n]

Backlash

K3

32700

ENC_COMP_ENABLE[n]

Interpolatory compensation

K3

Equivalent time constant of speed control loop for


feedforward control

K3

32810

* EQUIV_SPEEDCTRL_TIME[n]

33630

FFW_ACTIVATION_MODE

Activate feedforward control from program

K3

35100

SPIND_VELO_LIMIT

Maximum spindle speed

S1

36200 *

AX_VELO_LIMIT[n]

Threshold value for velocity monitoring

A3

36210

CTRLOUT_LIMIT[n]

Max. speed setpoint

37600**

PROFIBUS_ACTVAL_LEAD_TIME

Actual-value sensing time (Profibus Ti)

The machine date marked with an * (asterisk) are contained in a parameter set of the position controller.

** This machine data is not available with the 802D base line.

3-78

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Acceleration (B2)

4.1

Acceleration profiles

Sudden acceleration
In case of the v/t linear velocity control of an axis, which is usually used, the motion is controlled such that the acceleration changes suddenly over the time. With this discontinuous, sudden acceleration, jerk-free starting and deceleration of the axes is not possible, but a timeoptimized velocity/time profile can be realized.

Jerk-limited acceleration
The jerk is the change of the acceleration over the time. With jerk-limited acceleration, the
maximum acceleration is specified not suddenly, but along a ramp. Due to the smoother acceleration characteristic, the traversing time increases towards a sudden acceleration whereas
the path, velocity and acceleration remain the same. In some cases, this loss in time can be
compensated by setting a higher settable axis acceleration.
This, however, has the following advantages:


Saving of the machine mechanics

Reduction of the excitation of high-frequency vibrations of the machine, which can badly
be controlled.

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

4-79

Acceleration (B2)
4.2

4.2

Jerk limitation on interpolator level

Jerk limitation on interpolator level

Note
This function is not available with the 802D base line.

Selection and deselection of jerk-limited acceleration


MD 32431: MAX_AX_JERK (maximum axial jerk on path traversing) can be used to limit the
acceleration change for each machine axis separately. It is active for the axes that are interpolated by the path provided that SOFT is active. The jerk-limited acceleration is exclusively
carried out on the interpolator level.
The jerk-limited acceleration is enabled by:
programming SOFT in the part program. SOFT is modally active and deselects the sudden
acceleration profile (BRISK). If SOFT is programmed with path axes in one and the same
block, the previous block is completed with exact stop.
The jerk-limited acceleration (SOFT) is disabled by:
programming BRISK in the part program. BRISK is modally active. If path axes are programmed with BRISK in one and the same block, the previous block is completed with
exact stop. The sudden acceleration profile of the v/t linear velocity control is enabled
using BRISK.

Active range
The path-related jerk limitation is available for the interpolating path axes in the operating modes AUTO and MDA. The acceleration profiles SOFT and BRISK can be used together with
the traversing mode Exact stop G09, G60, continuous-path mode G64 and LookAhead. The
profiles are also active with the function Dry Run Feed. Alarms that trigger off a rapid stop
will disable both acceleration profiles.
For more detailed information on the behavior of velocity, acceleration, jerk when traversing in
the continuous-path mode and, in particular, at block transitions, please refer to:
References:

Section Continuous Path Mode, Exact Stop and Look Ahead

Note: It is recommended to set the MD 32431: MAX_AX_JERK and


MD 32432: PATH_TRANS_JERK_LIM (maximum axis-specific jerk with path movement at
the block transition) to the same values for the appropriate axis.

4-80

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Acceleration (B2)
4.3

4.3

Jerk limitation in JOG mode

Jerk limitation in JOG mode

Note
This function is not available with the 802D base line.

The jerk limitation is active for axes in JOG mode on




manual traversing

handwheel traversing

repositioning.

The jerk limitation is not active




during reference point approach.

for alarms that cause rapid stop.

The jerk limitation can be specified axis-specifically. The acceleration behavior corresponds
to the acceleration profile SOFT of the path-related jerk limitation. This limitation cannot be
deselected for the axes in the individual operating modes.
Which of the desired axes will be provided with a jerk limitation, can be set in MD 32420:
JOG_AND_POS_JERK_ENABLE. The permissible axis-specific maximum jerk is stored in
MD 32430: JOG_AND_POS_MAX_JERK.

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

4-81

Acceleration (B2)
4.4

Percentage acceleration correction, ACC

4.4

Percentage acceleration correction, ACC

Function
Some program sections may require to programmably modify the axis or spindle acceleration
defined in machine data. This programmable acceleration is a percentage acceleration correction.
The program command: ACC[channel axis name] = percentage value
can be used to program a percentage value > 0% and 200% for each axis (e.g.: X) or
spindle (S1). In this case, the axis interpolation is carried out on the basis of this proportional
acceleration. The acceleration stored in the axis-specific MD 32300: MAX_AX_ACCEL constitutes the reference for an axis (100%). For the spindle, this reference (100%) depends on
the active spindle mode and the gear stage (n = 1 ... 5)
MD 35200: GEAR_STEP_SPEEDCTRL_ACCEL[n] in control mode or
MD 35210: GEAR_STEP_POSCTRL_ACCEL[n] in positioning mode.
References:

Chapter Spindle

Example: N10 ACC[X]=80


References:

; 80% of the acceleration for the X axis

Operation and Programming

Activation
The limitation is active in all interpolation modes of AUTOMATIC and MDA modes. The limitation is not active in JOG mode and during reference point approach.
The value assignment ACC[...] = 100 disables the correction (100% of the MD values); the
same applies to RESET and end of program.
The programmed value is also active during dry run feed.

Error states
The limitation of the acceleration is inactive in error states that lead to a rapid stop with open
position control loop (since the axis is stopped along a braking ramp of the speed setpoint
value).
Note: A value programmed greater than 100% can only be executed if the drives have the
appropriate reserves - otherwise, alarm messages are output.

4-82

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Acceleration (B2)
4.5

4.5

Data descriptions (MD, SD)

Data descriptions (MD, SD)

32300
MAX_AX_ACCEL
MD number
Axis acceleration
Default: 1.0 m/s2
Min. input limit: 0.0
Max. input limit: ***
2.77 rev/s2
Change valid after NEW_CONF
Protection level: 2/7
Unit: m/s2, rev/s2
Data type: DOUBLE
Valid from SW release:
Meaning:
The acceleration specifies a velocity change of the axis over a certain time. Different axes need
not absolutely necessary have the same acceleration. The lowest acceleration value will be used
for interpolating axes.
For rotary axes, the entered value corresponds to the angular acceleration.
The machine manufacturer must find out for which permanent brake mode and which permanent
acceleration is suited for the machine. This value must then be entered in this machine data.
The acceleration value is active for each acceleration/deceleration process.
MD inapplicable to ......
error states resulting in rapid stop

32420
MD number
Default: 0
Change valid after RESET
Data type: BOOLEAN
Meaning:
Related to ....

JOG_AND_POS_JERK_ENABLE
Enable axis-specific jerk limitation
Min. input limit: 0
Max. input limit: 1
Protection level: 2/2
Unit: Valid from SW release:
Enables the function of axis-specific jerk limitation for the modes JOG, REF and the positioning
axis mode.
MD 32430: JOG_AND_POS_MAX_JERK
(axis-specific jerk)

32430
MD number
Default: 1000.00 m/s3,
2777.77 rev./s3

JOG_AND_POS_MAX_JERK
Axis-specific jerk
Min. input limit: 10 - 9

Change valid after RESET

Unit: m/s3, rev./s3


Valid from SW release:
The jerk limit value limits the change in axis acceleration in JOG mode.
path interpolation and error states resulting in rapid stop
MD 32420: JOG_AND_POS_JERK_ENABLE (enable axis-specific jerk limitation)

Data type: DOUBLE


Meaning:
MD inapplicable to ......
Related to ......

Max. input limit: ***

Protection level: 2/2

32431**
MAX_AX_JERK
MD number
Maximum axis-specific jerk when traversing along the contour
Default: 1000.00 m/s3,
Min. input limit: 10 - 9
Max. input limit: ***
3
2777.77 rev./s
Change valid after NEW_CONF
Protection level: 3/3
Unit: m/s3, rev./s3
Data type: DOUBLE
Meaning:
Related to ...

Valid from SW release:


This maximum axis-specific jerk is active with path movements.
Path movements are possible in AUTO and MDA modes..
MD 32432: PATH_TRANS_JERK_LIM is active at block transition.
It is recommended to set both MD to the same value.

** This machine data is not available with the 802D base line.

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

4-83

Acceleration (B2)
4.6

4.6

Data fields, lists

Data fields, lists

Number

Identifier

Name

Ref.

Axis-specific machine data


32300

MAX_AX_ACCEL

Axis acceleration

32420

JOG_AND_POS_JERK_ENABLE

Enable axis-specific jerk limitation

32430

JOG_AND_POS_MAX_JERK

Axial jerk

32431

MAX_AX_JERK

Maximum axis-specific jerk for path movement

32432

PATH_TRANS_JERK_LIM

Maximum axis-specific jerk for path movement at block


transition

4-84

B1

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Spindle (S1)

5.1

Brief description

Spindle application
Depending on the machine type, the following functions are possible for an NC-controlled
spindle:


Definition of a direction of rotation of the spindle (M3, M4)

Definition of a spindle speed (S)

Spindle stop, without orientation (M5)

Spindle positioning (SPOS=)


(position-controlled spindle required)

Gear step switchover (M40 to M45)

Thread cutting/tapping (G33, G331, G332, G63)

Revolutional feed (G95)

Constant cutting speed (G96)

Programmable spindle speed limitations (G25, G26, LIMS=)

Position encoder mounted on the spindle or on the spindle motor

Spindle monitoring for min. and max. speed

Dwell time in spindle revolutions (G4 S)

Instead of the controlled spindle, a switched spindle can be used. In this case, the spindle
speed (S) is not specified from the program, but, e.g. by manual operation (gearbox) on the
machine. It is thus also not possible to program any speed limitations. The following is possible via the program:


Definition of a direction of rotation of the spindle (M3, M4)

Spindle stop, without orientation (M5)

Tapping (G63)

If the spindle is equipped with a position encoder, in addition to the above mentioned functions, the functions listed below are possible:


Thread cutting/tapping (G33)

Revolutional feed (G95)

For a switched spindle, the setpoint output for the spindle via MD 30130: CTRLOUT_TYPE =0
must be suppressed.

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

5-85

Spindle (S1)
5.2

Spindle modes

Defining the spindle


A machine axis is declared a spindle by setting the following machine data:
MD 30300: IS_ROT_AX, MD 30310: ROT_IS_MODULO, MD 30320: DISPLAY_IS_MODULO
and MD 35000: SPIND_ASSIGN_TO_MACHAX. The spindle mode is signaled by the IS
Spindle/no axis (V390x 0000.0).

5.2

Spindle modes

Spindle modes
The spindle can be operated in the following modes:


Control mode

see Section 5.2.1

Oscillation mode

see Section 5.2.2.

Positioning mode

see Section 5.2.3

Tapping without compensating chuck


also refer to SectionFeed (Thread Interpolation) and
References: Operation and Programming

Changing the spindle mode

Oscillation m.
Change
gear stage

Gear stage
changed
SPOS

Control mode
M3, M4, M5,
M41-45

Positioning mode

SPOS

G331
G332

Rigid tapping
(without compensating chuck)

Fig. 5-1

5-86

Changing between the spindle modes

Control mode - - -> oscillation mode


The spindle changes to oscillation mode if a new gear stage has been specified using the
automatic gear stage selection (M40) in conjunction with a new S value or by M41 to M45.
The spindle will only change to oscillation mode if the new gear stage is other than the current actual gear stage.

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Spindle (S1)
5.2

5.2.1

Spindle modes

Oscillation mode - - -> control mode


If the new gear stage has been selected, the IS Oscillation mode (V390x2002.6) is reset,
and the IS Gear switched over (V380x2000.3) will cause the spindle to change to control
mode. The spindle speed last programmed (S value) is active again.

Control mode - - -> positioning mode


If the spindle is to be stopped from rotation (M3 or M4) with orientation or if the spindle is
to be re-oriented from the standstill (M5), switchover to positioning mode is carried out
using SPOS.

Positioning mode - - -> control mode


To end the orientation of the spindle, M3, M4 or M5 are used to switch over to control
mode. The spindle speed last programmed (S value) is active again.

Positioning mode - - -> oscillation mode


To end the orientation of the spindle, M41 to M45 can be used to switch over to oscillation
mode. If the gear stage change is completed, the spindle speed last programmed (S value)
and M5 (control mode) are active again.

Positioning mode - - -> tapping without compensating chuck (rigid tapping)


Tapping without compensating chuck (helix interpolation) is activated using G331/G332.
First the spindle must be switched to position-controlled mode using SPOS.

Spindle mode: Control mode

When control mode?


The spindle is in control mode if the following functions are active:


Constant spindle speed S, M3/M4/M5 and G94, G95, G97, G33, G63

Constant cutting rate G96 S, M3/M4/M5

Prerequisites
A spindle actual position encoder is absolutely necessary for M3/M4/M5 in conjunction with
revolutional feed (G95, F in mm/rev. or inch/rev.), constant cutting rate (G96, G97) and thread
cutting (G33).

Separate spindle reset


MD 35040: SPIND_ACTIVE_AFTER_RESET is used to set the reaction of the spindle after
reset or program end (M2, M30):


In the case of MD value=0, the spindle is immediately braked down to a standstill at the
valid acceleration. The spindle speed last programmed and the direction of rotation of the
spindle will be deleted.

In the case of MD value=1 (separate spindle reset), the last programmed spindle speed (S
function) and the last programmed sense of rotation of the spindle (M3, M4, M5) will be
maintained.
If prior to reset or end of program the constant cutting rate (G96) is active, the current
spindle speed (referred to 100% spindle override) is internally accepted as the spindle
speed last programmed.

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

5-87

Spindle (S1)
5.2

Spindle modes

Note
The spindle can always be decelerated using the IS Delete distance to go/spindle reset.
CAUTION: If G94 is provided, the program will go on running. With G95, the axes will come
to a standstill due to the missing feed and thus also the program run if G1, G2, ... is active.

5.2.2

Spindle mode: Oscillation mode

Starting the oscillation mode


This oscillating movement facilitates meshing of a new gear stage. Generally, the new gear
stage may also be switched on without oscillation.
The spindle is in oscillation mode if a new gear stage has been set by the automatic gear
stage selection (M40) or by M41 to M45 (IS Switch over gear (V390x2000.3) has been set).
The IS Switch over gear is only set if the new gear stage specified is other than the current
actual gear stage. Oscillation of the spindle is started using the IS Oscillation speed
(V380x202.5).
If only the IS Oscillation speed is set without specifying a new gear stage, the spindle will not
change to oscillation mode.
The oscillation is started using the IS Oscillation speed. For the functional sequence, a distinction is made between the following cases, depending on the IS Oscillation by the PLC
(V380x2002.4):


Oscillation by the NCK

Oscillation by the PLC

Oscillation time
For each direction of rotation, the oscillation time can be defined in a machine data:


Oscillation time in M3 direction (in the following referred to as t1) in


MD 35440: SPIND_OSCILL_TIME_CW

Oscillation time in M4 direction (in the following referred to as t2) in


MD 35450: SPIND_OSCILL_TIME_CCW

Oscillation by the NCK


Phase 1: The IS Oscillation speed (V380x2002.5) enables the spindle motor to accelerate
to the speed set in MD 35400: SPIND_OSCILL_DES_VELO (oscillation speed) (with oscillation acceleration). The start direction is determined by MD 35430:
SPIND_OSCILL_START_DIR (start direction on oscillation).
Phase 2: If time t1 (t2) has elapsed, the spindle motor accelerates in the opposite direction
to the speed set in the MD 35400: SPIND_OSCILL_DES_VELO (oscillation speed) in the opposite direction. Time t2 (t1) is started.
Phase 3: If time t2 (t1) has elapsed, the spindle motor accelerates in the opposite direction
(the same direction as in phase 1), etc.

5-88

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Spindle (S1)
5.2

Spindle modes

Oscillation by the PLC


The IS Oscillation speed (V380x2002.5) accelerates the spindle motor to the speed set in
MD 35400: SPIND_OSCILL_DES_VELO (oscillation speed) (with oscillation acceleration).
The direction of rotation is set by the IS Set direction CCW or IS Set direction CW
(V380x2002.7 or .6). The oscillation (oscillation movement) and the two times t1 and t2 (time
for direction of rotation CW and CCW) must be simulated in the PLC.

End of oscillation mode


The IS Gear has been switched over (V380x2000.3) tells the NCK that the new gear stage
(IS Actual gear stage (V380x2000.0 to .2)) is valid, and that the oscillation mode is ended.
The actual gear stage should correspond to the set gear stage. The oscillation mode is also
ended if the IS Oscillation speed (V380x2002.5) is still set. The spindle speed last programmed (S function) and the direction of rotation of the spindle (M3, M4 or M5) are active again.
After the oscillation mode has been ended, the spindle is in control mode again.
All gear-specific limit values (min./max. speed of the gear stage, etc.) corresponding to the
specified values of the actual gear stage are switched off at spindle standstill.

Block change
If the spindle has been switched over to oscillation mode (IS Switchover gear
(V390x2000.3) is set), the part program execution is stopped. No new block will be started. If
the oscillation mode is ended by the IS Gear has been switched over (V380x2000.3), the
part program execution is resumed. A new block will be executed.

Speed
(1/min)

IS: Gear switched


Block change is carried out here

Time (s)

Fig. 5-2

Block change after oscillation mode

Special features


The acceleration is defined in MD 35410: SPIND_OSCILL_ACCEL (acceleration on oscillation).

If the IS Oscillation speed (V380x2002.5) is reset, the oscillation stops. The spindle mode
Oscillation, however, is not quitted.

The gear stage change should always be ended by the IS Gear is switched over.

The IS Reset (V30000000.7) will not cancel the oscillation mode.

If an indirect measuring system is used, the synchronization gets lost. Upon next zero
mark overtravel, a synchronization is carried out again.

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

5-89

Spindle (S1)
5.2

Spindle modes

Reset during gear stage change


A spindle stop is not possible through the IS Reset (V30000000.7) or the IS NC stop
(V32000007.3), if the spindle is in oscillation mode for gear stage change and if the IS Gear
is switched over (V380x2000.3) is not yet present.
In these cases if reset is selected the alarm 10640 Stop not possible during gear stage
change is displayed.
After the gear steps have been changed, the reset request is carried out and the alarm cleared if this is still provided at the interface.

Note
Possibility to abort: Set IS Delete distance-to-go/spindle reset (V380x0002.2)

5.2.3

Spindle mode: Positioning mode

When positioning mode?


In positioning mode, the spindle is stopped at the specified position. The position control is
enabled and remains active until it is deselected. During the program function SPOS =....., the
spindle is in positioning mode (also refer to Chapter 5.5 Programming).

Block change
Programming with SPOS:
The block change is carried out as soon as all functions programmed in the block have reached their block end criterion (e.g. axes terminated, all auxiliary functions acknowledged
from the PLC) and as soon as the spindle has reached its position (IS Exact stop fine for
the spindle (V390x0000.7)).

Prerequisites
Spindle actual position encoder is absolutely necessary.

5-90

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Spindle (S1)
5.2

Spindle modes

Positioning from rotation


Phases 1 to 5:
Speed
(1/min)

MD 36300: ENC_FREQ_LIMIT
( limit frequency of the encoder)

1a
4a

SPOS=...

Fig. 5-3

MD 36302: ENC_FREQ_LIMIT_LOW
(encoder limit frequency resynchronization)

MD 35300: SPIND_POSCTRL_VELO
(position controller threshold speed)
4

Time (s)

Positioning from the rotation at different speeds

Sequence
Phase 1: The spindle rotates at a speed less than the encoder limit frequency. The spindle is
synchronized. It is in control mode. Continued with phase 2.
Phase 1a: The spindle rotates at a speed less than the position controller threshold speed.
The spindle is synchronized. It is in control mode. Continuation is possible with 4a.
Phase 1b (not shown): The spindle rotates at a speed higher greater than the encoder limit
frequency. First, the spindle is not synchronized, but will be synchronized when the speed
defined in MD 3602: ENC_FREQ_LIMIT_LOW (percentage value of MD 36300) is undershot.
Continued with phase2.
Phase 2: When the SPOS instruction comes into effect, the spindle starts to decelerate to the
position controller threshold speed at the acceleration stored in MD 35200:
GEAR_STEP_SPEEDCTRL_ACCEL.
Phase 3: When the position controller threshold speed stored in
MD 35300: SPIND_POSCTRL_VELO + is reached:


the position control is connected,

the distance to go (to the target position) is calculated , (it is more likely to be possible from
phase 1a)

the acceleration to MD 35210: GEAR_STEP_POSCTRL_ACCEL (acceleration in position


control mode) is switched over (is always active below the position controller threshold
speed)

Phase 4: The spindle brakes from the calculated braking point at


MD 35210: GEAR_STEP_POSCTRL_ACCEL until the target position is reached.
Phase 5: The position control remains active and keeps the spindle in the programmed position. The IS Position reached at exact stop fine (V390x0000.7) and ... coarse
(V390x0000.6) are set, if the distance between the actual spindle position and the programmed position (spindle setpoint position) is less than the exact stop fine and coarse (determined in MD 36010: STOP_LIMIT_FINE and MD 36000 :STOP_LIMIT_COARSE).

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

5-91

Spindle (S1)
5.2

Spindle modes

Positioning from the standstill, spindle not synchronized


After the control system has been turned on, spindle is not synchronized. The first movement
of the spindle will be positioning (SPOS=...).
Speed
(1/min)

Phases 1 to 4:

MD 35300:

SPIND_POSCTRL_VELO
(Position controller threshold speed)
1

3
4

Start at: SPOS=...


sychronized at zero mark

Fig. 5-4

Position reached

Time (s)

Brake threshold point

Positioning with the spindle stopped and not synchronized

Sequence
Phase 1: If SPOS is programmed, the spindle will accelerate at the acceleration defined in
MD 35210: GEAR_STEP_ POSCTRL_ACCEL (acceleration in position control mode) until
the speed entered in MD 35300: SPIND_POSCTRL_VELO (position controller switch-on
speed) is reached.
The direction of rotation is determined by MD 35350: SPIND_POSITIONING_ DIR (direction
of rotation when positioning from the standstill), unless there is no preset value from the
SPOS programming ( ACN, ACP, IC). The spindle is synchronized with the next zero mark of
the position actual-value encoder.
Phase 2: After the spindle has been synchronized, the position control is enabled. The
spindle will rotate not faster than specified in MD 35300: SPIND_POSCTRL_VELO until the
brake starting point calculation recognizes when the spindle may exactly approach the programmed spindle position with the acceleration defined.
Phase 3: The spindle brakes at the brake threshold point at the acceleration defined in
MD 35210: GEAR_STEP_ POSCTRL_ACCEL (acceleration in position control mode).
Phase 4: The spindle has reached the position and is at a standstill. The position control is
active and keeps the spindle in the programmed position. The IS Position reached with exact
stop fine (V390x0000.7) and ... coarse (V390x0000.6) are set if the distance between the
spindle actual position and the programmed position (spindle setpoint position) is less than
the value of exact stop fine and coarse ( MD 36010: STOP_LIMIT_FINE and MD 36000:
STOP_LIMIT_COARSE).

5-92

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Spindle (S1)
5.2

Spindle modes

Positioning from the standstill, spindle is synchronized


The spindle has already been rotated by at least one spindle revolution using M3 or M4 and
has then be stopped with M5.
Speed
(1/min)

Phases 1 to 4:

MD 35300:

SPIND_POSCTRL_VELO
(Position controller switch-on speed)
1

3a
4a

Start at: SPOS=...

4
Position reached

Time (s)

Brake threshold point

Fig. 5-5

Positioning with the spindle stopped and synchronized

Sequence
The spindle is traversed time-optimized until the programmed time is reached. Depending on
the related boundary conditions, the spindle will pass the phases 1 - 2 - 3 - 4 or 1 - 3a - 4a.
Phase 1: SPOS will switch the spindle to position control mode. The acceleration from the
MD 35210: GEAR_STEP_POSCTRL_ACCEL (acceleration in position control mode) becomes active. The direction of rotation is determined by the present distance to go (type of path
specification with SPOS). The limit frequency set in MD 35300: SPIND_POSCTRL_VELO
(position control threshold speed) will not be exceeded.
The calculation of the distance to be traversed to the target position will be carried out. If the
target point can be reached from this phase immediately, it is continued with phases 3a and
4a, instead of phase 2.
Phase 2: The system has been accelerated up to the speed entered in
MD 35300: SPIND_POSCTRL_VELO (position controller threshold speed). The brake threshold point calculation will recognize at which time the programmed spindle position
(SPOS=...) can be approached at the acceleration stored in MD 35210:
GEAR_STEP_POSCTRL_ACCEL .
Phase 3 and phase 4: Braking and Position reached have the same sequence as with a
non-synchronized spindle.

Spindle reset
The positioning process can be canceld using the IS Delete distance to go/spindle reset
(V380x0002.2). However, the spindle will remain in positioning mode.

Notes


The spindle override switch continues to apply in Positioning mode.

The positioning (SPOS) can be canceled either with Reset or NC STOP.

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

5-93

Spindle (S1)
5.2

5.2.4

Spindle modes

Spindle mode: Axis mode

When axis mode?


For certain machining tasks on turning machines, such as end face machining via TRANSMIT
or peripheral surface machining via TRACYL, the spindle must be run as a rotary axis.
If TRANSMIT or TRACYL is not activated, standard rotary axis functions can be executed. In
this case, the programming is carried out under the rotary axis address, e.g. C.

Prerequisites
The spindle can be switched from the spindle mode to the axis mode (rotary axis) if a common
motor is used both for the spindle and for the axis modes.
The axis mode requires a position actual-value encoder.

Activation/deactivation
Set the spindle to the position-controlled mode (positining mode):
N10 SPOS=0
If the spindle is synchronized, switching to the position-controlled mode is also possible via
M70 or SPCON.
Now, the axis can be traversed in the program as a rotary axis:
N20 G94 G1 C124.4 F4000
; Feedrate F: 4,000 degrees/min
Switching back to the speed-controlled spindle mode is performed by programming
N100 M3
; or M4, M5, M41 ... M45 or SPCOF

Special features
The feedrate override factor is effective.
By default, RESET will not quit the axis mode.
The IS Spindle/no axis (V390x 0000.0) is set to zero.
The axis mode can be enabled in any gear stage.
If the axis mode is active, the gear stage cannot be changed.
In the axis mode, the MD of the parameter set with index zero apply in order to be able to
make adaptations in this mode.

5-94

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Spindle (S1)
5.3

5.3

Synchronizing

Synchronizing

Why synchronizing?
To ensure that the control system exactly finds the 0 degree position after the control system
has been turned on, the control system must be synchronized with the position encoder of the
spindle. Only a synchronized spindle can perform thread cutting or positioning.
As far as axes are concerned, this process is called referencing (see Chapter Reference
Point Approach).

Mounting locations of the position measuring systems




directly on the motor plus BERO switch on the spindle (zero marker encoder)

directly on the spindle

on the spindle above the resolver gearbox plus BERO switch on the spindle

Synchronization options
After the control system has been turned on, the spindle can be synchronized as follows:


The spindle is started at a spindle speed (S function) and with a spindle rotation direction
(M3 or M4) and synchronizes itself with the next zero mark of the position measuring system or BERO signal. The 0-degree position is offset by MD 34080: REFP_MOVE_DIST
+ MD 34090: REFP_MOVE_DIST - MD 34100: REFP_SET_POS.
Note: To offset the 0-degree position, only use MD 34080: REF_MOVE_DIST. The monitoring using MD 34060: REFP_MAX_MARKER_DIST should be set to two spindle revolutions (720 degrees).

by programming SPOS=... from different states (see Section 5.2.3 Spindle mode: Positioning mode)

In JOG mode, the spindle is started in speed control mode using the direction keys and
synchronizes itself with the next zero mark of the position measuring system or the BERO
SIGNAL.

Value acceptance
When synchronizing the spindle, the corresponding reference point value and a resulting offset of the reference point (if any) is accepted from MD 34100: REFP_SET_POS[0] (default
value =0). These offsets (machine data) act independently of the connected measuring system and are described in the Section Reference point approach.

Max. encoder frequency exceeded


If in spindle mode Control mode the spindle reaches a speed (large S value programmed)
that is greater than the max. encoder frequency (the max. speed of the encoder may not be
exceeded), the synchronization gets lost. The spindle goes on rotating, but with reduced functionality.
If thereafter a speed is reached which is below the maximum encoder limit frequency (smaller
S value programmed, spindle override switch changed, etc.), the spindle synchronizes itself
automatically from the next zero mark signal.

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

5-95

Spindle (S1)
5.4

Gear stage change

Resynchronizing
In the following case, however, the position measuring system of the spindle must be resynchronized:
The position measuring system is mounted on the motor, a BERO (clearance sensor for synchronization signal) is mounted on the spindle, and the gear stage is changed. The synchronization is internally initiated when the spindle rotates at the new gear stage.

5.4

Gear stage change

Number of gear stages


5 gear steps can be configured for the spindle. If the spindle motor is mounted directly on the
spindle (1:1) or via a transmission ratio that cannot be changed, MD 35010:
GEAR_STEP_CHANGE_ENABLE (gear stage change possible) must be set to zero.

Motor
speed
(1/min)

With automatic gear stage change,


this speed range will not be utilized
in gear stage 1.

Max. motor speed


Gear
stage 1

Gear
stage 2

0
n

1max

g1min

Spindle speed (1/min)


n2max

g1max

g2min
g2max
Can be defined by MD:
 n1max ...max. spindle speed of the 1st gear stage
 g1min ... min. spindle speed of the 1st gear stage
for autom. gear stage selection
 g1max ...max. spindle speed of the 1st gear stage
for autom. gear stage selection
 n2max ...max. spindle speed of the 2nd gear stage
 g2min ... min. spindle speed of the 2nd gear stage
for autom. gear stage selection
 g2max ...max. spindle speed of the 2nd gear stage
for autom. gear stage selection

Fig. 5-6

Gear stage change with gear stage selection

Preselecting a gear stage


A gear stage can be defined:


as a fixed gear stage by the part program (M41 to M45)

automatically by the programmed spindle speed (M40)

If M40 is active and automatic gear stage selection is to be carried out using an S word, the
spindle must be in control mode. Otherwise, the gear stage change is denied, and alarm
22000 No gear stage change possible is set.

5-96

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Spindle (S1)
5.4

Gear stage change

M41 to M45
The gear stage can be firmly defined in the part program using M41 to M45. If a gear stage is
specified using M41 to M45, which is not equal to the current (actual) gear stage, the IS
Switch over gear (V390x2000.3) and the IS Set gear stage A to C (V390x2000.0 bis .2) are
set. The programmed spindle speed (S function) refers to the gear stage defined as a fixed
gear stage. If a spindle speed is programmed which is above the max. speed of the firmly determined gear stage, a limitation of the max. speed of the gear stage is carried out, and the IS
Setpoint speed limited (V390x2001.1) is set.

M40
M40 in the part program serves to define the gear stage by the control system automatically. A
check is carried out to see whether the programmed spindle speed (S function) is possible. If
a gear stage is found which is not equal to the current (actual) gear stage, the IS Switch over
gear (V390x2000.3) and the IS Set gear stage A to C (V390x2000.0 bis .2) are set.

MD35100:SPIND_VELO_LIMIT:
MD35130:GEAR_STEP_MAX_VELO_LIMIT[2]:
MD35110:GEAR_STEP_MAX_VELO[2]:

MD35130:GEAR_STEP_MAX_VELO_LIMIT[1]:
MD35110:GEAR_STEP_MAX_VELO[1]:

MD35120:GEAR_STEP_MIN_VELO[2]:

MD35120:GEAR_STEP_MIN_VELO_LIMIT[2]:
MD35120:GEAR_STEP_MIN_VELO[1]:
MD35120:GEAR_STEP_MIN_VELO_LIMIT[1]:

Gear
stage 2

Speed
(1/min)

Gear
stage 1

The automatic gear stage selection is carried out such that first the programmed spindle
speed is compared with the min. and max. speed of the current gear stage. If the comparison
is positive, no new gear stage is set. If the comparison is negative, the comparison is carried
out for all 5 gear steps (starting with gear stage 1) until it is positive. If the comparison is not
positive even for the 5th gear stage, no gear stage change is carried out. The speed is limited,
if necessary, to the maximum speed of the current gear stage, and/or is raised to the minimum
speed of the current gear stage, and the IS Setpoint speed limited (V390x2001.1) and/or
Setpoint speed increased (V390x2001.2) is set).

Max. spindle speed


Max. speed of gear stage 2
Max. speed for gear stage change 2

Max. speed of gear stage 1


Max. speed for gear stage change 1

Min. speed of gear stage change 2

Min. speed for gear stage 2


Min. speed for gear stage change 1
Min. speed for gear stage 1

Fig. 5-7

Example of speed ranges with automatic gear stage selection (M40)

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

5-97

Spindle (S1)
5.4

Gear stage change

Changing the gear stage when the spindle is at a standstill


It is possible to switch over to a new gear stage while the spindle is at a standstill.
After the new gear stage has been preselected by M40 and the spindle speed by M41 to M45,
the IS Set gear steps A to C (V390x2000.0 bis .2) and IS Switch over gear (V390x2000.4)
are set. Depending on to which time the IS Oscillation speed (V380x2002.5) is set, the
spindle brakes down to a standstill at the acceleration defined for oscillation or at the acceleration defined for speed control mode/position control mode.
The next block in the part program after a gear stage switchover using M40 and S value or
M41 to M45 will not be executed (same effect as if the IS Read disable (V32000006.1) would
be set.).
When the spindle is at a standstill (IS Axis/spindle stop (V390x0001.4) ), the oscillation can
be switched on by the IS Oscillation speed (V380x2002.5). After the new gear stage has
been switched on, the PLC user sets the IS Actual gear stage (V380x2000.0 bis .2) and IS
Gear is switched over (V380x2000.3). The gear stage change is considered completed
(spindle mode Oscillation mode is deselected) and the spindle is switched to the parameter
set of the new actual gear stage. The spindle accelerates to the last programmed spindle
speed in the new gear stage (provided that M3 or M4 is active). The IS Switch over gear
(V390x2000.3) is reset by the NCK, whereupon the PLC user has to reset the IS Gear is switched over (V380x2000.3). The next block in the part program can be executed.

5-98

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Spindle (S1)
5.4

Gear stage change

Typical sequence of a gear stage change:

IS Control mode
IS Oscillation mode
Programmed S value

1000 1300

IS Gear is switched over


IS Switch over gear
IS Set gear stage

1 2

IS Spindle in set range


IS Spindle stopped
IS Actual gear stage
IS Oscillation speed

1st gear stage engaged


2nd gear stage engaged
Internal feed disable
T1 T2
Spindle speed

IS Spindle STOP

0
t1

t2

t3 t4

t1

The NCK recognizes a new gear stage by programming S1300 (2nd gear stage),
sets the IS Switch over gear and disables the execution of the next part program block.

t2

The spindle is at a standstill and oscillation is started (oscillation by the NCK).


The IS Oscillation speed must be set at the time t2 at the latest.

t3

The new gear stage is engaged. The PLC user transfers the new (actual)
gear stage to the NCK and sets the IS Gear is switched over.

t4

The NCK accepts the IS Switch over gear, completes oscillation,


enables the next part program block for execution and accelerates the spindle
to the new S value (S1300).

Fig. 5-8

Gear stage change with the spindle stopped

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

5-99

Spindle (S1)
5.4

Gear stage change

Set of parameters
One set of parameters each is provided for each of the 5 gear stages. The appropriate parameter set is enabled by the IS Actual gear stage A to ... C (V380x2000.0 to .2). The parameter set assignment is as follows:
Parameter set,
Index
n

PLC interface, coding for the


IS Actual gear stage A,
to ...C
CBA

Data of data record

Contents,
machine data
for

Data for axis mode

000
001

Data for 1st gear stage

010

Data for 2nd gear stage

011

Data for 3rd gear stage

100

Data for 4th gear stage

101

Data for 5th gear stage

servo gain factor,


factor
monitoring functions,
min/max speed,
p
,
accelerations
l ti

The machine data that are contained in a parameter set are especially marked in Section
3.7.2 Machine data. For each gear stage, the following machine data are added to parameter set index n (n=1 -> 1st gear stage of the spindle, etc.):
MD 35110: GEAR_STEP_MAX_VELO[n]
MD 35120: GEAR_STEP_MIN_VELO[n]
MD 35130: GEAR_STEP_MAX_VELO_LIMIT[n]
MD 35140: GEAR_STEP_MIN_VELO_LIMIT[n]
MD 35200: GEAR_STEP_SPEEDCTRL_ACCEL[n]
MD 35210: GEAR_STEP_POSCTRL_ACCEL[n]
MD 35310: SPIND_POSIT_DELAY_TIME[n]

5-100

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Spindle (S1)
5.5

5.5

Programming

Programming

Functions
The spindle can be programmed for the following functions:


G95

Revolutional feed

G96 S... LIMS=...

Constant cutting rate in m/min,


Upper limit speed

G97

Cancel G96 and freeze last spindle speed

G33, G331, G332

Thread cutting, tapping

G4 S...

Dwell time in spindle revolutions

M3
M4
M5
S...

Spindle rotation CW
Spindle rotation CCW
Spindle stop, without orientation
Spindle speed in 1/min, e.g.: S300

SPOS=...

Spindle positioning, e.g.: SPOS=270 -> to position 270 degrees.


The block change is only carried out if the spindle is positioned.
SPOS=DC(Pos) The direction of movement is maintained when positioning from the move
ment, and the position is approached. When positioning from the standstill,
the positon is approached using the shortest path.
SPOS=ACN(Pos) The position is always approached in the negative direction of movement.
If necessary the direction of movement is inverted prior to positioning.
SPOS=ACP(Pos) The position is always approached in the positive direction of movement.
If necessary the direction of movement is inverted prior to positioning.
SPOS=IC(Pos)
The distance to be traversed is given. The traversing direction results from
the sign of the distance to be traversed. If the spindle already rotates, the
direction of traversing may possible be inverted in order to be able to tra
verse in the programmed direction.
M40
M41 to M45

Automatic gear stage selection for the spindle


Selection of gear stage 1 to 5 for the spindle

SPCON
SPCOF
M70

Position control on
Position control off
Position control on

G25 S...
G26 S...
LIMS=...

Programmable lower spindle speed limitation, e.g.: G25 S8


Programmable upper spindle speed limitation, e.g.: G26 S1200
Programmable maximum spindle speed at G96

References:

Operation and Programming

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

5-101

Spindle (S1)
5.6

5.6

Spindle monitoring functions

Spindle monitoring functions

Speed ranges
The spindle monitoring functions and the currently active functions (G94, G95, G96, G33,
G331, G332, etc.) define the admissible speed ranges of the spindle.
Speed

Max. encoder limit frequency


Max. spindle speed

Max. spindle speed of current gear stage


Programmable speed limitation G26
Programmable speed limitation LIMS
Programmable spindle speed limitation G25

Min. spindle speed of current gear stage

Fig. 5-9

5.6.1

IS Referenced/synchronized

Speed range of current gear stage


limited by G25 and G26
Speed range of current gear stage
at constant cutting speed

Speed range of current gear stage

Speed range of spindle


or spindle chuck

IS Axis/spindle stopped

Spindle stopped
0

Ranges of spindle monitoring functions / speeds

Axis/spindle stopped
Only if the spindle has stopped, e.g. if the spindle actual speed falls below a value defined in
MD 36060: STANDSTILL_VELO_TOL, the IS Axis/spindle stopped (V390x 0001.4) is set. It
is thus possible to enable such function as tool change, open machine door or feedrate.
The monitoring is active in all three spindle modes.

5-102

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Spindle (S1)
5.6

5.6.2

Spindle monitoring functions

Spindle in set range


The spindle monitoring Spindle in set range checks whether the programmed spindle speed
has been reached, whether the spindle has stopped (IS Axis/spindle stopped) or is still in the
acceleration phase.
A comparison between the setpoint speed (programmed speed with spindle correction taking
into account the active limitations) and the actual speed is made in the spindle mode Control
mode.
If the actual speed deviates from the setpoint speed more than the spindle speed tolerance
value (MD 35150: SPIND_DES_VELO_TOL (spindle speed tolerance):

5.6.3

the IS Spindle in set range (V390x2001.5) is set to zero.

the next processing block is not enabled, if MD 35500:


SPIND_ON_SPEED_AT_IPO_START is set.

Max. spindle speed

Max. spindle speed


For the spindle monitoring Max. spindle speed, a max. speed is defined which may not be
exceeded by the spindle. The max. spindle speed is entered in MD 35100: SPIND_VELO_LIMIT. The control system will limit a spindle speed that is too large to this value. If the actual
spindle speed
nevertheless exceeds the max. spindle speed taking into account the spindle speed tolerance
(MD 35150: SPIND_DES_VELO_TOL (spindle speed tolerance)), there is a drive error, and
the
IS Speed limit exceeded (V390x2002.0) is set. In addition, the alarm 22100 is output and the
spindle is decelerated.

Speed limitation from the PLC


The spindle speed can be limited to a defined value by the PLC: This value is contained in
MD 35160: SPIND_EXTERN_VELO_UNIT and is activated via the IS Velocity/spindle speed
limitation (V380x0003.6).

5.6.4

Min./max. speed of the gear stage

Max. speed
The maximum speed of the gear stage is entered in MD 35130:
GEAR_STEP_MAX_VELO_LIMIT. In the gear stage engaged, this (set) speed can never be
exceeded. In the case of a limitation of the programmed spindle speed, the IS Setpoint speed
limited (V390x2001.1) is set.

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

5-103

Spindle (S1)
5.6

Spindle monitoring functions

Min. speed
In MD 35140: GEAR_STEP_MIN_VELO_LIMIT, the minimum speed of the gear stage is entered. It is not possible that the speed falls below this (set) speed if an S value is programmed,
which is too small; the interface signal Setpoint speed increased (V390x2001.2) is set in this
case.
The min. speed of the gear stage is only active in control mode of the spindle and can only be
undershot of by:

5.6.5

Spindle override 0%

M5

S0

IS Spindle stop

Disable IS Servo enable

IS Reset

IS Spindle Reset

IS Oscillation speed

NST NC-STOP Axis and spindle

IS Axis/spindle lock

Max. encoder limit frequency

Warning
The max. encoder limit frequency of the spindle actual position encoder is monitored by the
control system (exceeding possible). The machine tool manufacturer must ensure by appropriate dimensioning of the components spindle motor, gearbox, resolver gearbox and encoder
in conjunction with the corresponding machine data that the max. speed (mechanical limit
speed) of the spindle actual position encoder cannot be exceeded.

Max. encoder limit frequency exceeded


If in spindle mode Control mode the spindle reaches a speed (large S value programmed)
that is above the max. encoder limit frequency (the max. mechanical limit speed of the encoder must not be exceeded), the synchronization gets lost. However, the spindle will go on rotating.
If one of the functions thread cutting (G33), revolutional feedrate (G95) or constant cutting rate
(G96, G97) is programmed, the spindle speed is automatically lowered until the active measuring system operates safely again.
The max. encoder limit frequency is exceeded in spindle mode Positioning mode and for
position-controlled threads (G331, G332).

5-104

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Spindle (S1)
5.6

Spindle monitoring functions

If the encoder limit frequency is exceeded, the IS Referenced / synchronized 1


(V390x0000.4) for the measuring system is reset, and the IS Encoder limit frequency 1 exceeded (V390x0000.2) is set.
If the max. encoder limit frequency is exceeded and then a speed is reached again which is
below the limit frequency defined in MD 36302: ENC_FREQ_LIMIT_LOW (percentage value
of MD36300: ENC_FREQ_LIMIT), the spindle automatically synchronizes itself with the next
zero mark or the next Bero signal.

5.6.6

Target position monitoring

Function
On positioning (spindle is in spindle mode Positioning mode), the distance how far the actual
position of the spindle is away from the programmed spindle set position (target point) is monitored.

Set position

To this aim, two limit values can be set in MD 36000: STOP_LIMIT_COARSE (exact stop coarse) and MD 36010: STOP_LIMIT_FINE (exact stop fine) as an incremental path (starting
from the setpoint position). Irrespective of the two limit values, the accuracy of the spindle positioning is always as good as specified by the connected spindle transducer, the backlash,
the gear transmission ratio, etc.

Speed

Position
Exact stop limit fine
Exact stop limit coarse

Fig. 5-10

Exact stop zones of a spindle when positioning

IS Position reached with exact stop ...


When the limit values MD 36000: STOP_LIMIT_COARSE and MD 36010: STOP_LIMIT_FINE (exact stop limit coarse and fine) are reached, the corresponding IS Position reached with exact stop coarse (V390x0000.6) and IS Position reached with exact stop fine
(V390x0000.7) are output to the PLC.

Block change at SPOS


When positioning the spindle using SPOS, the block change is carried out in accordance with
the target point monitoring using the IS Position reached with exact stop fine. During this
process, all the other functions programmed in the block must also have reached their block
end criterion (e.g. axes ready, all auxiliary functions acknowledged by the PLC).

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

5-105

Spindle (S1)
5.7

2nd spindle / master spindle

5.7

2nd spindle / master spindle


With SINUMERIK 802D, a 2nd spindle is provided with SW 2.0 and higher.

Function
With SW 2.0 and higher, the kinematic transformation functions TRANSMIT and TRACYL are possible to carry out milling on turning machines. These functions require a 2nd spindle for the driven
milling toll. When using these functions, the main spindle is run as a rotary axis.

Master spindle
The master spindle is connected to various functions which are only possible with this spindle:


G95

; Revolutional feedrate

G96, G97

; Constant cutting rate

LIMS

; Upper limit speed with G96, G97

G33, G34, G35, G331, G332

M3, M4, M5, S...

; Thread cutting, thread interpolation

; Simple specifications for the direction of rotation, stop and speed

The master spindle is defined via configuration (machine data). This is usually the main
spindle (spindle 1). In the program, it is also possible to define a different spindle as the master spindle:


SETMS(n)

; Spindle n (= 1 or 2) is master spindle as of now

Switching back is also possible as follows:




SETMS

; The configured master spindle is master spindle as of now again or

SETMS(1)

; Spindle 1 is master spindle as of now again.

The definition of the master spindle changed in the program only applies up to the end of the
program / program abortion. Then, the configured master spindle is active again.

Programming via the spindle number


Some spindle functions can also be selected via the spindle number:

5-106

S1=..., S2=...

M1=3, M1=4, M1=5 ; Specifications for the direction of rotation, stop for spindle 1

M2=3, M2=4, M2=5 ; Specifications for the direction of rotation, stop for spindle 2

M1=40, ..., M1=45

; Gear stages for spindle 1 (if any)

M2=40, ..., M2=45

; Gear stages for spindle 2 (if any)

SPOS[ n ]

; Position spindle n

SPI (n)

; converts spindle number n into axis identifier, e.g. SP1 or CC


; n must be a valid spindle number (1 or 2)
; The functions of the spindle identifiers SPI(n) and Sn are the same.

P_S[ n ]

; Speed of spindle n, which was last programmed

$AA_S[ n ]

; Actual speed of spindle n

; Spindle speed for spindle 1 or 2

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Spindle (S1)
5.8

Analog spindle

$P_SDIR[ n ]

; Direction of rotation of spindle n, which was last programmed

$AC_SDIR[ n ]

; Current direction of rotation of spindle n

2 spindles fitted
It is possible to interrogate the following in the program:

5.8

$P_NUM_SPINDLES

; Number of spindles configured (in the channel)

$P_MSNUM

; Number of the programmed master spindle

$AC_MSNUM

; Number of the active master spindle

Analog spindle

Function
For the function Analog spindle, the analog output of the SIMODRIVE 611UE closed-loop
control unit is used as the setpoint output and the encoder interface as the actual value input.
For special machine data settings and the parameterization of the SIMODRIVE 611UE drive,
please refer to:
References:
Start-Up Guide 802D
References:
Description of Functions, SIMODRIVE 611UE

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

5-107

Spindle (S1)
5.9

5.9

Data descriptions (MD, SD)

Data descriptions (MD, SD)

5.9.1

Channel - specific machine data

20090
SPIND_DEF_MASTER_SPIND
MD number
Default: 1
Min. input limit: 0
Max. input limit: 2
Change valid after Power On
Protection level: 2/2
Unit: Data type: BYTE
Valid from SW release: 2.0
Meaning:
Definition of the default setting for the master spindle (in the channel).
The number of the spindle is entered.
The master spindle is connected to various functions which are not possible with a different
spindle.
Note:
using the language command SETMS(n), the spindle number n can be declared a master spindle.
With SETMS, the spindle defined in this MD becomes a master spindle again.
At program end / program abortion, the spindle defined in this MD is also defined a master spindle.
Further references

5.9.2

Axis/spindle - specific machine data

30134
IS_UNIPOLAR_OUTPUT
MD number
Setpoint output is unipolar
Default: 0
Min. input limit: 0
Max. input limit: 2
Change valid after Power On
Protection level: 2/2
Unit: Data type: BYTE
Valid from SW release:
Meaning:
Application example(s)

Unipolar output driver (for unipolar analog drive actuators) ->analog spindle:
In the case of unipolar setting, only positive speed setpoint values are delivered to the drive; the
sign of the speed setpoint is output separately in a separate digital control sign.
0:
1:

Further references

35000
MD number
Default: 0
Change valid after Power On
Data type: BYTE
Meaning:
Application example(s)

Related to ....

5-108

bipolar output (10V) with pos./neg. speed setpoint, servo enable (normal case)
unipolar output 0...+10V with enable and direction signals
(servo enable, neg. traversing direction)
2:
unipolar output 0...+10V with linking of the enable and direction signals
(servo enable for pos. traversing direction, servo enable for neg. traversing direction)
For the assignment of the signal terminals on the SIMODRIVE 611UE drive, please refer to:
Start-Up Guide 802D
SPIND_ASSIGN_TO_MACHAX
Assignment of spindle to machine axis
Min. input limit: 0
Max. input limit: 1
Protection level: 2/2
Unit: Valid from SW release:
This MD is used to enter which machine axis is used as the spindle.
Example of a milling machine with 3 machine axes (X1, Y1, Z1) and a spindle:
SPIND_ASSIGN_TO_MACHAX [AX1] = 0 - - ->
X1
SPIND_ASSIGN_TO_MACHAX [AX2] = 0 - - ->
Y1
SPIND_ASSIGN_TO_MACHAX [AX3] = 0 - - ->
Z1
SPIND_ASSIGN_TO_MACHAX [AX4] = 1 - - ->
Spindle 1 is the 4th machine axis
MD 30300: IS_ROT_AX (rotary axis/spindle)
MD 30310: ROT_IS_MODULO (modulo conversion for rotary axis/spindle)
These machine data must be set; otherwise, the alarms 4210 Rotary axis declaration missing
and 4215 Modulo axis declaration missing (modula display 360 degrees) are output.
IS Spindle/no axis (V390x 0000.0)

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Spindle (S1)
5.9

35010
MD number
Default: 0
Change valid after RESET
Data type: BOOLEAN
Meaning:

Related to ....

Data descriptions (MD, SD)

GEAR_STEP_CHANGE_ENABLE
Gear stage change is possible
Min. input limit: 0

Max. input limit: 2 (not available with the


802D)
Protection level: 2/2
Unit: Valid from SW release:
If the spindle motor is directly mounted on the spindle (1:1) or with a transmission ratio that cannot
be changed, GEAR_STEP_CHANGE_ENABLE (gear stage change is possible) must be set to
zero. A gear stage change with M40 to M45 is not possible.
If the spindle motor is mounted on the spindle via a gear with variable gear steps,
GEAR_STEP_CHANGE_ENABLE must be set to one. The gear may have up to 5 gear stages
that can be selected using M40, M41 to M45.
MD 35110: GEAR_STEP_MAX_VELO (max. speed for gear stage change)
MD 35120: GEAR_STEP_MIN_VELO (min. speed for gear stage change)
GEAR_STEP_MAX_VELO and GEAR_STEP_MIN_VELO must cover the entire speed range.

35040
SPIND_ACTIVE_AFTER_RESET
MD number
Spindle activate after RESET
Default: 0
Min. input limit: 0
Max. input limit: 1
Change valid after Power On
Protection level: 2/2
Unit: Data type: BOOLEAN
Valid from SW release:
Meaning:
This MD is used to set how the spindle behaves after reset (V32000000.7) and program end (M2,
M30). It is only active in the spindle mode Control mode.
0:
Control mode:
- Spindle stops, is valid for M2/M30 and reset
- Program is aborted; applies to M2/M30
Oscillation mode:

Alarm 10640 No stop during gear stage change


Oscillation is not aborted
Axes are stopped
Program is aborted after gear stage change or spindle reset;
the alarm is deleted.
Positioning mode: - is stopped.
Axis mode:
- is stopped.
------------------------------------------------------------------------1:
Control mode:
- Spindle does not stop
- Program is aborted.
Oscillation mode:

Positioning mode:
Axis mode:

Alarm 10640 No stop during gear stage change


Oscillation is not aborted
Axes are stopped
Program is aborted after gear stage change, the
alarm is deleted and the spindle continues to rotate
at the programmed M and S values.
- is stopped.
- is stopped

The IS Spindle reset (V380x0002.2) is always active, irrespective of


SPIND_ACTIVE_AFTER_RESET.
MD inapplicable to ......
Related to ....

spindle modes other than control mode


IS Reset (V32000000.7)
IS Spindle Reset (V380x0002.2)

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

5-109

Spindle (S1)
5.9

Data descriptions (MD, SD)

35100
SPIND_VELO_LIMIT
MD number
Maximum spindle speed
Default: 10 000.0
Min. input limit: 0.0
Max. input limit: ***
Change valid after Power On
Protection level: 2/7
Unit: rpm
Data type: DOUBLE
Valid from SW release:
Meaning:
In this MD, the max. spindle speed is entered which may not be exceeded by the spindle (the
spindle chuck with the workpiece or the tool). The NCK limits the set spindle speed to this value if
the set speed is too large. If the max. actual spindle speed with consideration of the spindle tolerance (MD 35150: SPIND_DES_VELO_TOL) is nevertheless exceeded, a drive error exists and
the IS Speed limit exceeded (V390x2001.0) is set. In addition, the alarm 22050 Maximum speed
reached is output, and all axes and spindle of the channel are decelerated (prerequisite: encoder
is not defective).
Related to ....
MD 35150: SPIND_DES_VELO_TOL (spindle speed tolerance)
IS Speed limit exceeded (V390x2001.0)
Alarm 22050 Maximum speed reached

35110
MD number

GEAR_STEP_MAX_VELO[n]

Max. speed for gear stage change [gear stage number]: 0...5
(Index 0 has no meaning for spindles)
Default:
Min. input limit: 0.0
Max. input limit: ***
(500, 500, 1000, 2000, 4000, 8000 )
Change valid after NEW_CONF
Protection level: 2/7
Unit: rpm
Data type: DOUBLE
Valid from SW release:
Meaning:
The max. of the gear stage for the automatic gear stage change (M40 ) is preset. The gear stages
must be defined by this MD and the MD 35120: GEAR_STEP_MIN_VELO such that no gaps result between the gear stages in the programmed spindle speed range.
Wrong
GEAR_STEP_MAX_VELO [gear stage 1] =1000
GEAR_STEP_MIN_VELO [gear stage 2] =1200
Right
GEAR_STEP_MAX_VELO [gear stage 1] =1000
GEAR_STEP_MIN_VELO [gear stage 2] =950
Related to ....
MD 35010: GEAR_STEP_CHANGE_ENABLE (gear stage change is possible)
MD 35120: GEAR_STEP_MIN_VELO (min. speed for gear stage change)
MD 35140: GEAR_STEP_MIN_VELO_LIMIT (min. speed of gear stage)
MD 35130: GEAR_STEP_MAX_VELO_LIMIT (max. speed of gear stage)

35120
GEAR_STEP_MIN_VELO[n]
MD number
Min. speed for gear stage change [gear stage number]: 0...5
Default:
Min. input limit: 0.0
Max. input limit: ***
(50, 50, 400, 800, 1500, 3000)
Change valid after NEW_CONF
Protection level: 2/7
Unit: rpm
Data type: DOUBLE
Valid from SW release:
Meaning:
The min. speed of the gear stage is preset for the automatic gear stage change (M40).
For further details, see MD 35120: GEAR_STEP_MAX_VELO.
Related to ....
MD 35110: GEAR_STEP_MAX_VELO (max. speed for gear stage change)
MD 35010: GEAR_STEP_CHANGE_ENABLE (gear stage change possible)
MD 35140: GEAR_STEP_MIN_VELO_LIMIT (min. speed of gear stage)
MD 35130: GEAR_STEP_MAX_VELO_LIMIT (max. speed of gear stage)

5-110

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Spindle (S1)
5.9

Data descriptions (MD, SD)

35130
GEAR_STEP_MAX_VELO_LIMIT[n]
MD number
Max. speed of gear stage [gear stage number]; 0...5
Default:
Min. input limit: 0.0
Max. input limit: ***
(500, 500, 1000, 2000, 4000, 8000 )
Change valid after NEW_CONF
Protection level: 2/2
Unit: rpm
Data type: DOUBLE
Valid from SW release:
Meaning:
The maximum speed of the gear stage is entered. This speed can never be exceeded in the gear
stage currently engaged.
Special cases, errors, ......
 If the position control is enabled, the speed is limited to 90% of this value (control margin)
 If an S value is programmed, which is greater than the max. speed of the gear stage
engaged, the speed setpoint is limited to the max. speed of the gear stage (with gear stage
selection - M41 to M45); furthermore, the IS: Programmed speed too high is set.
 If the programmed S value is greater than the max. speed required for the gear stage change, a
new gear stage will be specified (with automatic gear stage selection - M40).
 If the programmed S value is greater than the max. speed of the highest gear stage, the
speed is limited to the max. speed of the gear stage (with automatic gear stage
selection - M40).
 If an S value is programmed for which no matching gear stage exists, no gear stage
change is carried out.
Related to ....
MD 35010: GEAR_STEP_CHANGE_ENABLE (gear stage change is possible)
MD 35110: GEAR_STEP_MAX_VELO (max. speed for gear stage change)
MD 35120: GEAR_STEP_MIN_VELO (min. speed for gear stage change)
MD 35140: GEAR_STEP_MIN_VELO_LIMIT (min. speed of gear stage)
IS Set speed limited (V390x 2001.1)

35140
GEAR_STEP_MIN_VELO_LIMIT[n]
MD number
Min. speed of gear stage [gear stage number]: 0...5
Default:
Min. input limit: 0.0
Max. input limit: ***
(5, 5, 10, 20, 40, 80)
Change valid after NEW_CONF
Protection level: 2/7
Unit: rpm
Data type: DOUBLE
Valid from SW release:
Meaning:
The minimum speed of the gear stage is entered. This speed cannot be undershot by programming an S value that is too small.
The minimum speed can only be undershot by the signals/commands/states that occur in conjunction with Min./max. speed of gear stage.
MD inapplicable to ......
 Spindle modes Oscillation mode, Positioning mode
Application example(s)
Smooth run of the motor is no longer guaranteed below the minimum speed.
Related to ....
MD 35010: GEAR_STEP_CHANGE_ENABLE (gear stage change is possible)
MD 35110: GEAR_STEP_MAX_VELO (max. speed for gear stage change)
MD 35120: GEAR_STEP_MIN_VELO (min. speed for gear stage change)
MD 35130: GEAR_STEP_MAX_VELO_LIMIT (max. speed of gear stage)
IS Set speed increased (V390x 2001.2)

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

5-111

Spindle (S1)
5.9

Data descriptions (MD, SD)

35150
MD number
Default: 0.1
0.1 = 10%
Change valid after RESET
Data type: DOUBLE
Meaning:

MD inapplicable ......

SPIND_DES_VELO_TOL
Spindle speed tolerance
Min. input limit: 0.0

Max. input limit: 1.0

Protection level: 2/2


Unit:
Valid from SW release:
factor for the spindle speed for determining the tolerance in the spindle mode Control mode.
The setpoint speed (programmed speed x spindle override with taking into account the limitations)
is compared with the actual speed.
 If the actual speed differs from the set speed more than SPIND_DES_VELO_TOL,
the IS Spindle in set range (V390x2001.5) is set to zero.
 If the actual speed exceeds the maximum spindle speed (MD 35100: SPIND_VELO_LIMIT)
more than SPIND_DES_VELO_TOL, the IS Speed limit exceeded (V390x2001.0) is set and
the alarm 22050 Maximum speed reached is output. All axes and spindles of the channel are
decelerated.
Spindle mode Oscillation mode
Spindle mode Positioning mode

Fig. 5-11
Speed
(1/min)

SPIND_DES_VELO_TOL

Upper
spindle speed tolerance
Set speed
Lower
spindle speed tolerance
Actual speed

Time (t)
Related to ....

MD 35500: SPIND_ON_SPEED_AT_IPO_START
MD 35100: SPIND_VELO_LIMIT (max. spindle speed)
IS Spindle in set range (V390x2001.5)
IS Speed limit not reached (V390x2001.0)
Alarm 22050 Max. speed reached

35160
SPIND_EXTERN_VELO_LIMIT
MD number
Spindle speed limiting from PLC
Default: 1000.0
Min. input limit: 0.0
Max. input limit: ***
Change valid after NEW_CONF
Protection level: 2/7
Unit: rpm
Data type: DOUBLE
Valid from SW release:
Meaning:
A limit value for the spindle speed is entered, which is taken into account if the IS Velocity/speed
limitation (V380x0003.6) is set. The control system will limit the speed to this value.

35200
GEAR_STEP_SPEEDCTRL_ACCEL[n]
MD number
Acceleration in speed control mode [gear stage number]: 0...5
Default:
Min. input limit: 0.001
Max. input limit: ***
(30, 30, 25, 20, 15, 10)
Change valid after NEW_CONF
Protection level: 2/7
Unit: rev./s2
Data type: DOUBLE
Valid from SW release:
Meaning:
If the spindle is in control mode, the acceleration is entered in
GEAR_STEP_SPEEDCTRL_ACCEL.
Special cases, errors, ......
The acceleration in speed control mode can be set in such a way that the current limit is reached.
Related to ....
MD 35210: GEAR_STEP_POSCTRL_ACCEL (acceleration in position control mode)

5-112

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Spindle (S1)
5.9

Data descriptions (MD, SD)

35210
GEAR_STEP_POSCTRL_ACCEL[n]
MD number
Acceleration in position control mode [gear stage number]: 0...5
Default:
Min. input limit: 0.001
Max. input limit: ***
(30, 30, 25, 20, 15, 10)
Change valid after NEW_CONF
Protection level: 2/7
Unit: rev./s2
Data type: DOUBLE
Valid from SW release:
Meaning:
The acceleration in position control mode must be adjusted such that the current limit is not
reached.
Related to ....
MD 35200: GEAR_STEP_SPEEDCTRL_ACCEL

35300
SPIND_POSCTRL_VELO
MD number
Position control threshold speed
Default: 500.0
Min. input limit: 0.0
Max. input limit: ***
Change valid after NEW_CONF
Protection level: 2/2
Unit: rpm
Data type: DOUBLE
Valid from SW release:
Meaning:
When positioning a spindle not operated in position control mode, the position control is only connected if the spindle has reached the speed defined in SPIND_POSCTRL_VELO. The speed can
be varied using FA[Sn] from the part program.
For the behavior of the spindle under different boundary conditions (positioning from the movement, positioning from the standstill), see Section Spindle mode: Positioning mode
Related to ....
MD 35350: SPIND_POSITIONING_DIR (direction of rotation when positioning from the standstill)
if no snychronization is provided.

35310
SPIND_POSIT_DELAY_TIME[n]
MD number
Positioning delay time [gear stage number]: 0...5
Default:
Min. input limit: 0.0
Max. input limit: ***
(0.0, 0.05, 0.1, 0.2, 0.4, 0.8)
Change valid after NEW_CONF
Protection level: 2/2
Unit: s
Data type: DOUBLE
Valid from SW release: 1.1
Meaning:
After the end of positioning has been reached (exact stop fine), the delay time is enabled if block
search is active when an accumulated positioning block is output (SPOS).
Related to ....

35350
MD number
Default: 3
Change valid after RESET
Data type: BYTE
Meaning:

Related to ....

SPIND_POSITIONING_DIR
Direction of rotation when positioning with the spindle not synchronized
Min. input limit: 3
Max. input limit: 4
Protection level: 2/2
Unit: Valid from SW release:
The programming of SPOS switches the spindle to position control mode and accelerates it at the
acceleration defined in MD 35210: GEAR_STEP_POSCTRL_ACCEL (acceleration in position
control mode) if no synchronization is provided. The direction of rotation is determined by
MD 35350: SPIND_POSITIONING_ DIR (direction of rotation when positioning from the standstill).
SPIND_POSITIONING_DIR = 3 - - ->
direction of rotation in CW direction
SPIND_POSITIONING_DIR = 4 - - ->
direction of rotation in CCW direction
MD 35300: SPIND_POSCTRL_VELO (position control threshold speed)

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

5-113

Spindle (S1)
5.9

Data descriptions (MD, SD)

35400
SPIND_OSCILL_DES_VELO
MD number
Oscillation speed
Default: 500.0
Min. input limit: 0.0
Max. input limit: ***
Change valid after NEW_CONF
Protection level: 2/2
Unit: rpm
Data type: DOUBLE
Valid from SW release:
Meaning:
On oscillation, a certain motor speed is specified for the spindle motor using the IS Oscillation
speed (V380x2002.5). This motor speed is defined here. This motor speed does not depend on
the current motor speed. In the AUTOMATIC and MDA screen forms, the oscillation speed is displayed in the Set Spindle window until the gear stage change has been carried out.
MD inapplicable ......
spindle modes other than oscillation mode
Application example(s)
The engaging of a new gear stage can be facilitated by oscillation of the spindle motor, since the
gear wheels may thus be better meshed.
Special cases, errors, ......
For the oscillation speed defined in this MD, the acceleration on oscillation applies
(MD 35410: SPIND_OSCILL_ACCEL).
Related to ....
MD 35410: SPIND_OSCILL_ACCEL (acceleration on oscillation)
MD 35130: GEAR_STEP_MAX_VELO_LIMIT[n] (maximum speed ofthe gear stage)
IS Oscillation by the PLC (V380x2002.4)
IS Oscillation speed (V380x2002.5)

35410
SPIND_OSCILL_ACCEL
MD number
Acceleration on oscillation
Default: 16.0
Min. input limit: 0.001
Max. input limit: ***
Change valid after NEW_CONF
Protection level: 2/2
Unit: rev./s2
Data type: DOUBLE
Valid from SW release:
Meaning:
The acceleration defined here only applies to the output of the oscillation speed
(MD 35400: SPIND_OSCILL_DES_VELO) to the spindle motor. The oscillation speed is selected
using the IS Oscillation speed.
MD inapplicable ......
spindle modes other than oscillation mode
Related to ....
MD 35400: SPIND_OSCILL_DES_VELO (oscillation speed)
IS Oscillation speed (V380x2002.5)
IS Oscillation from PLC (V380x2002.4)

35430
MD number
Default: 0
Change valid after RESET
Data type: BYTE
Meaning:

MD inapplicable ......
Related to ....

5-114

SPIND_OSCILL_START_DIR
Start direction on oscillation
Min. input limit: 0
Max. input limit: 4
Protection level: 2/2
Unit: Valid from SW release:
With the IS Oscillation speed, the spindle motor accelerates to the speed defined in MD 35400:
SPIND_OSCILL_DES_VELO. The starting direction is defined by this
MD: SPIND_OSCILL_START_DIR if the IS Oscillation from PLC is not set.
0:
Starting direction according to the last direction of rotation
1:
Start direction opposite to the last direction of rotation
2:
Start direction opposite to the last direction of rotation
3:
Start direction is M3
4:
Start direction is M4
spindle modes other than oscillation mode
MD 35400: SPIND_OSCILL_DES_VELO (oscillation speed)
IS Oscillation speed (V380x2002.5)
IS Oscillation by the PLC (V380x2002.4)

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Spindle (S1)
5.9

Data descriptions (MD, SD)

35440
MD number
Default: 1.0

SPIND_OSCILL_TIME_CW
Oscillation time for M3 direction
Min. input limit: 0.0
Max. input limit: ***
(0 means a time from one interpolation
clock)
Change valid after NEW_CONF
Protection level: 2/2
Unit: s
Data type: DOUBLE
Valid from SW release:
Meaning:
The oscillation time set here is active in the M3 direction.
MD inapplicable ......
 spindle modes other than oscillation mode
 if oscillation by the PLC (IS Oscillation by PLC (V380x2002.4) is set)
Related to ....
MD 35450: SPIND_OSCILL_TIME_CCW (oscillation time for M4 direction)
NST Oscillation speed (V380x2002.5)
NST Oscillation by PLC (V380x2002.4)

35450
MD number
Default: 0.5

SPIND_OSCILL_TIME_CCW
Oscillation time for M4 direction
Min. input limit: 0.0
Max. input limit: ***
(0 means a time from one interpolation
clock)
Change valid after NEW_CONF
Protection level: 2/2
Unit: s
Data type: DOUBLE
Valid from SW release:
Meaning:
The oscillation time defined here acts in the M4 direction.
MD inapplicable ......
 spindle modes other than oscillation mode
 if oscillation by the PLC (IS Oscillation from PLC (V380x2002.4) is set)
Fig. 5-12
Speed
(1/min)

Oscillation time

Time (t)
Related to ....

MD 35440: SPIND_OSCILL_TIME_CW (oscillation time for M3 direction)


IS Oscillation speed (V380x2002.5)
IS Oscillation by the PLC (V380x2002.4)

35500
MD number
Default: 1
Change valid after RESET
Data type: BYTE
Meaning:

SPIND_ON_SPEED_AT_IPO_START
Feed enable for spindle in set range
Min. input limit: 0
Max. input limit: 2
Protection level: 2/2
Unit: Valid from SW release:
0: The path interpolation is not influenced
1: The path interpolation is only enabled if the spindle has reached the preset speed (tolerance
band is set via MD 35150).
2: Function as with value=1,
value=1 and,
and in addition:
Traversing path axes are also stopped before the machining starts, e.g.:, continuous path mode
(G64) and change from rapid traverse (G0) to a machining block (G1, G2,..). The path is stopped
at the last G0 block and starts only when the spindle is in the speed setpoint range.
see MD 35510
MD 35150: SPIND_DES_VELO_TOL (spindle speed tolerance)
IS Spindle in set range (V390x2001.5)

Application example(s)
Related to ....

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

5-115

Spindle (S1)
5.9

Data descriptions (MD, SD)

35510
MD number
Default: 0
Change valid after RESET
Data type: BOOLEAN
Meaning:

Application example(s)

Related to ....

SPIND_STOPPED_AT_IPO_START
Feed enable with the spindle stopped
Min. input limit: 0
Max. input limit: 1
Protection level: 2/2
Unit: Valid from SW release:
If a spindle is stopped (M5), the path feed is disabled if SPIND_STOPPED_AT_IPO_START is set
and the spindle is in control mode.
If the spindle has come to a standstill (IS Axis/spindle stopped (V390x0001.4) is set), the feedrate will be enabled.
MD 35500 and this MD 35510 can be used to handle the feedrate as follows, depending on the
spindle actual speed (control mode):
 If the spindle is in the acceleration phase (programmed set speed not yet reached), the feedrate
will be disabled.
 If the actual speed deviates from the set speed less than the spindle speed tolerance
(MD 35150: SPIND_DES_VELO_TOL), the feedrate is enabled.
 If the spindle is in the brake phase, the feedrate will be disabled.
 If the spindle is signaled stopped (IS: Axis/spindle stopped V390x0001.4),
the feedrate is enabled.
 Blocks that contain G0 cannot be manipulated in this way.
MD 35500: SPIND_ON_SPEED_AT_IPO_START (feed enable for spindle in set range)

36720
DRIFT_VALUE
MD number
Drift base value
for analog spindle only
Default: 0.0
Min. input limit: -5.0
Max. input limit: 5.0
Change valid after NEW_CONF
Protection level:: 2/2
Unit: %
Data type: DOUBLE
Valid from SW release: 1.1
Meaning:
The drift base value entered here is always provided as an additional speed setpoint if an analog
spindle is used.
MD inapplicable ......

5.9.3

Spindle - specific setting data

43210
SD number
Default: 0.0
Change valid: immediately
Data type: DOUBLE
Meaning:

SD inapplicable ......
Special cases, errors, ......

Related to ....

5-116

SPIND_MIN_VELO_G25
Programmable lower spindle speed limitation with G25
Min. input limit: 0.0
Max. input limit: ***
Protection level: 7/7
Unit: rpm
Valid from SW release:
In this SDS, a min. spindle speed limitation is entered, which may not be exceeded by the spindle.
If the spindle speed is too low, the NCK will limit it to this value.
The minimum spindle speed may ony be undershot by:
 Spindle override 0%
 M5
 S0
 IS Spindle stop (V380x0004.3)
 IS Servo enable (V380x0002.1)
 IS Reset (V30000000.7)
 IS Spindle reset (V380x0002.2)
 IS Oscillation speed (V380x2002.5)
any other spindle modes than control mode
The value in SPIND_MIN_VELO_G25 can be modified by:
 G25 S.... in the part program
 Operation from HMI
The value in SD: SPIND_MIN_VELO_G25 remains stored even after RESET or mains power off.
SD 43220: SPIND_MAX_VELO_G26
SD 43230: SPIND_MAX_VELO_LIMS (progr. spindle speed limitation with G96)

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Spindle (S1)
5.9

43220
SD number
Default: 1000.0
Change valid: immediately
Data type: DOUBLE
Meaning:
SD inapplicable to ......
Special cases, errors, ......

Related to ....

43230
SD number
Default: 100.0
Change valid: immediately
Data type: DOUBLE
Meaning:

SD inapplicable to ......
Application example(s)

Special cases, errors, ......

Related to ....

Data descriptions (MD, SD)

SPIND_MAX_VELO_G26
Progr. spindle speed limitation with G26
Min. input limit: 0.0
Max. input limit: ***
Protection level: 7/7
Unit: rpm
Valid from SW release:
In this SD, a max. spindle speed limitation is entered which may not be exceeded by the spindle. If
the spindle speed is too high, the NCK will limit the spindle speed to this value.
spindle modes other than control mode
The value in SD: SPIND_MIN_VELO_G26 can be modified by:
 G26 S.... in the part program
 Operation from HMI
The value in SD: SPIND_MIN_VELO_G26 remains stored even after RESET or mains power off.
SD 43210: SPIND_MIN_VELO_G25 (progr. spindle speed limiting G25)
SD 43230: SPIND_MAX_VELO_LIMS (progr. spindle speed limiting with G96)

SPIND_MAX_VELO_LIMS
Progr. spindle speed limitation G96
Min. input limit: 0.0
Max. input limit: ***
Protection level: 7/7
Unit: rpm
Valid from SW release:
With constant cutting rate (G96 and G97), in addition to the limitations permanently active, an additional limitation acts, which is entered in SPIND_MAX_VELO_LIMS. Furthermore, it is possible to
describe SPIND_MAX_VELO_LIMS in the part program using LIMS=.... .
all spindle modes except for G96 and G97 (constant cutting rate)
On parting and in the case of very small machining diameters, the spindle with the workpiece (turning machine) accelerates higher and higher at constant cutting rate (G96), theoretically reaching
an infinitely high set speed in the position of the traverse axis X=0. In these cases, the spindle
accelerates to its max. spindle speed of the current gear stage (if applicable, limited by G26). If
you wish to limit the spindle to a lower speed (especially, with G96), this can be dopne using
LIMS=.... SPIND_MAX_VELO_LIMS.
The value in SD 43210: SPIND_MIN_VELO_LIMS can be modified by:
 LIMS S.... in the part program
 Operation from HMI
The value in SD: SPIND_MIN_VELO_LIMS remains stored even after RESET and mains off.
SD 43220: SPIND_MAX_VELO_G26 (max. spindle speed)
SD 43210: SPIND_MIN_VELO_G25 (min. spindle speed)

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

5-117

Spindle (S1)
5.10

5.10

Signal descriptions

Signal descriptions

5.10.1

Axis/spindle - specific signals

Transferred M/S functions, axis-specific


VD370x 0000
Interface signal
Edge evaluation:

Related to ....

VD370x 0004
Interface signal
Edge evaluation:

Related to ....

M function for spindle


Signal(s) from axis/spindle (NCK -> PLC), axis-specific
Signal(s) updated: cyclically
Signal(s) valid from SW release:
Generally, the M functions are output channel-specifically in V2500.... In the range V25001...., they
are present only for one PLC cycle, and in V25003..., they are only present until a new output is
provided.
This IS M function for spindle provides selected M functions for the spindle as integer current
values of the PLC.
 M3 -> value: 3
 M4 -> value: 4
 M5 -> value: 5
IS S function for spindle (VD370x 0004), axis-specific
IS Transfer of auxiliary function from NC channel (V2500...)

S function for spindle


Signal(s) from axis/spindle (NCK -> PLC), axis-specific
Signal(s) updated: cyclically
Signal(s) valid from SW release:
Generally, the S function is transferred to the PLC channel-specifically in VD2500 4000 as a floating point value.
In this IS S function for spindle, the output is provided as a floating point value to the PLC axisspecifically:
 S.... as a spindle speed in 1/min (programmed value)
 S.... as a constant cutting rate in m/min or ft/min with G96
The following S functions are not output here:
 S.... as a progr. spindle speed limitation G25
 S.... as a progr. spindle speed limitation G26
 S.... as a dwell time in spindle revolutions
IS M function for spindle (VD370x 0000), axis-specific
IS Transferred S function (VD2500 4000 ), channel-specific

Signals to axis/spindle
V380x 0002.2
Interface signal

Spindle reset/delete distance to go


Signal(s) to axis/spindle (PLC -> NCK)

Edge evaluation: yes


Edge change 0 - - -> 1

Signal(s) updated: cyclically


Signal(s) valid from SW release:
Irrespective of MD 35040: SPIND_ACTIVE_AFTER_RESET, Spindle reset selects the following
spindle modes in the following way:
Control mode:
- Spindle stops.
- Program is continued.
- Spindle goes on rotating with the next following M and S commands
Oscillation mode:

Positioning mode:

5-118

Oscillation is aborted
Axes go on moving
Program is continued with current gear stage
If necessary the IS Set speed limited (V390x2001.1) is set with the
next following M value and a larger S value.
- is stopped

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Spindle (S1)
5.10

Signal descriptions

V380x 0002.2
Interface signal
Signal state 0 or edge
change 1 - - -> 0

Spindle reset/delete distance to go


Signal(s) to axis/spindle (PLC -> NCK)
No effect

Related to ....

MD 35040: SPIND_ACTIVE_AFTER_RESET (separate spindle reset)


IS Reset (V30000000.7)
IS Delete distance to go (V380x0002.2) is another name for the same signal, but applicable to
the axis

V380x 2000.3
Interface signal
Edge evaluation: yes
Signal state 1 or edge
change 0 - - -> 1

Gear is switched over


Signal(s) to axis/spindle (PLC -> NCK)
Signal(s) updated: cyclically
Signal(s) valid from SW release:
If the new gear stage is engaged, the IS Actual gear stages A to C and the IS Gear is switched
over are set by the PLC user. This will tell the NCK that the right gear stage has been sucessfully
engaged. The gear stage change is considered completed (spindle mode Oscillation mode deselected), the spindle rotates in the new gear stage to the spindle speed last programmed and the
next block in the part program can be executed. The IS Switch over gear is reset by the NCK,
and the PLC user will reset the IS Gear is switched over as a reaction.
No effect

Signal state 0 or edge


change 1 - - -> 0
Signal inapplicable ......
Special cases, errors, ......

Related to ....

V380x 2000.0 to .2
Interface signal
Edge evaluation: yes
Signal state 1 (status-controlled)

spindle modes other than oscillation mode


If an actual gear stage other than that fed back from the NCK to the PLC as the set gear stage is
fed back from the PLC user to the NCK, then the gear stage is nevertheless considered successfully completed and the actual gear stage A to C is activated.
IS Actual gear stage A to C (V380x2000.0 to .2)
IS Set gear stage A to ...C (V390x2000.0 to .2)
IS Switch over gear (V390x2000.3)
IS Oscillation speed (V380x2002.5)

Actual gear stages A to C


Signal(s) to axis/spindle (PLC -> NCK)
Signal(s) updated: cyclically
Signal(s) valid from SW release:
If the new gear stage is engaged, the IS Actual gear stages A to C and the IS Gear is switched
over are set by the PLC user. This will tell the NCK that the right gear stage has been successfully engaged. The gear stage change is considered completed (spindle mode Oscillation mode
is deselected), the spindle accelerates in the new gear stage to the spindle speed last programmed and the next block in the part program can be executed.
The actual gear stage is specified in coded form.
For each of the 5 gear steps, one parameter set each is provided, which is assigned as follows:
Parameter
Set No. Code
0

CBA
-

Data of data record

Contents

Data for axis mode

Servo gain factor


Monitoring functions
M40 speed
Min./max. speed
.Accelerations
etc.

000
001

Data for 1st gear stage

2
3
4
5

010
011
100
101
110
111

Data for 2nd gear stage


Data for 3rd gear stage
Data for 4th gear stage
Data for 5th gear stage

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

5-119

Spindle (S1)
5.10

Signal descriptions

V380x 2000.0 to .2
Interface signal
Special cases, errors, ......

Related to ....

V380x 2001.4
Interface signal
Edge evaluation: yes
Signal state 1
Signal state 0 or edge
change 1 - - -> 0
Signal inapplicable ......
Application example(s)

Related to ....

V380x 2001.6
Interface signal
Edge evaluation: yes
Signal state 1 or edge
change 0 - - -> 1

Application example(s)

V380x 2002.7 / .6
Interface signal
Edge evaluation: yes
Signal state 1 or edge
change 0 - - -> 1

Signal inapplicable ......


Application example(s)
Special cases, errors, ......
Related to ....

5-120

Actual gear stages A to C


Signal(s) to axis/spindle (PLC -> NCK)
If an actual gear stage other than that fed back from the NCK to the PLC as the set gear stage is
fed back from the PLC user to the NCK, then the gear stage is nevertheless considered successfully completed and the actual gear stage A to C is activated.
IS Set gear stage A to C (V390x2000.0 to .2)
IS Switch over gear (V390x2000.3)
IS Gear switched over (V380x2000.3)
IS Oscillation speed (V380x2002.5)
Parameter sets (MDs) for gear stages

Resynchronize spindle when positioning 1


Signal(s) to axis/spindle (PLC -> NCK)
Signal(s) updated: cyclically
The spindle is to be resynchronized when positioning.
No effect

Signal(s) valid from SW release:

spindle modes other than positioning mode


The spindle has an indirect measuring system, and a slip may occur between motor and workholder. When the positioning process is started if the signal=1, the old reference is deleted and the
zero marker is searched again before the final position is approached.
IS Referenced/synchronized 1 (V390x0000.4)

Invert M3/M4
Signal(s) to axis/spindle (PLC -> NCK)
Signal(s) updated: cyclically
Signal(s) valid from SW release:
The direction of rotation of the spindle motor changes with the following functions:
 M3
 M4
 M5
 SPOS from the movement; not active for SPOS from the standstill.
The machine can be switched over between vertical and horizontal spindle. It is mechanically designed such that with the horizontal spindle one gear wheel more is meshed than with the vertical
spindle. As a result, the direction of rotation of the vertical spindle must be changed if the spindle is
always to rotate clockwise with M3.

Set direction of rotation CCW / set direction of rotation CW


Signal(s) to axis/spindle (PLC -> NCK)
Signal(s) updated: cyclically
Signal(s) valid from SW release: 1.1
If the IS Oscillation from PLC is set, the two IS Set direction of rotation CCW and CW can be
used to define the direction of rotation for the oscillation speed. The times for the oscillation movement of the spindle motor are defined such that the IS Set direction of rotation CCW and CW are
set correspondingly long.
spindle modes other than oscillation
see IS Oscillation by the PLC
 If both IS are set at the same time, no oscillation speed is output.
 If no IS is set, no oscillation speed is output.
IS Oscillation by the PLC (V380x2002.4)
IS Oscillation speed (V380x2002.5)

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Spindle (S1)
5.10

V380x 2002.5
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 - - -> 1

Signal state 0 or edge


change 1 - - -> 0
Signal inapplicable ......
Application example(s)
Related to ....

V380x 2002.4
Interface signal
Edge evaluation: yes
Signal state 1 or edge
change 0 - - -> 1

Signal state 0 or edge


change 1 - - -> 0

Application example(s)

Related to ....

Signal descriptions

Oscillation speed
Signal(s) to axis/spindle (PLC -> NCK)
Signal(s) updated: cyclically
Signal(s) valid from SW release: 1.1
To carry out a gear stage change (IS Switch over gear (V390x2000.3) is set), the spindle mode
changes to oscillation mode.
Depending on at which moment the IS Oscillation speed (V380x2002.5) is set, the spindle will
brake to a standstill at different accelerations:
1. The IS Oscillation speed is set before the IS Switch over gear is set by the NCK. The
spindle is decelerated to a standstill at the acceleration of oscillation
(MD: SPIND_OSCILL_ACCEL). If the spindle has stopped, the oscillation is started
immediately.
2. The IS Oscillation speed is set after the IS Switch over gear has been set by the NCK and
after the spindle has come to a standstill. The position control is switched off. The spindle will
be decelerated at the acceleration of the speed control mode. After the IS Oscillation speed
has been set, the spindle starts to oscillate at the oscillation acceleration
(MD: SPIND_OSCILL_ACCEL).
If the IS Oscillation from PLC (V380x2002.4) is not set, the IS Oscillation speed is used to
carry out automatic oscillation in the NCK. The two times for the directions of rotation are entered
in SPIND_OSCILL_TIME_CW (oscillation time for M3 direction) and SPIND_OSCILL_TIME_CCW
(oscillation time for M4 direction).
If the IS Oscillation by the PLC is set, a speed is output with the IS Oscillation speed only in
conjunction with the IS Set direction of rotation CW and CCW. The oscillation, i.e. the continuous
change of the direction of rotation, is carried out by the PLC user using the IS Set direction of
rotation CW and CCW (oscillation from PLC).
The spindle will not oscillate.
all spindle modes except for oscillation mode
The oscillation speed is used to facilitate meshing of a new gear stage.
IS Oscillation by the PLC (V380x2002.4)
IS Set direction of rotation CCW (V380x2002.7)
IS Set direction of rotation CW (V380x2002.6)

Oscillation by the PLC


Signal(s) to axis/spindle (PLC -> NCK)
Signal(s) updated: cyclically
Signal(s) valid from SW release:
If the IS Oscillation by the PLC is set, a speed is output with the IS Oscillation speed only in
conjunction with the IS Set direction of rotation CW and CCW. The oscillation, i.e. the continuous
change of the direction of rotation, is carried out by the PLC user using the IS Set direction of
rotation CW and CCW (oscillation from PLC).
If the IS Oscillation by the PLC is not set, the IS Oscillation speed is used to carry out automatic oscillation in the NCK. The two time values for the directions of rotation are entered in the
MD 35440: SPIND_OSCILL_TIME_CW (oscillation time for the M3 direction) and MD 35450:
SPIND_OSCILL_TIME_CCW (oscillation time for the M4 direction).
If the new gear stage cannot be engaged despite several attempts during oscillation by the NCK, it
is possible to switch over to oscillation by the PLC. In this case, the two time values for the directions of rotation can be modified by the PLC user as he wants. This will guarantee that a safe
switch-over of the gear stage is possible even if the gears are in unfavorable position.
MD 35440: SPIND_OSCILL_TIME_CW (oscillation time for M3 direction)
MD 35450: SPIND_OSCILL_TIME_CCW (oscillation time for M4 direction)
IS Oscillation speed (V380x2002.5)
IS Set direction of rotation CCW (V380x2002.7)
IS Set direction of rotation CW (V380x2002.6)

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

5-121

Spindle (S1)
5.10

Signal descriptions

Signals from axis/spindle


V390x 0000.0
Interface signal
Edge evaluation: yes
Signal state 1 or edge
change 0 - - -> 1

Signal state 0 or edge


change 1 - - -> 0

Application examples

V390x 2000.3
Interface signal
Edge evaluation: yes
Signal state 1 or edge
change 0 - - -> 1

Special cases, errors, ......


Related to ....

5-122

Spindle/no axis
Signal(s) from axis/spindle (NCK -> PLC)
Signal(s) updated: cyclically
Signal(s) valid from SW release:
The machine axis is operated as a spindle in the following spindle operating modes:
 Control mode
 Oscillation mode
 Positioning mode
 Tapping without compensating chuck
The IS provided to the axis (V380x1000 to V380x1003) and from the axis (V390x1000 to
V390x1003) are invalid.
The IS provided to the spindle (V380x2000 tois V380x2003) and from the spindle (V380x2000 to
V380x2003) are invalid.
The machine axis is operated as an axis.
The IS provided to the axis (V380x1000 to V380x1003)) and from the axis (V390x1000 to
V390x1003) are valid.
The IS provided to the spindle (V380x2000 to V380x2003) and from the spindle (V380x2000 to
V380x2003) are invalid.
If a spindle on a machine tool is sometimes also operated as a rotary axis (turning machine with
spindle/C axis or milling machine with spindle/rotary axis for rigid tapping), it is possible to recognize from the IS Spindle/no axis whether the machine axis is in axis or in spindle mode.

Switch gear
Signal(s) from axis/spindle (NCK -> PLC)
Signal(s) updated: cyclically
Signal(s) valid from SW release:
A gear stage can be defined:
 fixed by the part program (M41 to M45)
 automatically by the programmed spindle speed (M40)
M41 to M45:
 The gear stage can be specified in the part program as a fixed gear stage using M41 to M45.
If a gear stage other than the current (actual) gear stage is specified using M41 to M45, the
IS Switch over gear and the IS Set gear stage A to C is set.
M40:
D With M40 in the part program, the gear stage is automatically set by the control system. In
this case a check is carried out to see in which gear stage the programmed spindle
speed (S function) is possible. If a gear stage is found which is different than the current
(actual) gear stage, the IS Switch gear and the IS Set gear stage A to C is set.
 When the signal = 1, the text Waiting for gear stage change ... is displayed in the channel
process message.
The IS Switch over gear is only set if the new gear stage specified is other than the current actual gear stage.
IS Set gear stage A to C (V390x2000.0 to .2)
IS Actual gear stage A to C (V380x2000.0 to .2)
IS Gear is switched over (V380x2000.3)

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Spindle (S1)
5.10

V390x 2000.0 to .2
Interface signal
Edge evaluation: yes
Signal state 1 or edge
change 0 - - -> 1

Signal inapplicable to ......


Related to ....

V390x 2001.7
Interface signal
Edge evaluation: yes
Signal state 1 or edge
change 0 - - -> 1
Signal state 0 or edge
change 1 - - -> 0
Signal inapplicable to ......

Related to ....

V390x2001.5
Interface signal
Edge evaluation: yes
Signal state 1 or edge
change 0 - - -> 1

Signal state 0 or edge


change 1 - - -> 0

Signal inapplicable to ......

Signal descriptions

Set gear stages A to C


Signal(s) from axis/spindle (NCK -> PLC)
Signal(s) updated: cyclically
Signal(s) valid from SW release:
A gear stage can be defined:
 fixed by the part program (M41 to M45)
 automatically by the programmed spindle speed (M40)
M41 to M45:
 The gear stage can be specified in the part program as a fixed gear stage using M41
to M45. If a gear stage other than the current (actual) gear stage is specified using M41 to
M45, IS Switch gear and the IS Set gear stage A to C is set.
M40:
 With M40 in the part program, the gear stage is automatically set by the control system. In this
case a check is carried out to see in which gear stage the programmed spindle speed (S
function) is possible. If a gear stage other than the current (actual) gear stage is found, the
IS Switch over gear and the IS Set gear stage A to C is set.
The set gear stage is output coded:
1st gear stage
0 0 0 (C B A)
1st gear stage
001
2nd gear stage
010
3rd gear stage
011
4th gear stage
100
5th gear stage
101
Invalid value
110
Invalid value
111
all spindle modes except for oscillation mode
IS Switch over gear (V390x2000.3)
IS Actual gear stage A to C (V380x2000.0 to .2)
IS Gear is switched over (V380x2000.3)

Actual direction of rotation CW


Signal(s) from axis/spindle (NCK -> PLC)
Signal(s) updated: cyclically
Signal(s) valid from SW release:
When the spindle rotates, the IS Actual direction of rotation CW = 1 signals CW direction of rotation. The actual direction of rotation is derived from the spindle position encoder.
When the spindle rotates, the IS Actual direction of rotation CCW = U signals CCW direction of
rotation.
 Spindle at a standstill, IS Axis/spindle stopped = 1 (at a standstill, no evaluation of a
direction of rotation possible)
 Spindles without position encoder
IS Spindle stopped (V390x0001.4)

Spindle in set range


Signal(s) from axis/spindle (NCK -> PLC)
Signal(s) updated: cyclically
Signal(s) valid from SW release:
The IS Spindle in set range signals whether the programmed and (sometimes) limited spindle
speed is reached.
In the spindle mode Control mode, the set speed (programmed speed * spindle override with
taking into account the limitations) is compared with the actual speed. If the actual speed deviates
from the set speed less than allowed by the spindle speed tolerance MD 35150:
SPIND_DES_VELO_TOL, the IS Spindle in set range is set.
The IS Spindle in set range signals whether the spindle is still in the acceleration/brake phase.
In the spindle mode Control mode, the set speed (programmed speed * spindle override with
consideration of the limitings) is compared with the actual speed. If the actual speed deviates from
the set speed more than allowed by the spindle tolerance SPIND_DES_VELO_TOL, the
IS Spindle in set range is reset.
all spindle modes except for speed control mode (control mode).

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

5-123

Spindle (S1)
5.10

Signal descriptions

V390x2001.5
Interface signal
Application example(s)

Related to ....

V390x 2001.2
Interface signal
Edge evaluation: yes
Signal state 1 or edge
change 0 - - -> 1

Signal state 0 or edge


change 1 - - -> 0
Application example(s)

V390x 2001.1
Interface signal
Edge evaluation: yes
Signal state 1 or edge
change 0 - - -> 1

Signal state 0 or edge


change 1 - - -> 0
Application example(s)

5-124

Spindle in set range


Signal(s) from axis/spindle (NCK -> PLC)
When the spindle is in the acceleration phase (programmed set speed not yet reached), normally,
the feedrate must be disabled.
This can be done in the following manner:
 The IS Spindle in set range is evaluated and the IS Feed disable (V32000006.0) set.
 The MD 35500: SPIND_ON_SPEED_AT_IPO_START (feed enable for spindle in set
range) is set and the NCK internally evaluates whether the spindle is in the set range. The
feedrate will only be enabled if the spindle is in set range again. Positioning axes will never be
stopped by this function.
MD 35500: SPIND_DES_VELO_TOL (spindle speed tolerance)

Set speed increased (programmed speed too low)


Signal(s) from axis/spindle (NCK -> PLC)
Signal(s) updated: cyclically
Signal(s) valid from SW release:
If a spindle speed (1/min) or a constant cutting rate (m/min and/or ft/min) is programmed, one of
the following limit values has been undershot:
 min. speed of the specified gear stage
 min. spindle speed
 speed limitation by the PLC
 programmed spindle speed limitation G25
 programmed spindle speed limitation with G96
The spindle speed is limited to the min. limit value.
If a spindle speed (1/min) or constant cutting speed (m/min or ft/min) has been programmed, no
limit values have been undershot.
It can be recognised from the IS Set speed increased that the programmed speed cannot be
reached. The PLC user can recognise this state as inadmissible and disable the feedrate, or he
can disable the feedrate or the entire channel. If the IS Spindle in set range is set, the machining
is carried out.

Set speed limited (programmed speed too high)


Signal(s) from axis/spindle (NCK -> PLC)
Signal(s) updated: cyclically
Signal(s) valid from SW release:
If a spindle speed (1/min) or a constant cutting rate (m/min and/or ft/min) is programmed, one of
the following limit values has been exceeded:
 max. speed of the specified gear stage
 max. spindle speed
 speed limitation by interface signal from PLC
 progr. spindle speed limitation G26
 progr. spindle speed limitation with G96
The spindle speed will be limited to the max. limit value.
If a spindle speed (1/min) or a constant cutting rate (m/min or ft/min) has been programmed, no
limit values have been exceeded.
It can be recognized from the IS Set speed limited that the programmed speed cannot be reached. The PLC user can recognise this state as inadmissible and disable the feedrate, or he can
disable the feedrate or the entire channel. If the IS Spindle in set range is set, the machining is
carried out.

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Spindle (S1)
5.10

V390x2001.0
Interface signal
Edge evaluation: yes
Signal state 1 or edge
change 0 - - -> 1

Related to ....

Signal descriptions

Speed limit exceeded


Signal(s) from axis/spindle (NCK -> PLC)
Signal(s) updated: cyclically
Signal(s) valid from SW release:
If the actual speed exceeds the max. spindle speed MD 35100: SPIND_VELO_ LIMIT more than
allowed by the spindle speed tolerance MD 35150: SPIND_DES_VELO_TOL, the IS Speed limit
exceeded is set and alarm 22050 Max. speed reached is output. All axes and spindles of the
channel are decelerated.
MD 35150: SPIND_DES_VELO_TOL (spindle speed tolerance)
MD 35100: SPIND_VELO_LIMIT (max. spindle speed)
Alarm 22050 Max. speed reached

V390x 2002.7
Interface signal
Edge evaluation: yes
Signal state 1 or edge
change 0 - - -> 1
Related to ....

Active spindle mode Control mode


Signal(s) from axis/spindle (NCK -> PLC)
Signal(s) updated: cyclically
Signal(s) valid from SW release:
With the following function, the spindle is in control mode:
Specification of direction of rotation of the spindle M3/M4 or spindle stop M5
IS Active spindle mode Oscillation mode (V390x2002.6)
IS Active spindle mode Positioning mode (V390x2002.5)

V390x 2002.6
Interface signal
Edge evaluation: yes
Signal state 1 or edge
change 0 - - -> 1

Active spindle mode Oscillation mode


Signal(s) from axis/spindle (NCK -> PLC)
Signal(s) updated: cyclically
Signal(s) valid from SW release:
The spindle is in oscillation mode if a new gear stage has been specified (IS Switch over gear is
set)) either by automatic gear stage selection (M40) or by M41 to M45 (IS Switch over gear is
set). The IS Switch over gear is only set if the new gear stage specified is other than the current
actual gear stage.
IS Active spindle mode Control mode (V390x2002.7)
IS Active spindle mode Positioning mode (V390x2002.5)
IS Switch over gear (V390x2000.3)

Related to ....

V390x 2002.5
Interface signal
Edge evaluation: yes
Signal state 1 or edge
change 0 - - -> 1
Related to ....

Active spindle mode Positioning mode


Signal(s) from axis/spindle (NCK -> PLC)
Signal(s) updated: cyclically
Signal(s) valid from SW release:
If SPOS=..... is programmed, the spindle is in positioning mode.

V390x 2002.3
Interface signal
Edge evaluation: yes
Signal state 1 or edge
change 0 - - -> 1

Rigid tapping active


Signal(s) from axis/spindle (NCK -> PLC)
Signal(s) updated: cyclically
Signal(s) valid from SW release :
The spindle is operated with the function Rigid tapping (thread interpolation G331/G332).
On rigid tapping (tapping without compensating chuck), the spindle speed programming is also
carried out with S.... in 1/min, but the direction of rotation is defined by a sign and stored with the
pitch.
No reaction or updating of all spindle-specific interface signals is carried out, such as:
IS Spindle reset
IS Synchronize spindle
IS Invert M3/M4
IS Spindle in set range
IS Programmable speed too high

IS Active spindle mode Control mode (V390x2002.7)


IS Active spindle mode Oscillation mode (V390x2002.6)

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

5-125

Spindle (S1)
5.10

Signal descriptions

V390x 2002.3
Interface signal
Application example(s)

Rigid tapping active


Signal(s) from axis/spindle (NCK -> PLC)
During rigid tapping, certain functions should not be used, e.g.:
 Reset IS Servo enable (V380x0002.1)
 IS Set feed stop (V380x0004.3)
 Reset
 If EMERGENCY STOP is pushed during rigid tapping, it should be taken into account that a
workpiece is clamped in the tool.

Related to ....

V390x 2002.0
Interface signal
Edge evaluation: yes
Signal state 1 or edge
change 0 - - -> 1
Related to ....

5-126

Constant cutting rate active


Signal(s) from axis/spindle (NCK -> PLC)
Signal(s) updated: cyclically
Signal(s) valid from SW release:
If G96 S... is programmed, the function Constant cutting rate is executed.
The S word is now applicable as the cutting value.

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Spindle (S1)
5.11

5.11

Data fields, lists

Data fields, lists

5.11.1

Interface signals

Number

.Bit

Name

Ref.

Axis-specific
VD30x 000

M function for the spindle (DINT), axis-specific

VD30x 004

S function for the spindle (REAL), axis-specific

VB380x 0000

Feed override

V380x 0001

.7

Override active

V380x 0001

.5

Position measuring system 1

V380x 0001

.3

Axis/spindle lock

V380x 0002

.2

Spindle reset/delete distance to go

V380x 0002

.1

Servo enable

V380x 0003

.6

Velocity/spindle speed limitation

V380x 2000

.3

Gear is switched over

V380x 2000

.0 to .2

Actual gear stages A to C

V380x 2001

.4

Resynchronize when positioning 1 (spindle)

V380x 2001

.6

Invert M3/M4

V380x 2002

.7

Set direction of rotation CCW

V380x 2002

.6

Set direction of rotation CW

V380x 2002

.5

Oscillation speed

V380x 2002

.4

Oscillation by the PLC

VB380x 2003

Spindle override

V390x 0000

.7

Position reached with exact stop fine

V390x 0000

.6

Position reached with exact stop coarse

V390x 0000

.4

Referenced/synchronized 1

V390x 0000

.2

Encoder limit frequency exceeded 1

V390x 0000

.0

Spindle/no axis

V390x 0001

.7

Current controller acitve

V390x 0001

.6

Speed controller active

V390x 0001

.5

Position controller active

V390x 0001

.4

Axis/spindle stopped (n < nmin )

V390x 2000

.3

Switch over gear

V390x 2000

.0 to .2

Set gear stage A to ...C

V390x 2001

.7

Actual direction of rotation CW

V390x 2001

.5

Spindle in set range

V390x 2001

.2

Set speed increased

V390x 2001

.1

Set speed limited

V390x 2001

.0

Speed limit exceeded

V390x 2002

.7

Active spindle mode Control mode

V390x 2002

.6

Active spindle mode Oscillation mode

V390x 2002

.5

Active spindle mode Positioning mode

V390x 2002

.3

Rigid tapping active

V390x 2002

.0

Constant cutting rate active (G96)

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

5-127

Spindle (S1)
5.11

Data fields, lists

5.11.2

Machine data

Number

Identifier

Name

Ref.

Channel-specific
20090

SPIND_DEF_MASTER_SPIND

Masterspindel

Axis-specific
30134

IS_UNIPOLAR_OUTPUT

Setpoint output is unipolar

30300

IS_ROT_AX

Rotary axis

R2

30310

ROT_IS_MODULO

Modulo conversion

R2

30320

DISPLAY_IS_MODULO

Position display

R2

31050

DRIVE_AX_RATIO_DENOM[n]

Load gear denominator

G2

31060

DRIVE_AX_RATIO_NUMERA[n]

Load gear numerator

G2

32200

POSCTRL_GAIN[n]

Servo gain factor

G2

32810

EQUIV_SPEEDCTRL_TIME[n]

Equivalent time constant for feedforward control of


speed control loop

K3

34040

REFP_VELO_SEARCH_MARKER

Reference shutdown speed

R1

34060

REFP_MAX_MARKER_DIST

Monitoring of zero reference mark distance

R1

34080

REFP_MOVE_DIST

Reference point distance/target position with


distance-coded system

R1

34090

REFP_MOVE_DIST_CORR

Reference-point offset/absolute offset distance


coded

R1

34100

REFP_SET_POS

Reference-point value

R1

34200

ENC_REFP_MODE

Referencing mode

R1

35000

SPIND_ASSIGN_TO_MACHAX

Assignment of spindle to machine axis

35010

GEAR_STEP_CHANGE_ENABLE

Gear step change possible

35040

SPIND_ACTIVE_AFTER_RESET

Spindle activated by reset

35100

SPIND_VELO_LIMIT

Max. spindle speed

35110

GEAR_STEP_MAX_VELO[n]

Max. speed for gear stage change

35120

GEAR_STEP_MIN_VELO[n]

Min. speed for gear stage change

35130

GEAR_STEP_MAX_VELO_LIMIT[n]

Max. speed of gear stage

35140

GEAR_STEP_MIN_VELO_LIMIT[n]

Min. speed of gear stage

35150

SPIND_DES_VELO_TOL

Spindle speed tolerance

35160

SPIND_EXTERN_VELO_LIMIT

Spindle speed limitation from PLC

35200

GEAR_STEP_SPEEDCTRL_ACCEL[n]

Acceleration in speed control mode

35210

GEAR_STEP_POSCTRL_ACCEL[n]

Acceleration in position control mode

35300

SPIND_POSCTRL_VELO

Position control threshold speed

35350

SPIND_POSITIONING_DIR

Direction of rotation when positioning with the


spindle not synchronized

35400

SPIND_OSCILL_DES_VELO

Oscillation speed

35410

SPIND_OSCILL_ACCEL

Acceleration on oscillation

35430

SPIND_OSCILL_START_DIR

Start direction on oscillation

35440

SPIND_OSCILL_TIME_CW

Oscillation time for M3 direction

35450

SPIND_OSCILL_TIME_CCW

Oscillation time for M4 direction

35500

SPIND_ON_SPEED_AT_IPO_START

Feed enable with spindle in set range

35510

SPIND_STOPPED_AT_IPO_START

Feed enable with the spindle stopped

5-128

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Spindle (S1)
5.11

Number

Identifier

Data fields, lists

Name

Ref.

Axis-specific
36060

STANDSTILL_VELO_TOL

Threshold speed Axis/spindle stopped

A3

AX_VELO_LIMIT[n]

Threshold for speed monitoring

A3

36300

ENC_FREQ_LIMIT

Encoder limit frequency

A3

36302

ENC_FREQ_LIMIT_LOW

Encoder limit frequency - resynchronization

R1

36720

DRIFT_VALUE

Drift value

36200

The machine data marked with a * (asterisk) are contained in


the parameter set for one gear stage.

5.11.3

Setting data

Number

Identifier

Name

Ref.

General
41200

JOG_SPIND_SET_VELO

JOG speed for spindle

H1

Spindle-specific
43210

SPIND_MIN_VELO_G25

Progr. spindle speed limitation G25

43220

SPIND_MAX_VELO_G26

Progr. spindle speed limitation G26

43230

SPIND_MAX_VELO_LIMS

Progr. spindle speed limitation with G96

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

5-129

Spindle (S1)
5.11

Data fields, lists

notice

5-130

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Rotary Axes (R2)

6.1

General

Features of a rotary axis


Rotary axes are generally programmed in degrees. In general, they are characterized by the
fact that they are back to the same position exactly after one rotation (modulo 360 degrees).
Depending on the application type, the traversing range of the rotary axis can be limited to
values less than 360 degrees (e.g., with swivel axes for tool holders) or endlessly (e. g., with
rotary movements of the tool or workpiece).

Definition of the rotary axis


An axis is declared a rotary axis using MD 30300: IS_ROT_AX = 1.

Note
The geometry axes ( X, Y, Z) cannot be used as rotary axes or as a spindle. These geometry axes
are defined by MD 20050: AXCONF_GEOAX_ASSIGN_TAB (assignment of geometry axes to
channel axis).

Axis adresses, axis identifier, direction


+Y

Cartesian coordinate system

+B

-Z

-X

+C

+A

+Z

+X

-Y
Fig. 6-1

Axis designations and positive direction of movement of rotary axes

For axes/rotary axes, an extended addressing (e.g.: C2=) or a free axis address (name) can
be defined by configuration using MD 1000: AXCO=NF_MACHAX_NAME_TAB or
MD 20080: AXCONF_CHANAX_NAME_TAB.

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

6-131

Rotary Axes (R2)


6.1

General

Units
By default, the following units are used for the input and output of rotary axes:
Table 6-1

Units for rotary axes

Physical Quantity

Unit

Angular position

Degrees

Programmed angular speed

Degrees/minute

MD for angular speed

Rev./minute

1)

MD for angular acceleration

Rev./second2

1)

MD for angular jerk limitation

Rev./second3

1)

1)

These units will be interpreted by the control system with axis-specific machine data if the axis concerned is
declared a rotary axis.

References: Section Velocities, Setpoint/Actual-Value Systems, Closed-Loop Control

Feed
With rotary axes alone in a block, the programmed feedrate F corresponds to a certain angular speed [degrees/min].
If rotary axes and linear axes traverse along a certain path with G94 or G95, the feed must be
interpreted in the unit of the linear axes [e.g. mm/min, inch/min].
The tangential velocity of the rotary axes refers to the diameter DE (unit diameter DE = 360/p
whereby p = circular constant). If the diameter is equal to the unit diameter (D=DE), the numerical values of the programmed angular speed in degrees/min. and of the tangential speed in
mm/min (or inch/min) are the same.
The following general rule applies to the tangential speed:
F = FW * D / DE

F = tangential speed [mm/min]


FW = angular speed [degrees/min]
D = diameter at which F is active [mm]

with DE = 360 / p

DE = unit diameter [mm]


p = circular constant Pi = 3.14...

JOG speed for rotary axes


SD 41130: JOG_ROT_AX_SET_VELO (JOG speed for rotary axes) can be used to define a
JOG speed that will apply to all rotary axes.
If value = 0 is entered in the setting data, the axis-specific MD 32020: JOG_VELO (conventional axis velocity) will be active for the JOG velocity of the rotary axis.
References:

6-132

Section Manual Traversing and Handwheel Traversing

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Rotary Axes (R2)


6.2

Modulo 360 degrees

Software limit switches


The software limit switches and work area limitings are active and are required for swiveling
axes with a limited work area. However, for endlessly turning rotary axes, (with MD 30310:
ROT_IS_MODULO=1) the software limit switches and work area limitings are switched axisspecifically to the inactive condition.
References:

6.2

Section Axis monitoring

Modulo 360 degrees

The term modulo 360 degrees


The term modulo in conjuncion with a rotary axis means a control-internal imaging of the
rotary axis position in the range from 0 to 359,999 degrees. For path specifications > 360 degrees (e.g. for incremental programming G91), the position is imaged to the range of values
from 0 to <360 degrees using a control system-internal conversion. The imaging is carried out
both in JOG mode and in AUTOMATIC mode. Exception: Service display.

Machine data settings


The programming and positioning (MD 30310: ROT_IS_MODULO), as well as the position
display (MD 30320: DISPLAY_IS_MODULO) in modulo 360 can be defined for each rotary
axis separately in modulo 360 by means of machine data according to the machine requirements.

Axis is modulo
MD 30310 : ROT_IS_MODULO = 1:
With activation of the machine data, the specific rotary axes features become obvious. These
features also determine the positioning behavior of the rotary axis on programming (G90, AC,
ACP, ACN or DC). After taking into account the current zero offsets internally by the control
system, a modulo 360 imaging is carried out. The target position determined in this way is
then approached within one revolution.
The software limit switches and the work area limitings are not active and the work area is
thus endless.
For a modulo axis, the position display Modulo 360 should always be selected (MD 30320:
DISPLAY_IS_MODULO = 1).

Modulo position display


MD 30320: DISPLAY_IS_MODULO = 1:
The position display for rotary axes is often needed in modulo 360 (1 revolution), i.e. in the
positive direction of rotation, the control system internally resets the display to 0.000 periodically after 359.9995; in the negative direction of rotation, the positions are also displayed in
the range 0...359,999.

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

6-133

Rotary Axes (R2)


6.3

Programming rotary axes

MD 30320 : DISPLAY_IS_MODULO = 0:
In contrast to the display Modulo 360, +360 is displayed after one revolution, and +720 after
two revolutions etc. in absolute position display mode, e.g. for a positive direction of rotation.
In this case, the display range is limited by the controller according to the linear axes.

6.3

Programming rotary axes


Note
For general information on programming, refer to:
References:
Operation and Programming

6.3.1

Rotary axis with active modulo conversion

Absolute programming (AC, ACP, ACN, G90)


Example with ACP: C=ACP(5.33), generally: axis name=ACP(value)


The value describes the target position of the rotary axis in a range from 0 ... 359.999. In
case of values with a negative sign or 360, alarm 16830 Wrong modulo position pro
grammed is output.

ACP (positive) and ACN (negative) define the traversing direction of the rotary axis (irrespective of the actual position) unambiguously.

If AC or G90 is programmed, the traversing direction is dependent on the actual position of


the rotary axis. If the target position is greater than the actual position, the axis will traverse
in the positive direction of rotation, otherwise, in the negative direction of rotation.

Use of ACP and ACN: For unsymmetrical workpieces, it must be possible to define the
traversing direction to rule out collisions during the rotary movement.

Absolute programming on the shortest path (DC)


Example with DC: C=DC(25.3), generally: axis name=DC(value)


The value defines the target position of the rotary axis in a range of 0 ... 359.999. In case
of values with a negative sign or 360, the alarm 16830 Wrong modulo position programmed is output.

With DC (Direct Control), the rotary axis approaches the programmed position on the
shortest path within one revolution (traversing movement max. +180).

Depending on the current actual position, the control system determines the direction of
rotation and the distance to be traversed. If the distance to be traversed is the same (180)
in both directions, the positive direction of rotation is given preference.

Application example of DC: The rotary table is to approach the change position within the
shortest possible time (and thus on the shortest path).

Note: If DC is programmed for a linear axis, the alarm message 16800 Unable to execute
traversing instruction DC is displayed.

6-134

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Rotary Axes (R2)


6.3

Programming rotary axes

Incremental programming (IC, G91)




The value defines the distance to be traversed by the rotary axis. The value can be either
negative or 360.

The sign of the value specifies the traversing direction of the rotary axis definitely.

Example:
C=IC(720) ;C axis incrementally traverses in the positive direction by 720 (2 revolutions)
C=IC(-180) ;C axis incrementally traverses in negative direction by 180

Endless traversing range


Once the modulo function is active, the traversing range will not be limited (software limit switches not active). Through appropriate programming, the rotary axis can be traversed in an
endless range.
Example:
N10 LOOP: C=IC(7200)
N20 GOTOB LOOP

6.3.2

Rotary axis without modulo conversion

Absolute programming (AC, G90)


Example of AC: C=AC(-410), generally: axis name=AC (+/-value)


The value and its sign define the target position of the rotary axis unambiguously. The value can be greater than +/-360 degrees. The position value is limited by the software limit
switches.

The traversing direction is determined by the control system, depending on the signed actual position of the rotary axis.

If ACP or ACN are programmed, the alarms 16810 Unable to execute traversing instruction ACP or 16820 Unable to execute traversing instruction ACN are output.

Absolute programming on the shortest path (DC)


Example of DC: C=DC(60.3), generally: axis name=DC(value)
Even if the rotary axis is not defined as a modulo axis, the axis can be positioned using DC
(Direct Control). In this case, the behavior is as a modulo axis.

Incremental programming (IC, G91)


Example of IC: C=IC(-532.4), generally: axis name=IC(+/-value)
With incremental programming, the rotary axis traverses the same path as with the modulo
axis. The traversing range, however, is limited here by SW limit switches.

Traversing range limited


The traversing range is limited as with the linear axes. The range limits are defined by the
software limit switches plus and minus.

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

6-135

Rotary Axes (R2)


6.4

6.4

Data descriptions (MD, SD)

Data descriptions (MD, SD)

6.4.1

Axis/spindle - specific machine data

30300
MD number
Default: 0
Change valid after
Data type: BOOLEAN
Meaning:

IS_ROT_AX
Rotary axis

Special cases, errors, ......


Related to ....

Further references

30310
MD number
Default: 0
Change valid after
Data type: BOOLEAN
Meaning:

MD inapplicable ......
Tab. 2.2
Application example(s)
Related to ....

6-136

Min. input limit: 0


Max. input limit: 1
Protection level: 2/2
Unit: Valid from SW release:
1: Axis: The axis is defined as a rotary axis.
By default, the units of the axis-specific machine and setting data are interpreted
by the control system as follows:
 Positions
in degrees
 Velocities
in rev./minute
 Accelerations
in rev./s2
 Jerk limiting
in rev./s3
Spindle:
For a spindle, the machine data must generally be set to 1; otherwise,
alarm 4210 Rotary axis declaration missing is signaled.
0: The axis is defined as a lineary axis.
For axis: Alarm 4200 if the axis is already defined as a geometry axis.
For spindle: Alarm 4210
The following machine data are active only after activation of
MD 30300:IS_ROT_AX = 1 :
 MD 30310:ROT_IS_MODULO
(Modulo conversion for rotary axis)
 MD 30320:DISPLAY_IS_MODULO
(Position display is modulo)
 MD 10210:INT_INCR_PER_DEG
(Calculation resolution for angular positions)
Tab. 2.2 Possible combinations of machine data

Power On

ROT_IS_MODULO
Modulo conversion for a rotary axis
Min. input limit: 0
Max. input limit: 1
Power On
Protection level: 2/2
Unit: Valid from SW release:
1:
With the setpoint positions for the rotary axis, a modulo conversion is carried out.
The software limit switches and the work area limitations are inactive; the
traversing range is therefore endless in both directions.
The MD 30300: IS_ROT_AX must be set to 1
0:
no modulo conversion
MD 30300: IS_ROT_AX = 0 (Linear axis)
possible combinations of machine data
Endless rotating rotary axes (e. g. for out-of-center turning, grinding, winding)
MD 30320: DISPLAY_IS_MODULO
(position display is modulo 360)
MD 30300: IS_ROT_AX = 1
(rotary axis)
MD 36100: POS_LIMIT_MINUS
(software limit switch minus)
MD 36110: POS_LIMIT_PLUS
(software limit switch plus)
SD 43430: WORKAREA_LIMIT_MINUS
(working area limitation minus)
SD 43420: WORKAREA_LIMIT_PLUS
(working area limitation plus)

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Rotary Axes (R2)


6.4

Data descriptions (MD, SD)

30320
MD number
Default: 1
Change valid after
Data type: BOOLEAN
Meaning:

DISPLAY_IS_MODULO
Position display is modulo 360
Min. input limit: 0
Max. input limit: 1
Power On
Protection level: 2/2
Unit: Valid from SW release:
1: Position display Modulo 360 is active:
The position display of rotary axis or spindle (with base or machine coordinate system) is
defined to Modulo 360. With the positive direction of rotation, the position display is
thus internally reset by the control system to 0.000 degrees periodically after 359.999. The
display range is always positive and always between 0 and 359,999.
0: Absolute position display is active:
In contrast to the position display Modulo 360, with the absolute position display, e.g. with the
positive direction of rotation +360 is displayed after 1 revolution, +720 after 2 revolutions, etc.
The display range is limited according to the linear axes.
MD inapplicable to ......
Linear axes MD 30300: IS_ROT_AX = 0
Application example(s)
 For endlessly turning rotary axes (MD 30310:ROT_IS_MODULO = 1), it is
recommended to activate also the position display by modulo 360.
 For spindles, the position display must always be activated with modulo 360.
Related to ....
MD 30300: IS_ROT_AX = 1 (axis is rotary axis)

34220
MD number
Default: 4096
Change valid after
Data type: DWORD
Meaning:

ENC_ABS_TURNS_MODULO[n]
Range of rotatory absolute encoders
Min. input limit: 1
Max. input limit: 4096
Power On
Protection level: 2 / 2
Unit: Valid from SW release:
Number of encoder revolutions that a rotatory absolute encoder can resolve.
0 degrees <= position <= n*360 degrees, (where n = ENC_ABS_TURNS_MODULO)
Note: If the control system is turned off, the encoder may be turned by max. the half of this value.
Special cases, errors, ......
Only numbers raised to the power of 2 are permitted as values ( 1, 2, 4, 8, 16, ..., 4096).
If any other values are entered, these will be rounded off. If such a rounding has been carried
out, it is visible in the machine data and signaled by alarm 26025.
The MD only applies to rotary encoders (at linear and rotary axes).
Important recommendation:
When using an encoder with smaller Multiturn information or when using single-turn encoders, this
value must be reduced accordingly. In any case the value for multiturn-absolute encoders should
be matched with the value max. supported in order to be able to use the max. defined traversing
range (Note: This value also influences the permissible position offset with the encoder inactive/
Power Off).
Related to ....

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

6-137

Rotary Axes (R2)


6.5

6.5

Data fields, lists

Data fields, lists

6.5.1

Machine data

Number

Identifier

Name

Ref.

General
10000

AXCONF_MACHAX_NAME_TAB

Machine axis name

Chpt. 19

10210

INT_INCR_PER_DEG

Computational resolution for angular positions

G2

Channel-specific
20050

AXCONF_GEOAX_ASSIGN_TAB

Assignment geometry axis - channel axis

Chpt. 19

20080

AXCONF_CHANAX_NAME_TAB

Channel axis name

Chpt. 19

Axis/spindle-specific
30300

IS_ROT_AX

Axis is a rotary axis

30310

ROT_IS_MODULO

Modulo conversion for rotary axis

30320

DISPLAY_IS_MODULO

Actual-value display modulo

34220

ENC_ABS_TURNS_MODULO

Range of rotary absolute encoders

36100

POS_LIMIT_MINUS

Software limit switch minus

A3

36110

POS_LIMIT_PLUS

Software limit switch plus

A3

6.5.2

Setting data

Number

Identifier

Name

Ref.

General
41130

JOG_ROT_AX_SET_VELO

JOG speed for rotary axes

H1

Axis-specific
43430

WORKAREA_LIMIT_MINUS

Working area limitation minus

A3

43420

WORKAREA_LIMIT_PLUS

Working area limitation plus

A3

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Transverse Axes (P1)

7.1

Defining a transverse axis

Geometry axis as a transverse axis


The geometry axis X is defined as a transverse axis. A transverse axis is important for turning machine functions..

7.2

Diameter programming

Enabling and disabling


Transverse axes can be programmed either in radius or diameter dimensions.
The program commands DIAMON or DIAMOF can be used to enable/disable the diameter
programming of a transverse axis.
DIAMON and DIAMOF are G commands of group 29 and are modally active.

JOG mode
If DIAMON is active, the increments of the related transverse axis, which have been entered
for the machine functions INC (incremental dimension) and hand-wheel traversing in JOG
mode, will be interpreted in and traversed by diameter values (traversing in the WCS with this
axis).

Setpoint/actual value display


If the function DIAMON is active for a transverse axis, position, distance to go and REPOS
offset are displayed in diameter dimensions provided the workpiece coordinate system is selected.
In the machine coordinate system (MCS), the display is always carried out in radius dimensions.

Offsets
All offsets (e. g. tool offsets, programmable and settable zero offsets) are always entered, programmed and displayed as radius dimensions (even if they are active for the transverse axis
and if DIAMON is active).

Working area limitations, software limit switches, feed values


These data are always entered, programmed and displayed as radius values.

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7-139

Transverse Axes (P1)


7.3

Constant cutting rate: G96

Conversion of diameter values to internal radius values


In case of active diameter programming, a conversion to internal radius values is carried out
for the transverse axis (i.e. halving of the programmed values):


programmed end positions

absolute interpolation parameters (e. g. I, J, K) for G2/G3 programming


Absolute interpolation parameters will be referred to the coordinate zero of WCS.
Any interpolation parameters programmed in relative dimensions will not be converted.
References:
Operation and Programming

Conversion of internal radius values to diameter values


In case of active diameter programming, when measuring in the WCS using the functions
MEAS and MEASW, the results of measurement are converted to diameter values for the
transverse axis (i.e. doubling of the internal radius values) and stored.
When measuring or reading in the MCS, the values determined are stored as radius values.

7.3

Constant cutting rate: G96

Functionality
Prerequisite: A controlled spindle must be provided.
With the G96 function enabled, the spindle speed is matched with the diameter of the workpiece currently machined (position of the transverse axis=geometry axis X) such that a programmed cutting rate S at the tool edge remains constant (spindle speed by diameter = constant).
From the block that contains G96, the S word is interpreted as the cutting rate. G96 is modally
active until it is canceled by another G function of the group (G94, G95, G97).

Programming
G96 S... LIMS=... F...
;Constant cutting rate ON
G97
;Constant cutting rate OFF
S
Cutting rate, unit m/min
LIMS=
Upper limit speed of spindle, active with G96, G97
F
Feed in the measuring unit mm/rev. -as with G95
References:
Operation and Programming

X (Transverse axis)

D2

D1

SD=Spindle speed
D1, D2 =Diameter

D1 x SD1=D2 x SD2=Dn x SDn=constant

Fig. 7-1

7-140

Constant cutting rate G96

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Reference Point Approach (R1)

8.1

Fundamentals

Why referencing?
To ensure that the control system detects the machine zero point exactly after the control system has been turned on, it must be synchronized with the position measuring system of
each machine axis. This process is called referencing.
The procedure for the spindle (synchronization) is to a large degree described in the Chapter
Spindle.

Positions measuring systems


The following position measuring systems can be installed on the motor/machine for an axis:


incremental rotatory measuring system

absolute rotatory measuring system

The referencing can be set for the installed position measuring systems using
MD 34200: ENC_REFP_MODE (referencing mode).

Cams
A cam for the reference point approach may be required for linear axes and performs the following tasks using its signal :


Selection of the traversing direction when approaching the zero mark (synchronous pulse)

Selection of the zero mark as necessary

BERO
A BERO (inductive proximity switch) can be used as an encoder for the synchronous pulse
(instead of the position encoder zero mark) (preferrably for rotary axes, spindle).
In this case, the connection is made on the drive SIMODRIVE 611U. This drive must be parameterized accordingly (using SimoComU).
References:

Start - Up Guide

IS Active machine function REF (V3100 0001.2)


The reference point approach is carried out with the machine function REF (IS Active machine function REF) enabled. The machine function REF can be selected in the operating
mode JOG (IS Machine function REF (V3000 0001.2)).

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8-141

Reference Point Approach (R1)


8.1

Fundamentals

Axis - specific referencing


The axis - specific referencing is started for each machine axis separately using the IS Traversing keys plus/minus (V380x0004.7 /.6). All axes can be referenced simultaneously. To
reference the machine axes in a certain order, the following is necessary:


The operator must observe the starting order.

The PLC user program must either check the starting order or define it automatically.

The order is defined in MD 34110: REFP_CYCLE_NR (see channel - specific referencing).

Channel - specific referencing


The channel - specific referencing is started using the IS Enable referencing (V3200
0001.0). The control system acknowledges the successful start with the IS Referencing active (V3300 0001.0). Using the channel - specific referencing, it is possible to reference each
machine axis assigned to the channel. (To this aim, the control system internally simulates
the traversing keys plus/minus.) The axis - specific MD 34110: REFP_CYCLE_NR (axis order
on channel - specific referencing) can be used to define in which order the machine axes are
referenced. If all axes specified in REFP_CYCLE_NR have reached their reference points,
the IS All axes to be referenced are referenced (V33000004.2) is set.

Special features


The IS Reset (V3000 0000.7) is used to cancel referencing. All axes that have not yet
reached their reference points until this moment are considered not referenced.
The IS Referencing active is reset, and alarm 20005 is output.

Working area limitations and software limit switches are not active for machine axes not
referenced.

When referencing, the specified axis - specific accelerations are observed at all times (except in case of alarms).

To start reference - point approach, only the direction key defined for the corresponding
direction in MD 34010: REFP_CAM_DIR_IS_MINUS will be active.

Referencing in the part program


One or several axes can be referenced at the same time, which have lost their reference during operation. The sequence of the individual phases completely corresponds to the axis specific referencing, while the start is not carried out using the traversing keys plus/minus,
but using the G74 command and the machine axis identifiers.
References:
Operation and Programming
Note: MD 20700: REFP_NC_START_LOCK = 1 will disable the start of a part program (alarm
output), unless all the specified axes are referenced.

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Reference Point Approach (R1)


8.2

8.2

Referencing using incremental measuring systems

Referencing using incremental measuring systems

Time sequence
The time sequence when referencing using incremental measuring systems can be divided
into 3 phases:
1st phase: Traversing to the reference cam
2nd phase: Synchronization with the zero mark
3rd phase: Traversing to the reference point
IS Delayed reference point approach
(V380x1000.7)
IS Traversing command plus
(V390x0004.7)
IS Traversing command minus
(V390x0004.6)
NST Traversing key plus/minus
(V380x0004.7 und .6)
IS Referenced/synchronized
(V390x0000.4)
Position encoder zero mark
|Velocity|
MD 34020: REFP_VELO_SEARCH_CAM
Reference point approach velocity
MD 34070: REFP_VELO_POS
Reference point approach velocity
MD 34040: REFP_VELO_SEARCH_MARKER
Reference point shutdown velocity

t
Phase 1

Fig. 8-1

Phase 2

Phase 3

Referencing sequence when using incremental measuring systems (example)

Features when traversing to the reference point cam (phase 1)

Feed override and feed stop are active.

The machine axis can be stopped/started.

The cam must be areched within the traversing range defined by


MD 34030: REFP_MAX_CAM_DIST. Otherwise, an appropriate alarm is output.

The machine axis must come to a standstill on the cam. Otherwise, an alarm is output.

Features when synchronizing with the zero pulse (phase 2)

The feed override is not active. The feed override of 100 % is active. The operation is aborted at a feed override of 0 %.

Feed Stop is active, the axis stops and an appropriate alarm is displayed.

The machine axis cannot be stopped/started using NC Stop/NC Start.

The monitoring of the zero mark using MD 34060: REFP_MAX_MARKER_DIST is active.

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Reference Point Approach (R1)


8.2

Referencing using incremental measuring systems

Features when traversing to the reference point (phase 3)

Feed override and feed stop are active.

The machine axis can be stopped/started using NC Stop/NC Start.

If the reference point offset is less than the braking distance of the machine axis from the
reference point approch velocity to the standstill, the reference point is approached from
the other direction.

Different sequences of motion when referencing:

Type of referencing

Synchronuous
pulse

Sequence of motions

(zero mark, BERO)


Synchronuous pulse
before cam,

with reference point cams


(MD 34000:
REFP_CAM_IS_ACTIVE = 1)

RV

VC

reference coordinate
before synchronuous
pulse
= without reversal:
(MD 34050:
REFP_SEARCH_MARK
ER_REVERSE = 0)

VP

VM
RK

Start

Synchronuous pulse
on the cam,

RV

VC

VP

reference coordinate
after synchronuous pulse
on the cam
= with reversal:
(MD 34050:
REFP_SEARCH_MARK
ER_REVERSE = 1)

Cam

Synchronuous
pulse

VM
RK

Start
Cam
Synchronous pulse
RV

Without reference cams

(MD 34000:
REFP_CAM_IS_ACTIVE = 0)

Reference
coordinate after
synchronouspulse

VP

VM
Start

RK
Synchronuous pulse
VC
VM
VP
RV

- reference point approach velocity (MD 34020: REFP_VELO_SEARCH_CAM)


- ref. point shutdown velocity (MD 34040: REFP_VELO_SEARCH_MARKER)
- reference point approach velocity (MD 34070: REFP_VELO_POS)
- reference point offset (MD 34080: REFP_MOVE_DIST + MD 34090:
REFP_MOVE_DIST_CORR)
RK - reference point coordinate (MD 34100: REFP_SET_POS

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Reference Point Approach (R1)


8.2

Referencing using incremental measuring systems

What is the required minimum length of the reference cam?

Example for the case: Synchronuous pulse before the cam, reference coordinate before synchronuous pulse = synchronuous pulse search with falling cam edge).
The reference cam must have such a length that the braking procedure is terminated on the
cam when approaching the cam at reference point approach velocity (standstill on the cam),
and that the cam is left again when starting in the opposite direction at reference point shutdown velocity (leaving at a constant velocity).
To calculate the minimum length of the cam, insert the larger of the following speeds in the
formula below:
Minimum length =

( reference point approach velocity or shutdown speed)2


2 x axis acceleration (MD 32300: MAX_AX_ACCEL)

If the machine axis does not come to a standstill at the reference cam (IS Reference point
approach delay (V380x1000.7) has been reset), alarm 20001 is output. Alarm 20001 may
occur if the reference - cam is too short and the machine axis overruns the reference cam
when decelerating in phase 1.
If the reference cam extends up to the traversing end of the axis, an inadmissible starting
point for the referencing (after the cam) is excluded.

Reference cam adjustment


The reference cam must be adjusted exactly. The following factors influence the time response for recognition of the reference cam (IS Reference point approach delay):


Switching accuracy of the reference cam switch

Time delay of reference cam switch (normally closed contact)

Time delay at the PLC input

PLC cycle time

Internal processing time

Practice has shown that it is best to adjust the edge of the reference cam required for the
synchronization in the middle between two synchronuous pulses (zero marks). This can be
achieved as follows:


Set MD 34080: REFP_MOVE_DIST = MD 34090: REFP_MOVE_DIST_CORR = MD


34100: REFP_SET_POS = 0.

Reference axis.

In JOG mode, traverse the axis by half the length of the distance to be traversed between
two zero marks. This distance is dependent on the leadscrew pitch S and the gear ratio n
(e.g.: S=10 mm/rev. , n=1:1 results in a distance to be traversed of 5 mm).

Adjust the cam switches such that the switching action is carried out exactly at this position (IS Reference point approach delay (V380x 1000.7).

Alternative, instead of shifting the cam switch, the value of MD 34092:


REFP_CAM_SHIFT can be changed.

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8-145

Reference Point Approach (R1)


8.3

Referencing using absolute encoders

Warning

8.3

If the reference cam is not adjusted exactly, it may happen that a false sychronuous pulse (zero mark) is evaluated. As a result, the control system is assigned an incorrect machine zero point and it will traverse the axes to
wrong positions. The software limit switches will be active at false positions and will therefore not be able to
protect the machine.

Referencing using absolute encoders

8.3.1

General

Prerequisites
Referencing of an axis using absolute encoders is carried out automatically when turning on
the control system and if the appropriate axis is recognized adjusted. This acceptance of the
absolute value is carried out without axis movement, e.g. at POWER ON. Two conditions
must be met for automatic referencing:


The axis has an absolute encoder for the position control.

The absolute encoder is adjusted (MD 34210: ENC_REFP_STATE=2)

Adjustment
In case of axes provided with absolute encoders, the measuring system is not synchronized
by approaching a reference cam. Instead of this, an adjustment is carried out. The actual value of the absolute encoder is set during the start - up once and accepted by the control system.

8.3.2

Operator - sssisted adjustment

General procedure
Move the axis to be adjusted to a defined position and then set the appropriate actual value.

Chronological sequence

1. Set MD 34200: ENC_REFP_MODE and MD 34210: ENC_REFP_STATE to 0 and enable


it by POWER ON. (MD: ENC_REFP_MODE = 0 means that the actual value of the axis is
set once.)
2. In JOG mode, traverse the axis manually to a known position. The direction in which the
position is approached must correspond to the direction defined in MD 34010:
REFP_CAM_DIR_IS_MINUS (0 = positive direction, 1 = negative direction).

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Reference Point Approach (R1)


8.3

Referencing using absolute encoders

Note
This known position must be approached at a slow velocity and always from a defined direction to make sure that this position is not invalidated by the backlash in the drive system.

3. Enter the actual value that corresponds to the position approached in MD 34100:
REFP_SET_POS. This value may be a specific design - related value (e. g. fixed stop), or
it can now be determined using a measuring system.
4. Set MD 34210: ENC_REFP_STATE to 1. This will enable the Adjustment function.
5. Press RESET to enable the changed machine data.
6. Change to JOG - REF mode.
7. Pressing the traversing key already used in step 2 will enter the current offset into
MD 34090:REF_MOVE_DIST_CORR, and MD 34210: ENC_REFP_STATE will change to
2, i.e. the axis is considered adjusted. (Pressing the traversing keys will also update the
display.)

Note
The axis will not move if the appropriate traversing key is pressed. The value entered in MD
34100: REFP_SET_POS will be displayed in the actual - value display of the axis position.

8. Quit JOG - REF mode; the axis is thus adjusted.

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Reference Point Approach (R1)


8.4

8.4
8.4.1

Supplementary conditions for absolute encoders

Supplementary conditions for absolute encoders


Adjusting the absolute encoder

Adjusting time
The adjustment determines the offset between the machine zero point and the encoder zero
point and stores it in a non - volatile memory. Normally, this adjustment must be made only
once during the commissioning. The control system will then know this value and can calculate the absolute machine position from the encoder absolute value at any time. This status is
characterized by
MD 34210: ENC_REFP_STATE=2.
The offset is stored in MD 34090: REFP_MOVE_DIST_CORR (SRAM).
This adjustment must be repeated:


after removing/installing or replacing the encoder or the motor with motor - integrated encoder;

after switching over a gearbox (if any) between motor (with absolute encoder) and load;

generally, whenever the mechanical connection between encoder and load has been disconnected and has not been mounted exactly in the way it was.

CAUTION: The control system cannot detect all cases that require a re - adjustment! If the
control system detects it, it will note this by setting machine data MD 34210:
ENC_REFP_STATE to the value 0 or 1.
The following is detected: Switching over to a gear stage with a different transmission ratio
between encoder and load.
In any other cases the user himself must overwrite the machine data
MD 34210: ENC_REFP_STATE.

Data back - up
Saving the machine data will also save the state of MD 34210: ENC_REFP_STATE.
By loading such a data record, the axis is therefore automatically declared adjusted.

8-148

Warning
If the data record arises from another machine (e. g. in case of series machine start - up), an adjustment must be carried out after loading and enabling the data.

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Reference Point Approach (R1)


8.5

8.5
8.5.1

Data descriptions (MD, SD)

Data descriptions (MD, SD)


Channel - specific machine data

20700
MD number
Default: 1
Change valid after RESET
Data type: BOOLEAN
Meaning:

REFP_NC_START_LOCK
NC START inhibit without reference point
Min. input limit: 0
Max. input limit: 1
Protection level: 2/7
Unit: Valid from SW release:
0: The IS NC START (V32000007.1) for starting part programs or part program blocks (MDA)
is possible even if none or not all axes of the channel are referenced. To ensure that the
axes nevertheless reach the correct position after NC START, the workpiece coordinate
system (WCS) must be set to a correct value using other methods (scratching method).
1: NC START only if all axes are referenced.

8.5.2

Axis/spindle - specific machine data

31122
BERO_DELAY_TIME_PLUS[0]
MD number
BERO delay time plus
Default: 0.000110
Min. input limit: 0.0
Max. input limit: ***
Change valid after NEW_CONF
Protection level: 2/2
Unit: s
Data type: DOUBLE
Valid from SW release:
Meaning:
In conjunction with the setting MD 34200: ENC_REFP_MODE = 7, this MD results in a signal
runtime compensation in the positive direction of movement when determining the position using
a BERO (zero mark).
Related to ....
MD 34200: ENC_REFP_MODE

31123
BERO_DELAY_TIME_MINUS[0]
MD number
BERO delay time minus
Default: 0.000078
Min. input limit: 0.0
Max. input limit: ***
Change valid after NEW_CONF
Protection level: 2/2
Unit: s
Data type: DOUBLE
Valid from SW release:
Meaning:
In conjunction with the setting MD 34200: ENC_REFP_MODE = 7, this MD results in a signal
runtime compensation in the negative direction of movement when determining the position
using a BERO (zero mark).
Related to ....
MD 34200: ENC_REFP_MODE

34000
MD number
Default: 1
Change valid after RESET
Data type: BOOLEAN
Meaning:

REFP_CAM_IS_ACTIVE
Axis with reference point cam
Min. input limit: 0
Max. input limit: 1
Protection level: 2/2
Unit: Valid from SW release:
Machine axes that have only one zero mark over their entire traversing range or rotary axes that
have only one zero mark per revolution will not be marked as a machine axis with reference cam
by REF_CAM_IS_ACTIVE. The machine axis marked in this way will accelerate to the velocity
specified in MD 34040: REFP_VELO_SEARCH_MARKER (reference point shutdown velocity)
after the traversing key plus/minus has been pressed, and will synchronize itself with the next
zero mark.

MD inapplicable ......

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8-149

Reference Point Approach (R1)


8.5

Data descriptions (MD, SD)

34010
MD number
Default: 0
Change valid after RESET
Data type: BOOLEAN
Meaning:

REFP_CAM_DIR_IS_MINUS
Reference- point approach in minus direction
Min. input limit: 0
Max. input limit: 1
Protection level: 2/2
Unit: Valid from SW release:
0:
Reference point approach in plus direction
1:
Reference point approach in minus direction
Approach with incremental measuring systems:
Starting using the traversing key is only possible in the specified direction. If the wrong traversing
key is pressed, no reference point approach start is carried out.
If the machine axis is upstream the reference cam, it accelerates to the velocity specified in
MD 34020: REFP_VELO_SEARCH_CAM (reference point approach velocity).
If the machine axis is on the reference cam, it accelerates to the velocity specified in MD 34020:
REFP_VELO_SEARCH_CAM and first moves in the opposite direction of the cam.
Note regarding absolute encoders:
The direction of the traversing key is also important for the adjustment of absolute encoders:
Approach in the direction of a fixed position; update of values in MD 34090 and MD 34210.

34020
MD number
Default: 5000.0 mm/min
13.88 rpm
Change valid after RESET

REFP_VELO_SEARCH_CAM
Reference point approach velocity
Min. input limit: 0.0

Data type: DOUBLE


Meaning:

Valid from SW release:


The reference point approach velocity is the velocity at which the machine axis traverses in the
direction of the reference cam after pressing the traversing key (phase 1). This value should be
set to such a large value that the axis can be decelerated to 0 before it reaches a hardware limit
switch.

Protection level: 2/2

Max. input limit: ***


Unit:

mm/min,
rpm

MD inapplicable ......

34030
MD number
Default: 10000.0
Change valid after RESET
Data type: DOUBLE
Meaning:

REFP_MAX_CAM_DIST
Max. distance to be traversed to the reference cam
Min. input limit: 0.0
Max. input limit: ***
Protection level: 2/2
Unit: mm, degrees
Valid from SW release:
If the machine axis traverses a path defined by REFP_MAX_CAM_DIST from its home position
in the direction of the reference cam without reaching the reference cam (IS Delayed reference point approach is reset), the axis stops, and alarm 20000 Reference cam not reached is output.

MD inapplicable ......

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Reference Point Approach (R1)


8.5

Data descriptions (MD, SD)

34040
MD number
Default: 300.0 mm/min
0.833 rpm
Change valid after RESET

REFP_VELO_SEARCH_MARKER[n]
Reference point shutdown velocity [encoder No.]: 0
Min. input limit: 0.0

Data type: DOUBLE


Meaning:

Valid from SW release:


1) With incremental measuring systems:
The axis traverses at this velocity within the time from detecting the first reference
cam and until the synchronization with the first zero mark (phase 2).
Traversing direction: opposite to the direction set for the cam search
(MD 34010: REFP_CAM_DIR_IS_MINUS)
If MD 34050: REFP_SEARCH_MARKER_REVERSE (direction reversal to reference
cam) is set, in case of synchronization with the rising reference cam will traverse to
the cam at the velocity specified in MD 34020: REFP_VELO_SEARCH_CAM.

Protection level: 2/2

Max. input limit: ***


Unit:

mm/min,
rpm

2) Indirect measuring system with load - end BERO (preferably for the spindle)
The zero mark belonging to the BERO is searched at this speed/velocity.
The zero mark is accepted if the actual speed is within the tolerance range
determined by MD 35150: SPIND_DES_VELO_TOL of the speed/velocity specified by
MD 34040: REFP_VELO_SEARCH_MARKER[n].

34050
MD number
Default: 0
Change valid after RESET
Data type: BOOLEAN
Meaning:

REFP_SEARCH_MARKER_REVERSE[n]
Direction reversal to the reference cam [encoder No.]: 0
Min. input limit: 0
Max. input limit: 1
Protection level: 2/2
Unit: Valid from SW release:
This machine data can be used to set the direction in which the zero mark is searched.
0:
Synchronization with falling reference cam edge
The machine axis accelerates to the velocity defined in MD 34040:
REFP_VELO_SEARCH_MARKER (reference - point shutdown velocity).
When leaving the reference point (IS Delayed reference point approach is reset), the control
system will synchronize itself with the first zero mark.
1:
Synchronization with rising reference cam edge
The machine axis accelerates to the velocitiy specified in MD 34020: REFP_CAM_DIR_IS_MINUS, irrespective of the pressed traversing key plus/minus. When leaving the reference point (IS
Delayed reference point approach is reset), the machine axis will decelerate to a standstill and
will then traverse at the velocity specified in MD: REFP_VELO_SEARCH_MARKER in the opposite direction to the reference cam. If the reference cam is reached (IS Delayed reference - point
approach is set), the control system synchronizes itself with the first zero mark.

MD inapplicable ......

34060
MD number
Default: 20.0
Change valid after RESET
Data type: DOUBLE
Meaning:

Application example(s)

REFP_MAX_MARKER_DIST[n]
Max. distance to the reference mark [encoder No.]: 0
Min. input limit: 0.0
Max. input limit: ***
Protection level: 2/2
Unit: mm, degrees
Valid from SW release:
With incremental measuring systems:
If the machine axis traverses a distance defined in MD: REFP_MAX_MARKER_DIST (IS Delayed reference point approach is reset) without detecting the reference mark, the axis stops
and alarm 20002 Zero mark missing is output.
If it is intended that with incremental measuring systems the control system reliably detects that
the same zero mark is always used for synchronization (otherwise, a wrong machine zero point
is recognized), the max. value in this MD may not exceed the distance between two reference
marks.

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Reference Point Approach (R1)


8.5

Data descriptions (MD, SD)

34070
MD number
Default: 1000.0 mm/min
2.77 rpm
Change valid after RESET

REFP_VELO_POS
Reference point approach velocity
Min. input limit: 0.0

Data type: DOUBLE


Meaning:

Valid from SW release:


With incremental measuring systems:
The axis traverses at this velocity from the synchronization with the zero mark until the reference
point is reached.

34080
MD number
Default: - 2.0
Change valid after RESET
Data type: DOUBLE
Meaning:

REFP_MOVE_DIST[n]
Reference point distance/target position with distance - coded system [encoder No.]: 0
Min. input limit: ***
Max. input limit: ***
Protection level: 2/2
Unit: mm, degrees
Valid from SW release:
With incremental measuring systems:
After synchronization with the first zero mark, the machine axis accelerates to the velocity
specified in MD 34070: REFP_VELO_POS (reference point approach velocity), and traverses a distance resulting from adding up the distances efined in MD:REFP_MOVE_DIST
and MD 34090: REFP_MOVE_DIST_CORR (reference point offset). The distance determined by addition is exactly the distance between the zero mark (in phase 2) and the reference point.

Max. input limit: ***

Protection level: 2/2

Unit:

mm/min,
rpm

MD 34100: REFP_SET_POS[0]
Velocity

MD: REFP_MOV_DIST + MD: REFP_SET_POS_CORR

MD 34020:
REFP_VELO_SEARCH_CAM
(ref. point approach velocity)
MD 34040: REFP_VELO_SEARCH_
MARKER
(ref. point shutdown velocity)

Zero mark

8-152

Delayed
ref. pt. approach

Ref. point cam

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8.5

Data descriptions (MD, SD)

34090
MD number
Default: 0.0
Change valid after RESET
Data type: DOUBLE
Meaning:

REFP_MOVE_DIST_CORR[n]
Reference point offset/absolute offset distance - coded, n: [encoder No.]: 0
Min. input limit: ***
Max. input limit: ***
Protection level: 2/2
Unit: mm, degrees
Valid from SW release:

Incremental encoder with zero mark(s):
After detecting the zero reference mark, the axis is positioned away from the zero mark by the
distance MD 34080: REFP_MOVE_DIST + REFP_MOVE_DIST_CORR. If this axis has been
traversed, the axis has reached its reference point. MD 34100: REFP_SET_POS is accepted as
the actual value.
During the traversing movement as defined in REFP_MOVE_DIST+REFP_MOVE_DIST_CORR,
override switches are active

Absolute value encoder:
REFP_MOVE_DIST_CORR acts as an absolute offset. It describes the offset between machine
zero point and the zero point of the absolute measuring system.
Note: The control system will change this machine data in conjunction with absolute encoders if
adjusting processes and modulo corrections are required.

34092
MD number
Default: 0.0
Change valid after RESET
Data type: DOUBLE
Meaning:

REFP_CAM_SHIFT
Electronic reference cam offset for incremental measuring systems with equidistant zero marks
Min. input limit: 0.0
Max. input limit: ***
Protection level: 2/2
Unit: mm
Valid from SW release:
When the reference cam signal occurs, the search for the zero mark is started not immediately, but with a delay after the distance defined in REFP_CAM_SHIFT has been traversed. This ensures the repeatability of the zero mark search even in case of a temperature- dependent extension of the reference cam by defined selection of a zero mark.
Since the reference cam offset is calculated by the control system in the interpolation
clock, the real cam offset is at least REFP_CAM_SHIFT and max.
REFP_CAM_SHIFT+(MD 34040: REFP_VELO_SEARCH_MARKER*interpolation clock)
The reference cam offset acts in the search direction of the zero mark.
Only if the cam exists (MD 34000: REFP_CAM_IS_ACTIVE=1), the reference cam offset
is active.

Thermal extension

REMEDY

REFP_CAM_SHIFT

Cam signal

Zero mark search

Zero marker
2
Cam signal with
offset
1+2

34093
REFP_CAM_MARKER_DIST
MD number
Distance reference cam - reference mark
Default: 0.0
Min. input limit: ***
Max. input limit: ***
Change valid after POWER ON
Protection level: - /7
Unit: mm
Data type: DOUBLE
Valid from software release: 2.0
Meaning:
The value displayed corresponds to the distance between the time when the reference cam is
left and the time when the reference mark occurs. If these values are too low, it is possible that
the reference point cannot be determined due to temperature influences or due to a varying runtime of the cam signal. The distance traversed can be used as an orientation for the setting of
the electronic reference cam offset.
The machine data is read - only.
Related to ....

REFP_CAM_IS_ACTIVE, REFP_SHIFT_CAM

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8.5

Data descriptions (MD, SD)

34100
MD number
Default: 0.0
Change valid after RESET
Data type: DOUBLE
Meaning:

REFP_SET_POS[0]
Reference point with incremental systems
Min. input limit: ***
Max. input limit: ***
Protection level: 2/2
Unit: mm, degrees
Valid from SW release:

Incremental encoder with zero mark(s):
Position value set after detecting the zero mark and traversing the distance defined in
REFP_MOVE_DIST + REFP_MOVE_DIST_CORR (relative to the zero mark) as the current axis
position.

Absolute value encoder:
REFP_SET_POS corresponds to the correct actual value at the adjusting position. The reaction
of the machine depends on the state of MD34210: ENC_REFP_STATE:
If MD 34210: ENC_REFP_STATE = 1, the value of REFP_SET_POS is accepted as an absolute
value.
If MD 34210: ENC_REFP_STATE = 2 and MD 34330: REFP_STOP_AT_ABS_MARKER = 0, the
axis approaches the target position stored in REFP_SET_POS. The value defined in
REFP_SET_POS is used.
Note: MD: REFP_SET_POS[1]...[3] is reserved - do not use.

Related to ....

34110
MD number
Default: 0
Change valid after RESET
Data type: BYTE
Meaning:

MD inapplicable to ......
Related to ....

8-154

REFP_CYCLE_NR
Axis order on channel - specific referencing
Min. input limit: - 1
Max. input limit: 4
Protection level: 2/2
Unit: Valid from SW release:
0:
Axis - specific referencing
The axis - specific referencing is started by the IS Traversing keys plus/minus for each machine
axis separately. All axes can be referenced at the same time. If the machine axes are to be referenced in a defined order, the following is required:
 The operator must observe the starting sequence.
 The PLC must either check the starting sequence or define it automatically.
The machine axis will not be started by channel - specific referencing. NC Start is not possible
without referencing this axis.
- 1 : The machine axis will not be started by channel - specific referencing.
NC Start is not possible without referencing this axis.
Note:
The effect of setting all axes of a channel to - 1 can be achieved by setting the channel - specific
MD 20700: REF_NC_START_LOCK (NC Start inhibited without reference point) to zero.).
> 0 : Channel- specific referencing
The channel - specific referencing is started using the IS Enable referencing (V3200 0001.0).
The control system acknowledges the successful start with the IS Referencing active. Channel- specific referencing can be used to reference any machine axis assigned to the channel (to
this aim, the plus/minus traversing keys are simulated).
The MD: REFP_CYCLE_NR can be used to define in which order the machine axes are referenced:
1:
The machine axis is started by channel - specific referencing.
2:
The machine axis is started by channel - specific referencing if all machine axes marked
in MD: REFP_CYCLE_NR with 1 have been referenced.
3:
The machine axis is started by channel - specific referencing if all machine axes marked
in MD: REFP_CYCLE_NR with 2 have been referenced.
4:
The machine axis is started by channel - specific referencing if all machine axes marked in
MD: REFP_CYCLE_NR with 3 have been referenced.
axis - specific referencing
IS Enable referencing
IS Referencing active

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8.5

Data descriptions (MD, SD)

34200
ENC_REFP_MODE[n]
MD number
Referencing mode [encoder No.]: 0
Default: 1
Min. input limit: 0
Max. input limit: 7
Change valid after Power On
Protection level: 2/2
Unit: Data type: BYTE
Valid from SW release:
Meaning:
The installed position measuring systems can thus be divided for referencing as follows:
0: If an absolute encoder is provided: Acceptance of MD 34100: REFP_SET_POS
Other encoders: no reference point approach possible
1: Referencing using incremental measuring systems:
incremental rotary measuring system
incremental linear measuring system (length measuring system)
zero pulse on the encoder track
(not for absolute encoders)
2, 3, 4, 5, 6:
not available
7: Synchronize spindle with BERO, configured approach velocity (MD 34040)
Related to ....

34210
MD number
Default: 0
Change valid: immediately
Data type: BYTE
Meaning:

ENC_REFP_STATE[n]
Status of absolute encoder [encoder No.]: 0
Min. input limit: 0
Max. input limit: 2
Protection level: 2/2
Unit: Valid from SW release:
 Absolute value encoder:
0: Default on comissioning: Encoder not adjusted
1: Encoder adjustment enabled, encoder not yet adjusted
2: Encoder adjusted

Application example(s)

Incremental encoder:
0: Default: No automatic referencing
1: Automatic referencing enabled, but encoder not yet referenced and/or not at exact stop
2: Encoder is referenced and at exact stop, automatic referencing will be active with the
next encoder activation
MD ENC_REFP_STATE can be modified by the start - up engineer and from the operating system:

Absolute- value encoder:


-

Modification by the start - up engineer:


The data must be set to 1 if an adjustment of the encoder is necessary or desired.

Modification from the operating system:


in case of successful adjustment from 1 ==> 2
in case of invalid adjustment from 2 ==> 0 or 1
Any losses in the SRAM information or gear switchover operations with changes in the
transmission ratio will be detected by the operating system.
Any modifications to the construction of the machine mechanics
(e.g. change of encoder, motor incl. encoder etc.) will not be detected.

Incremental encoder:
-

Modification by the start - up engineer:


The data must be set to 1 if automatic referencing is required or desired.

Modification from the operating system:


in case of referenced axis and Axis at exact position stop from 1 ==> 2
in case of invalid referencing position reference or if the axis on exact position stop does
not change from 2 ==> 1
In contrast to the absolute encoder, any changes of the position with inactive encoder or
during Power - Off will not be detected.

MD inapplicable ......

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Reference Point Approach (R1)


8.5

Data descriptions (MD, SD)

36302
ENC_FREQ_LIMIT_LOW
MD number
Encoder limit frequency for re - synchronization
Default: 99.9
Min. input limit: 0.0
Max. input limit: 100
Change valid after NEW_CONF
Protection level: 2/2
Unit: %
Data type: DOUBLE
Valid from SW release:
Meaning:
The encoder limit frequency uses a hysteresis.
MD 36300: ENC_FREQ_LIMIT defines the encoder limit frequency at which the encoder is switched off, and ENC_FREQ_LIMIT_LOW the frequency at which the encoder is switched on again.
ENC_FREQ_LIMIT_LOW is a fraction of ENC_FREQ_LIMIT as a percentage.
Normally, the preselection of ENC_FREQ_LIMIT_LOW is sufficient. When using absolute encoders with an En - Dat interface, however, the limit frequency of the absolute track is considerably
lower than the limit frequency of the incremental track. With a smaller value in
MD: ENC_FREQ_LIMIT_LOW, it can be achieved that the encoder is only switched on below the
limit frequency of the absolute track and therefore only referenced if this is permitted by the absolute track. For spindles, this referencing is carried out automatically.
Example EQN 1325:
Encoder limit frequency of the incremental track: 430 kHz
===>MD 36300: ENC_FREQ_LIMIT = 430,000 Hz
Limit frequency of absolute track approx. 2,000 encoder rpm at 2,048 increments, i.e. at a limit
frequency of (2000/60) * 2048 Hz = 68 kHz
===>MD 36302: ENC_FREQ_LIMIT_LOW = 68/430 = 15 %
Related to ....

8-156

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Reference Point Approach (R1)


8.6

8.6

Signal descriptions

Signal descriptions

8.6.1

Channel - specific signals

Signals to channel
V32000001.0
Interface signal
Edge evaluation: yes
Signal state 1 or edge
change 0 - - - > 1

Application example(s)

Related to ....

Enable referencing
Signal(s) to channel (PLC - > NCK)
Signal(s) updated: cyclically
Signal(s) valid from SW release:
Channel- specific referencing is started using the IS Enable referencing. The control system
acknowledges the successful start with the IS Referencing active. Channel - specific referencing
can be used to reference each machine axis assigned to the corresponding channel (to this aim,
the traversing keys plus/minus are simulated internally in the control system). The axis - specific
MD 34110: REFP_CYCLE_NR (axis order on channel - specific referencing) can be used to define in which order the machine axes are referenced. If all axes entered in REFP_CYCLE_NR
have reached their reference points, the IS All axes referenced (V33000004.2) is set.
To reference the machine axes in a certain order, the following is necessary:
 The operator must observe the starting order.
 The PLC must either check the starting sequence or define it.
 The function Channel - specific referencing is used.
IS Referencing active (V33000001.0)
IS All axes to be referenced are referenced (V33000004.2)

Signals from channel


V33000001.0
Interface signal
Edge evaluation: yes
Signal state 1 or edge
change 0 - - - > 1
Signal state 0 or edge
change 1 - - - > 0
Signal inapplicable to ......
Related to ....

V33000001.2
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 - - - > 1
Signal state 0 or edge
change 1 - - - > 0
Special cases, errors, ......
Related to ....

Referencing active
Signal(s) to channel (PLC - > NCK)
Signal(s) updated: cyclically
Signal(s) valid from SW release:
The channel - specific referencing has been started by the IS Enable referencing and the successful start has been acknowledged by the IS Referencing active. The channel - specific referencing is on.
 Channel- specific referencing is completed.
 Axis - specific referencing is running.
 No referencing active.
spindles
IS Activate referencing (V32000001.0)

All axes to be referenced are referenced


Signal(s) from channel (PLC - > NCK)
Signal(s) updated: cyclically
Signal(s) valid from SW release: 1.1
All axes to be referenced are referenced.
(note for axes to be referenced:
MD 34110: REFP_CYCLE_NR, MD 20700: REFP_NC_START_LOCK )
One or several axes of the channel, which are to be referenced are not referenced.
The spindles of the channel do not affect this IS.
IS Referenced/synchronized 1 (V390x0000.4)

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Reference Point Approach (R1)


8.6

Signal descriptions

8.6.2

Axis/spindle - specific signals

Signals to axis/spindle
V380x1000.7
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 - - - > 1
Signal state 0 or edge
change 1 - - - > 0

Delayed reference point approach


Signal(s) to axis/spindle (PLC - > NCK)
Signal(s) updated: cyclically
The machine axis is on the reference cam.

Signal(s) valid from SW release:

The machine axis is before the reference cam. An appropriately long reference cam (up to the
end of the traversing range) should be used to rule out that the machine axis is after the reference cam.

Related to ....

Signals from axis/spindle


V390x0000.4
Interface signal
Edge evaluation:
Signal state 1 or edge
change 0 - - - > 1

Signal state 0 or edge


change 1 - - - > 0
Related to ....
Further references

8-158

Referenced/synchronized 1
Signal(s) from axis/spindle (NCK - > PLC)
Signal(s) updated:
Signal(s) valid from SW release:
Axes:
If the machine axis has arived at the reference point (incremental measuring systems) or at
the target point (length measuring systems with clearance - coded reference marks) during
the reference point approach; the machine axis is referenced and the
IS Referenced/synchronized 1 is set (depending on which position encoder is active on
referencing).
Spindles:
After mains ON, a spindle is synchronized after one spindle revolution at the latest (zero
mark) or when the BERO is overrun.
The machine axis/spindle is not referenced/synchronized with position measuring system 1.
IS Position measuring system 1 (V380x0000.5)
Chapter Spindles

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8.7

8.7

Data fields, lists

Data fields, lists

8.7.1

Interface signals

Number

.Bit

Name

Ref.

Mode- specific
V30000001

.2

Machine function REF

V31000001

.2

Active machine function REF

V32000001

.0

Enable referencing

V33000001

.0

Referencing active

V33000004

.2

All axes to be referenced are referenced.

V380x0000

.5

Position measuring system 1

V380x1000

.7

Delayed reference - point approach

V390x0000

.4

Referenced, synchronized 1

Channel- specific

Axis - specific

8.7.2

Machine data

Number

Identifier

Name

Ref.

Channel- specific
20700

REFP_NC_START_LOCK

NC START inhibited without reference point

Axis - specific
30200

NUM_ENCS

Number of encoders

G1

30240

ENC_TYP

Actual- value encoder type

G1

31122

BERO_DELAY_TIME_PLUS

BERO delay time in the plus direction

31123

BERO_DELAY_TIME_MINUS

BERO delay time in the minus direction

34000

REFP_CAM_IS_ACTIVE

Axis with reference cam

34010

REFP_CAM_DIR_IS_MINUS

Reference point approach in the minus direction

34020

REFP_VELO_SEARCH_CAM

Reference point approach velocity

34030

REFP_MAX_CAM_DIST

Max. distance to be traversed to the reference cam

34040

REFP_VELO_SEARCH_MARKER[0]

Reference point shutdown speed

34050

REFP_SEARCH_MARKER_REVERSE[0]

Direction reversal on reference cam

34060

REFP_MAX_MARKER_DIST[0]

Max. distance to be traversed to the reference cam;


max. distance to 2 reference marks with
clearance- coded scales

34070

REFP_VELO_POS

Reference point approach velocity

34080

REFP_MOVE_DIST[0]

Reference point distance/target point with clearance coded system

34090

REFP_MOVE_DIST_CORR[0]

Reference point/absolute offset, clearance - coded

34092

REFP_CAM_SHIFT

Electronic reference cam offset for incremental measuring systems with equidistant zero marks

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8-159

Reference Point Approach (R1)


8.7

Data fields, lists

Axis - specific
34093

REFP_CAM_MARKER_DIST

Distance reference cam/reference mark

34100

REFP_SET_POS[0]

Reference point value

34110

REFP_CYCLE_NR

Axis order on channel - specific referencing

34200

ENC_REFP_MODE[0]

Referencing mode

34210

ENC_REFP_STATE[0]

State of absolute encoder

34220

ENC_ABS_TURNS_MODULO

Range of absolute encoder with rotary encoders

R2

36300

ENC_FREQ_LIMIT

Encoder limit frequency

A3

36302

ENC_FREQ_LIMIT_LOW

Encoder limit frequency for re - synchronization

36310

ENC_ZERO_MONITORING

Zero mark monitoring

8-160

A3

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Manual Traversing and Handwheel Traversing


(H1)

9.1

General features when traversing in JOG mode

JOG mode
In JOG mode, the axes/spindle can be traversed by manual operation. The active operating
mode is signaled to the PLC via the IS Active mode: JOG (V3100 000.2) and is displayed
on the screen.
References:

Chapter Operating Modes, Program Mode

Traversing options
The axes can be traversed either using the traversing keys of a connected machine control
panel (manual traversing) or via connected handwheels (handwheel traversing).
It is possible either to use the keys to traverse all machine axes simultaneously (provided an
appropriate design of a user - specific machine control panel) or to traverse the axes using the
handwheel according to the number of handwheels connected.
In the case of this simultaneous movement of several machine axes, no interpolation is carried out between the axes.

Coordinate systems
The operator can traverse the axes in the following coordinate systems:


Machine coordinate system (MCS); each axis can be traversed manually.

Workpiece coordinate system (WCS); the geometry axes can be traversed manually.

Machine functions
There are the following variants of manual traversing (the so - called machine functions):


Continuous traversing

Incremental traversing (INC, specification of a certain number of traversing increments)


With metric scaling setting of the system, an increment is evaluated with 0.001 mm.

A machine function present at the machine control panel interface of the user must be converted by the PLC user program to the appropriate PLC/NCK interface. To this aim, the axis specific NCK/PLC interface must be used in the case of a machine axis/spindle, in the case
of a geometry axis, the channel - specific NCK/PLC interface, and for all axes/spindle and the
geometry axes the signals in the mode area (see also next Section).

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9.1

General features when traversing in JOG mode

Handwheel traversing
Traversing of the axes using the handwheel is also possible in the MCS or WCS. To evaluate
the handwheel pulses, set an incremental traversing method (INC...) (see Section 9.4).

Traversing the geometry axes


If workpieces are machined the workpiece coordinate system of which is not parallel to the
machine coordinate system (clamping at an angle, programmed rotation in the contour active), it is possible to traverse along the axes of the workpiece coordinate system using the
traversing keys or the handwheel. In this case, you will change from AUTO to JOG when the
axes are stopped and will traverse a geometry axis instead of a machine axis. In this case, 1
... 3 machine axes will move, depending on the active rotation of the workpiece coordinate
system.
While a machine axis traverses, it cannot additionally be traversed using the traversing keys
of a geometry axis; first, the traversing movement of the machine axis must be completed.
Otherwise, alarm 20062 Axis already active is output.
The handwheels 1 to 3 can be used to traverse 3 geometry axes simultaneously.
Note: Geometry axes are loaded with values via a separate, channel - specific PLC interface.

Transverse axis in conjunction with turning


A geometry axis is defined as a transverse axis. If radius programming (DIAMOF) is selected
here instead of diameter programming (DIAMON), the following must be observed when traversing in JOG mode:


Continuous traversing:
There are no differences when a transverse axis is transversed continuously.

Incremental traversing:
Only the half of the distance of the selected increment size is traversed.

Traversing using the handwheel:


As with incremental traversing, in this case, too, only the half of the distance is traversed
per handwheel pulse when using the handwheel.

References:

Section Transverse axis

Manual traversing of the spindle


In the JOG mode, it is also possible to traverse the spindle manually. This is subject mainly to
the same conditions as manual traversing of the axes. The spindles can be traversed continuously in JOG mode using the traversing keys/the IS continuous and/or INC.... The selection and enabling is carried out via the axis/spindle - specific PLC interface analogously to
the axes.
manual traversing of the spindle is possible noth in the positioning mode (spindle in position
control) and in control mode.
The parameter record (machine data) of the current gear stage will apply.
References:

9-162

Chapter Spindle

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9.1

General features when traversing in JOG mode

Velocity
The velocity/speed of the axes/spindle on manual traversing in JOG mode is defined by the
following value specifications:


in the case of linear axes using the general SD 41110: JOG_SET_VELO (JOG velocity
with G94) and in the case of rotary axes using SD 41130: JOG_ROT_AX_SET_VELO
(JOG velocity with rotary axes) er SD 41200: JOG_SPIND_SET_VELO (JOG speed for
the spindle).

If the appropriate SD is zero, the appropriate axis - specific MD 32020: JOG_VELO (conventional axis velocity) will apply.
With geometry axes, the value of the assigned machine axis is used in this case: X - >X1,
Y - >Y1, Z - >Z1 (with default setting).

Rapid traverse override


If with machine axes the rapid traverse override key is pressed in addition to the traversing
keys, the movement is carried out at the rapid traverse rate defined in the axis - specific MD
32010: JOG_VELO_RAPID (axis velocity in JOG mode with rapid traverse override).
In the case of geometry axes, the value of the assigned machine axis is used: X - >X1,
Y - >Y1, Z - >Z1 (with default setting). To the control, the separate PLC interface range of the
geometry axes must be used.

Speed override
The speed in JOG mode can additionally be controlled using the axis - specific feed override
switch provided the axial IS Override active (V380X0001.7) is set.
In switch position 0%, the axis will not be traversed even if the IS Override active is not set.
In the case of geometry axes, the channel - specific feed override switch or, in the case of rapid traverse override, the rapid traverse override switch will be active.
If a spindle is used, the enabled spindle override switch will be active.
References:

Section Feed

Acceleration
The maximum axis acceleration is defined using the axis - specific MD 32300: MAX_AX_ACCEL. When traversing in JOG mode, it is also possible to set the acceleration according to a
specified characteristic. For possible settings, please refer to:
References:

Section Acceleration

PLC interface
For geometry axes (axes in the WCS), a separate PLC interface is provided (VB 3200 1000,
ff or VB 3300 1000, ff), which contains the same signals as the axis - specific PLC interface.

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9.1

General features when traversing in JOG mode

When traversing the spindle manually, the PLC interface signals between NCK and PLC act
analogously as with the machine axes. The IS Position reached with exact stop fine or coarse will only be set if the spindle is in position control mode.
For the purely spindle - specific interface signals, the following must be observed when traversing the spindle in JOG mode:


The following PLC interface signals provided to the spindle will not be active:
-

IS Invert M3/M4 (V380x2001.6)

IS Set direction of rotation CCW or Set direction of rotation CW (V380x2002.7 or .6)

IS Oscillation speed (V380x2001.5)

The following PLC interface signals provided from the spindle will not be set:
-

IS Actual rotation CW (V390x2001.7)

IS Spindle in set range (V390x2001.5)

Note
Pressing Reset will cancel the manual traversing movement (axis/spindle) and generate a
braking ramp.

Limitations
On manual traversing, the following limitations are active:


Working area limitation (axis must be referenced)

Software limit switches 1 or 2 (axis must be referenced)

Hardware limit switches

The control system internally ensures that the traversing movement is aborted once the first
valid limitation is reached. The velocity control ensures that the braking process is initiated in
due time so that the axis comes to a stop exactly at the limit position (e.g. software limit
switch). The axis will only be decelerated with Rapid stop if the hardware limit switch responds.
If the corresponding limitation is reached, an alarm message is output. A continuation of the
movement in this direction is internally prevented by the control system. The traversing keys
and the handwheel remain inactive for this direction.

Important
To ensure that the software limit switches and working area limitations are enabled, first the
axis must be referenced.

Machine manufacturer
The retraction of an axis that has approached the limit position depends on the machine manufacturer. Please refer to the Documentation of the machine manufacturer.

For further information on working area limitations, as well as hardware and software limit
switches, refer to:
References:
Section Axis monitoring functions

9-164

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Manual Traversing and Handwheel Traversing (H1)


9.2

9.2

Continuous traversing

Continuous traversing

Selection
Selecting JOG mode will automatically set the active machine function IS continuous:
with geometry axes: V3300 1001.6, V3300 1005.6, V3300 1009.6)
with machine axes/spindle: V390x0005.6.
In JOG mode, it is also possible to activate continuous traversing via the PLC interface (IS
Machine function: continuous).
The PLC determines in which signal area the INC/continuous signals are provided to the
NCK via the IS INC inputs in mode group area active (V26000001.0):
V26000001.0 = 1 - >

in the mode group area: VB30000002,


applicable to all axes

V26000001.0 = 0 - >

in the geometry/axis area:


VB32001001, VB32001005,
VB32001009, VB380x0005

Traversing keys +/ The traversing keys plus and minus will traverse the corresponding axis in the desired direction. PLC traversing key signals to NCK IS:
with geometry axes (traversing in the WCS):
V3200 1000.7 /.6, V3200 1004.7
/.6,
V3200 1008.7 /.6
with machine axes/spindle (traversing in MCS): V380x 004.7 /.6V32001000.7/.6.
Pressing both traversing keys of an axis at the same time will not result in a traversing movement or will stop an axis being traversed.

Traversing commands +/ Once a traversing request is provided for an axis (e.g. when the traversing key is pressed),
the IS Traversing command + or Traversing command - is output to the PLC, depending
on the direction of movement.
with geometry axes:
V3300 1000.7 /.6, V3300 1004.7 /.6, V3300 1008.7 /.6
with machine axes/spindle: V390x 004.7 /.6

Continuous traversing in non - maintained command mode


The axis will traverse as long as the traversing key is pressed unless no axis limitation is reached beforehand. When the traversing key is released, the axis is decelerated to the standstill, and the movement is considered completed.

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

9-165

Manual Traversing and Handwheel Traversing (H1)


9.3

9.3

Incremental traversing (INC)

Incremental traversing (INC)

Setting increments
The distance to be traversed by the axis is defined by so - called increments (also called incremental dimension). Before the machine operator traverses the axis, he must set the desired increment.
The setting is carried out, e.g. on the machine control panel. The IS Machine function: INC1
to INCvar corresponding to the desired increment must be set in the PLC user program after
an appropriate logic operation.
The PLC defines in which signal area the INC signals are provided to the NCK via the IS INC
inputs in mode group area active (V26000001.0):
V26000001.0 = 1 - >

in the mode group area: VB30000002,


applicable to all axes

V26000001.0 = 0 - >

in the geometry/axis area:


VB32001001, VB32001005,
VB32001009, VB380x0005

The active machine function: IS INC... is signaled from the NCK to the PLC:
with geometry axes: V3300 1001.0 , V3300 1005.0, V3300 1009.0 to .5
with machine axes/spindle: V390x 0005.0 to .5

Settable increments
The operator can set different increment sizes. These divide into:


fixed increments whose increment sizes are common for all axes: INC1, INC10, INC100,
INC1000 (only via IC: INC10000 ).

and a variable increment (INCvar). Specifying an increment for a variable increment is


also possible together for all axes using the general SD: JOG_VAR_INCR_SIZE (size of
the variable increment with INC/handwheel).

Incremental traversing in the non - maintained command mode


Pressing the traversing key for the desired direction (e.g. +), the axis starts to traverse the set
increment. If the traversing key is released before the increment has been traversed completely, the movement is interrupted and the axis stops. If the same traversing key is pressed
again, the axis will traverse the remaining distance to go. The movement can also be interrupted by releasing the traversing key.
Pressing the traversing key in the opposite direction will have no effect unless the increment
has not been traversed completely or the movement has been canceled.

Traversing keys and traversing command


as with continuous traversing (see Section 9.2)

Aborting the traversing movement


If you wish not to traverse the increment completely, use RESET or the axis - specific IS Delete axis distance to go (V380x0002.2) to abort the movement.

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SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

Manual Traversing and Handwheel Traversing (H1)


9.4

9.4

Handwheel traversing in JOG mode

Handwheel traversing in JOG mode

Selection
JOG mode must be active. In addition, the operator must set the increment INC1, INC10, ...
active when traversing using the handwheel.
A maximum of 3 handwheels can be connected. It is thus possible to move simultaneously
and independently up to 3 axes using handwheels.
The geometry or machine axes (WCS or MCS) is assigned a handwheel via interface signals.
Which axis is traversed by turning the handwheel 1 ... 3, can be set:


via the PLC user interface with the IS Enable handwheel 1 to 3


with a machine axis (traversing in the MCS):
V380x 0004.0 to .2
with a geometry axis (traversing in the WCS): V3200 0000.0 to .2, V3200 0004.0 to .2,
V3200 0008.0 to .2
The linking to the PLC interface is carried out by the PLC user program. It is possible to
assign a handwheel several machine axes at a time

or via menu - assisted operation (HMI)


When the softkey Handwheel is pressed in the main menu of JOG mode, the window
Hand - wheel will be displayed. In this window, each handwheel can be assigned an axis
(WCS or MCS).

To activate the handwheel from the operator panel (HMI), a separate user interface is provided between HMI and PLC. This interface provided by the PLC basic program for handwheels 1 to 3 contains the following information:


the axis numbers assigned to the corresponding handwheel


IS Axis number of handwheel n (VB19001003, ff)

the additional information machine or geometry axis


IS Machine axis (VB19001003.7, ff)

The PLC user program must set the appropriate IS Enable handwheel either to 0 (Disable)
or to 1 (Enable) for the given axis.

Specification as a path or as a velocity


Turning the electronic handwheel will traverse the assigned axis either in the positive direction or in the negative direction, depending on the direction of rotation.
The specification type of the handwheel can be set and thus adapted to the particular application using the general MD 11346: HANDWH_TRUE_DISTANCE (handwheel path or velocity specification).
MD value=0 (default):
The handwheel specifications are velocity specifications. The braking process when the
handwheel stops is carried out on the shortest path.
MD value=1 :
The handwheel specifications are path specifications. No pulse are lost. Due to a limitation to
the maximum admissible velocity, the axes may follow up. This should be taken into account
in particular in the case of a high handwheel pulse weighting.
Further variants of path or velocity specification are possible using value =2 or 3.

SINUMERIK 802D, 802D base line


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9-167

Manual Traversing and Handwheel Traversing (H1)


9.4

Handwheel traversing in JOG mode

Weighting
The resulting distance to be traversed (=path)/velocity when turning the handwheel depends
on the following factors:


Number of handwheel pulses received at the interface

Active increment (machine function INC1, INC10, INC100, ... )


With metric system scaling setting, one increment is weighted with 0.001 mm.

Pulse weighting of handwheel using the general MD: HANDWH_IMP_PER_LATCH


(handwheel pulses per lathc position)

Traversing commands +/ During the axis movement, the IS Traversing command + or Traversing command - is provided to the PLC, depending on the direction of movement.
with geometry axes: V3300 1000.7/.6, V3300 1004.7/6, V3300 1008.7/.6
with machine axes/spindle: V390x 004.7/.6.
If the axis is already traversed using the traversing keys, additional handwheel traversing is
not possible. The alarm 20051 Handwheel traversing not possible is output.

Velocity
The velocity results from the pulses generated using the handwheel and the pulse weighting:
Distance to be traversed per time unit.
This velocity is limited by the value in the axis - specific
MD 32000: MAX_AX_VELO.

Aborting/interrupting the traversing movement


RESET or the axis - specific IS Delete distance to go (V380x0002.2) will abort the traversing
movement. The current set/actual difference are deleted.
The NC STOP command will only interrupt the traversing movement. Pressing NC START
will re - enable the handwheel movement.

Traversing in the opposite direction


Depending on MD 11310: HANDWH_REVERSE, the behavior when reversing the traversing
direction is as follows:

9-168

MD value =0:
If the handwheel is rotated in the opposite direction, the resulting distance to be traversed
is calculated and the end point calculated in this way is approached as fast as possible: If
this end point is before the point to which the traversing axis can brake with the traversing
direction currently selected, the axis will decelerate, and the end point will be approached
by traversing in the opposite direction. Otherwise, the newly calculated end point will be
approached immediately.

MD value >0:
If the handwheel is rotated by at least the number of pulses specified in the machine data,
the axis will be decelerated as fast as possible, and all pulses ariving until the end of the
interpolation will be ignored, ie. the axis will be traversed again only after the standstill (as
far as the setpoint is concerned).

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

Manual Traversing and Handwheel Traversing (H1)


9.4

Handwheel traversing in JOG mode

Behavior at software limit switch/working area limitation


When traversing in JOG mode, the axes are traversed only to the first active limitation and
the appropriate alarm is output. Depending on the machine data MD 11310: HANDWH_REVERSE, the behavior is as follows (provided the axis has not yet reached its setpoint end
position):


MD value =0:
The distance to go resulting from the handwheel pulses constitutes a fictive end point
which will be used for the calculations to follow. If this fictive end point is, e.g. 10 mm behind the limitation, these 10 mm must only be traversed in the opposite direction before
the axis will be able to traverse. If you wish to traverse from the limitation immediately in
the opposite direction again, the fictive distance to go can be deleted either by deleting
the distance to go or deselecting the handwheel assignment.

MD value >0:
All handwheel pulses resulting in any end point behind the limitation will be ignored. Moving the handwheel in the opposite direction will immediately result in traversing in the
opposite direction, i.e. from the limitation away.

SINUMERIK 802D, 802D base line


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Manual Traversing and Handwheel Traversing (H1)


9.5

9.5
9.5.1

Data descriptions (MD, SD)

Data descriptions (MD, SD)


General machine data

11310
MN_HANDWH_REVERSE
MD number
Threshold for handwheel direction reversal
Default: 2
Min. input limit: 0
Max. input limit: ***
Change valid after Power On
Protection level: 2/2
Unit: Data type: BYTE
Valid from SW release:
Meaning:
0:
No immediate traversing in the opposite direction
>0:
Immediate traversing in the oppositie direction if the handwheel is rotated in the
opposite direction at least by the specified number of pulses

11320
HANDWH_IMP_PER_LATCH[n]
MD number
Handwheel pulses per latch position [handwheel index]:
Default: (1, 1, 1)
Min. input limit: ***
Max. input limit: ***
Change valid after Power On
Protection level: 2/2
Unit: Data type: DOUBLE
Valid from SW release
Meaning:
This MD is used to match the connected handwheels with the control system.
In this MD, the number of pulses generated by the handwheel per latch position is entered. The
handwheel pulse weighting must be defined for each connected handwheel (1 ... 3) separately.
With this matching, each handwheel latch position has the same effect as a traversing key would
have been pressed on incremental traversing.
A negative value will result in a direction reversal of the handwheel rotation.
Related to ....
MD: JOG_INCR_WEIGHT (weighting of an increment of a machine axis with INC/handwheel)

11346
HANDWH_TRUE_DISTANCE
MD number
Handwheel path or velocity specification
Default: 0
Min. input limit: 0
Max. input limit: 3
Change valid after Power On
Protection level: 2/2
Unit: Data type: BYTE
Valid from SW release:
Meaning:
0: The specifications from the handwheel are velocity specifications. The braking
to the handwheel standstill is carried out on the shortest possible path.
1: The specifications from the handwheel are path specifications. No pulses are lost.
Due to a limitation to the maximum admissible velocity, overtraveling of the axes may occur.
2: The same ffect as with value=0, but longer deceleration dist. when the handwheel stops.
3: The same effect as with value=1, but longer deceleration dist. when the handwheel stops.
Related to ....

9-170

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

Manual Traversing and Handwheel Traversing (H1)


9.5

9.5.2

Data descriptions (MD, SD)

Axis/spindle - specific machine data

32010
MD number
Default: 10000 mm/min,
27.77 rpm
Change valid after RESET

JOG_VELO_RAPID
Conventional rapid traverse
Min. input limit: 0.0

Data type: DOUBLE


Meaning:

Valid from SW release:


The entered axis velocity applies to traversing in JOG mode with the rapid traverse override key
pressed and an axial feed override of 100%.
The entered value may not exceed the max. permissible axis velocity (MD MAX_AX_VELO).
MD 32010 is not used for the programmed rapid traverse G0.
AUTOMATIC and MDA modes
MD 32000: MAX_AX_VELO (max. axis velocity)
IS Rapid traverse override (V32001000.5, V32001004.5, V32001008.5, V380x0004.5,)
IS Feed override (VB380x 0000), axis - specific
IS Rapid traverse override (VB3200 0005), with geometry axes

MD inapplicable to ......
Related to ....

Protection level: 2/7

Max. input limit: ***


Unit:
Linear axis: mm/min
Rotary axis: rpm

32020
MD number
Default: 2000 mm/min
5.55 rpm
Change valid after RESET

JOG_VELO
Conventional axis velocity
Min. input limit: 0.0

Data type: DOUBLE


Meaning:

Valid from SW release:


The entered velocity applies to traversing axes in JOG mode with the feed override switch position 100%.
The velocity of MD 32020: JOG_VELO is only used if the general SD 41110: JOG_SET_VELO =
0 for linear axes or if the SD 41130: JOG_ROT_AX_SET_VELO = 0 is set for rotary axes.
If this is the case, the axis velocity is active:
- for continuous traversing
- for incremental traversing (INC1, ... INCvar)
The value entered must not exceed the maximum admissible velocity
(MD 32000: (MAX_AX_VELO).

MD inapplicable to ......
Application example(s)
Related to ....

Protection level: 2/7

Max. input limit: ***


Unit:
Linear axis: mm/min
Rotary axis: rpm

Spindles in JOG mode:


It is thus also possible to specify the velocity spindle - specifically when traversing the spindles in
JOG mode if
SD 41200: JOG_SPIND_SET_VELO = 0.
In this case, the velocity is influenced by the spindle override switch.
AUTOMATIC and MDA modes
If different velocities are required for the individual axes/spindles in JOG mode, the velocity can
be determined axis - specifically. The SD: JOG_SET_VELO must be set to 0!
MD 32000: MAX_AX_VELO (max. axis velocity)
SD 41110: JOG_SET_VELO (JOG velocity for G94)
SD 41130: JOG_ROT_AX_SET_VELO (JOG velocity for rotary axes)
SD 41200: JOG_SPIND_SET_VELO (JOG speed for the spindle)
Axis - specific IS Feed override (VB380x 0000)
Axis - specific IS Spindle override (VB380x 2003)
Channel- specific IS Feed override (VB3200 0004) with geometry axes

SINUMERIK 802D, 802D base line


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Manual Traversing and Handwheel Traversing (H1)


9.5

9.5.3

Data descriptions (MD, SD)

General setting data

41010
SD number
Default: 0.0
Change valid: immediately
Data type: DOUBLE
Meaning:

SD inapplicable ......
Related to ....

41110
SD number
Default: 0.0
Change valid: immediately
Data type: DOUBLE
Meaning:

SD inapplicable ......
Related to ....

JOG_VAR_INCR_SIZE
Size of the variable increment with INC/handwheel
Min. input limit: ***
Max. input limit: ***
Protection level: 7/7
Unit: mm or degrees
Valid from SW release: 1.1
This setting data defines the number of increments when selecting the variable increment
(INCvar). This increment size is traversed by the axis per latch position when pressing the traversing key or turning the handwheel if the variable increment is selected (IS Active machine
function: INC variable if the machine or geometry axis has a 1 - signal).
Note: Please take into account that the increment size applies both to incremental traversing
and handwheel traversing.
if INCvar is not active
IS Active machine function: INCvariabel(V32001001.5, V32001005.5, V32001009.5,
V380x0005.5)

JOG_SET_VELO
JOG velocity for linear axes (for G94)
Min. input limit: 0.0
Protection level: 7/7

Max. input limit: ***


Unit: mm/min
rpm
Valid from SW release:

Value > 0:
The entered velocity applies to all linear axes traversed in JOG mode if these are traversed manually using the traversing keys plus or minus..
The axis velocity is active:
- for continuous traversing
- for incremental traversing (INC1, ... INCvar)
The value entered may not exceed the maximum admissible axis velocity
(MD 32000: (MAX_AX_VELO).
Value = 0:
The appropriate axis - specific MD 32020: JOG_VELO Conventional axis velocity acts as the
feedrate in JOG mode. It is thus possible to define for each axis its own JOG velocity (axial MD).
- for rotary axes (SD 41130: JOG_ROT_AX_SET_VELO is active here)
Axis - specific MD 32020: JOG_VELO (conventional axis velocity)
Axis - specific MD 32000: MAX_AX_VELO (maximum axis velocity)
SD 41130: JOG_ROT_AX_SET_VELO (JOG velocity for rotary axes)

41130
SD number
Default: 0.0
Change valid: immediately
Data type: DOUBLE
Meaning:

JOG_ROT_AX_SET_VELO
JOG velocity for rotary axes
Min. input limit: 0.0
Max. input limit: ***
Protection level: 7/7
Unit: rpm
Valid from SW release: 1.1
as SD 41110: JOG_AX_SET_VELO - but for all rotary axes instead of linear axes

Application example(s)
Related to ....

The operator can thus specify a JOG velocity application - specifically.


MD 32020: JOG_VELO
(conventional velocity)
MD 32000: MAX_AX_VELO
(maximum axis velocity)

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SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

Manual Traversing and Handwheel Traversing (H1)


9.5

41200
SD number
Default: 0.0
Change valid: immediately
Data type: DOUBLE
Meaning:

SD inapplicable ......
Related to ....
Further references

Data descriptions (MD, SD)

JOG_SPIND_SET_VELO
JOG speed for the spindle
Min. input limit: 0.0
Max. input limit: ***
Protection level: 7/7
Unit: rpm
Valid from SW release:
Value > 0:
The entered velocity applies to spindles in JOG mode if these are traversed manually using the
traversing keys plus or minus.
The velocity is active:
- for continuous traversing
- for incremental traversing (INC1, ... INCvar)
The value entered may not exceed the max. admissible velocity (MD 32000: (MAX_AX_VELO).
Value = 0:
If 0 has been entered in the setting data, MD 32020: JOG_VELO will act as the JOG velocity
(conventional axis velocity). It is thus possible to define a separate JOG velocity for each axis
(axis - specific MD).
When the spindle is traversed in JOG mode, the maximum speeds of the active gear stage are
taken into account (MD 35130 : GEAR_STEP_MAX_VELO_LIMIT).
axes
MD 32020: JOG_VELO (conventional axis velocity)
MD 35130: GEAR_STEP_MAX_VELO_LIMIT (maximum speed of gear stages)
Section Spindle

SINUMERIK 802D, 802D base line


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Manual Traversing and Handwheel Traversing (H1)


9.6

9.6

Signal descriptions

Signal descriptions

9.6.1

Signals from HMI to PLC

V1900 0003.7
V1900 0004.7
V1900 0005.7
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 - - - > 1
Signal state 0 or edge
change 1 - - - > 0
Related to ....

V19001003.0 to .2
V19001004.0 to .2
V19001005.0 to .2
Interface signal
Edge evaluation: no
Signal meaning

Machine axis

for handwheel 1
for handwheel 2
for handwheel 3
Signal(s) from NC (HMI - > PLC)
Signal(s) updated: cyclically
Signal(s) valid from SW release:
The operator has assigned the handwheel (1, 2, 3) an axis directly from the operator panel. This
axis is a machine axis - no geometry axis (axis in WCS).
For more information, see IS Axis number.
The operator has assigned the handwheel (1, 2, 3) an axis directly from the operator panel. This
axis is a geometry axis - no geometry axis (axis in WCS).
For more information, see IS Axis number.
IS Axis number (V19000003.0 to .4, ff)

Axis number

for handwheel 1
for handwheel 2
for handwheel 3
Signal(s) from NC (HMI - > PLC)
Signal(s) updated: cyclically
Signal(s) valid from SW release:
The operator can assign each handwheel an axis directly from the operator panel. To this aim,
he specifies the desired axis (e.g. X).
The axis number assigned to the axis plus the information machine or geometry axis (IS Machine axis) is provided by the PLC user interface in the form of HMI interface signals.
The interface signal Enable handwheel must be set by the PLC user program for the specified
axis. Depending on the HMI interface signal Machine axis, the interface to the geometry axis or
the machine axis is used.
For the assignment of the axis name to the axis number, the following applies:
 IS Machine axis = 1; i.e. machine axis - not geometry axis:
The assignment is carried out via MD 10000: AXCONF_MACHAX_NAME_TAB[n]
(machine axis name).
 IS Machine axis = 0; i.e. geometry axis (axis in WCS):
The assignment is carried out via MD 20060: AXCONF_GEOAX_NAME_TAB[n]
(name of geometry axis in the channel). With the IS Channel number Geometry axis
Handwheel n, the channel number assigned to the handwheel is specified.
The following coding applies to the axis number:
Bit 2
Bit 1
Bit 0
Axis number
0
0
0
0
0
1
1
0
1
0
2
0
1
1
3
1
0
0
4
1
0
1
5
Note: Bit 3 and bit 4 must always remain 0.

Related to ....
IS Machine axis (V19001003.7 ff)
IS Enable handwheel 1 to 3 /geometry axes 1, 2, 3
(V32001000.0 to .2, V32001004.0 to .2, V32001008.0 to .2)
IS Enable handwheel 1 to 3 /machine axes (V380x0004.0 to .2)
MD 10000: AXCONF_MACHAX_NAME_TAB [n] (machine axis name)
MD 20060: AXCONF_GEOAX_NAME_TAB [n] (name of geometry axis in the channel)

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SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

Manual Traversing and Handwheel Traversing (H1)


9.6

9.6.2

Signal descriptions

NCK signals and signals in the operating mode area

Description of the signals provided to the NCK


V2600 0001.0
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 - - - > 1
Signal state 0 or edge
change 1 - - - > 0
Related to ....

INC inputs in the mode group area active


Signal(s) to NCK (PLC - > NCK)
Signal(s) updated: cyclically

Signal(s) valid from SW release:

The IS INC1, INC10, ..., Continuous in the operating mode area are used as input signals
(V3000 0002.0 to .6).
The IS INC1, INC10, ..., Continuous in the axis and geometry axis areas are used as input
signalsi.
IS Machine function INC1 to Continuous in the operating mode area (V3000 0002.0 to .6)
IS Machine function INC1,...,Continuous
for geometry axis 1 (V3200 1001.0 to .6)
for geometry axis 2 (V3200 1005.0 to .6)
for geometry axis 3 (V3200 1009.0 to .6)
IS Machine function INC1,...,Continuous in the axis area (V380x 0005.0 to .6)

Description of the signals provided to the operating modes


V3000 0000.0 to .6
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 - - - > 1

Signal state 0 or edge


change 1 - - - > 0

Related to ....

Machine function INC1, INC10, INC100, INC1000, INC10000, INCvar, continuous


Signal(s) to operating modes (PLC - > NCK)
Signal(s) updated: cyclically
Signal(s) valid from SW release:
This input area is only used if the IS INC inputs in mode group area active (V2600 0001.0) is
set. In this case, the signals will apply to all axes and geometry axes.
The IS INC... defines how many increments the axis traverses per latch position when the traversing key is pressed or the handwheel is turned. When doing so, JOG mode must be active.
With INCvar, the value in the general SD 41010: JOG_VAR_INCR_SIZE will apply.
With Continuous, the appropriate axis can be traversed using the plus or minus traversing key
with holding down the traversing key as required.
Once the selected machine function is active, this is signaled to the PLC interface (IS Active
machine function INC1; ... ). If several machine function signals (INC1, INC... or Continuous
traversing) are selected at the interface at the same time, no machine function is enabled internally in the control system.
Note:
The input IS INC... or Continuous to modify an active machine function must be present at
least one PLC cycle. It need not be present statically.
The appropriate machine function is not selected. No modification to the active machine function
is requested.
If an axis is just traversing an increment, the movement is aborted with deselection or switchover
of the machine function.
IS INC inputs in mode group area active (V2600 0001.0)
IS Machine function INC1, ..., continuous
for geometry axis 1 (V3200 1001.0 to .6)
for geometry axis 2 (V3200 1005.0 to .6)
for geometry axis 3 (V3200 1009.0 to .6)
IS Machine function INC1, ..., continuous in the axis area (V380x 0005.0 to .6)
IS Active machine function INC1, ..., continuous
for geometry axis 1 (V3300 1001.0 to .6)
for geometry axis 2 (V3300 1005.0 to .6)
for geometry axis 3 (V3300 1005.0 to .6)
IS Active machine function INC1, ..., continuous in the axis area (V390x 0005.0 to .6)

SINUMERIK 802D, 802D base line


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Manual Traversing and Handwheel Traversing (H1)


9.6

Signal descriptions

9.6.3

Channel - specific signals

Description of the signals provided to the channel


V3200 1000.0 to .2
V3200 1004.0 to .2
V3200 1008.0 to .2
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 - - - > 1

Signal state 0 or edge


change 1 - - - > 0
Application example(s)
Related to ....

V3200 1000.4
V3200 1004.4
V3200 1008.4
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 - - - > 1
Signal state 0
Application example(s)
Related to ....

V3200 1000.5
V3200 1004.5
V3200 1008.5
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 - - - > 1

Signal state 0 or edge


change 1 - - - > 0

9-176

Enable handwheel (1 to 3)

for geometry axis 1


for geometry axis 2
for geometry axis 3
Signal(s) to channel (PLC - > NCK)s
Signal(s) updated: cyclically
Signal(s) valid from SW release:
These PLC interface signals define whether the geometry axis is assigned to handwheel 1, 2, 3
or no handwheel.
One axis can be assigned only one handwheel at a time.
If several interface signals Enable handwheel are set, the priority is Handwheel 1 before
Handwheel 2 before Handwheel 3.
Note: Using handwheels 1 to 3, 3 geometry axes can be traversed simultaneously.
This axis is not assigned handwheel 1, 2 or 3.
The manipulation of the geometry axis by turning the handwheel can be locked via the interface
signal from the PLC user program.
IS Handwheel active 1 to 3
for geometry axis 1: V33001000.0 to .2
for geometry axis 2: V33001004.0 to .2
for geometry axis 3: V33001008.0 to .2

Traversing key lock

for geometry axis 1


for geometry axis 2
for geometry axis 3
Signal(s) to channel (PLC - > NCK)s
Signal(s) updated: cyclically
Signal(s) valid from SW release:
The traversing keys plus and minus have no effect on the geometry axes. For example, traversing of the geometry axis using the traversing keys on the MCP is not possible in JOG mode.
If the traversing key lock is enabled during a traversing movement, the geometry axis is stopped.
The traversing keys plus and minus are enabled.
Depending on the operating status, traversing of the geometry axis in JOG mode can be locked
from the PLC user program.
IS Traversing key plus and ... minus for geometry axis 1 (V32001000.7 and .6 )
for geometry axis 2 (V32001004.7 and .6 )
for geometry axis 3 (V32001008.7 and .6 )

Rapid traverse override

for geometry axis 1


for geometry axis 2
for geometry axis 3
Signal(s) to channel (PLC - > NCK)s
Signal(s) updated: cyclically
Signal(s) valid from SW release: 1.1
If the PLC interface signal Rapid traverse override is provided together with the traversing keys
plus or minus, the selected geometry axis will traverse at rapid traverse.
The rapid traverse velocity is defined in the machine data JOG_VELO_RAPID.
The rapid traverse override is active in JOG mode for the following variants:
- continuous traversing
- incremental traversing
With rapid traverse override active, the velocity/speed can be manipulated using the rapid traverse override switch.
The geometry axis traverses at the specified JOG velocity (SD: JOG_SET_VELO or MD:
JOG_VELO).

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

Manual Traversing and Handwheel Traversing (H1)


9.6

V3200 1000.5
V3200 1004.5
V3200 1008.5
Interface signal
Signal inapplicable ......
Related to ....

Further references

V3200 1000.7 and .6


V3200 1004.7 and .6
V3200 1008.7 and .6
Interface signal
Edge evaluation: yes
Signal state 1 or edge
change 0 - - - > 1

Signal state 0 or edge


change 1 - - - > 0
Signal inapplicable ......
Special cases, errors, ......

Related to ....

Signal descriptions

Rapid traverse override

for geometry axis 1


for geometry axis 2
for geometry axis 3
Signal(s) to channel (PLC - > NCK)s
- AUTOMATIC and MDA modes
- Reference point approach (JOG mode)
IS Traversing key plus and ... minus for geometry axis 1 (V32001000.7 and .6 )
for geometry axis 2 (V32001004.7 and .6 )
for geometry axis 3 (V32001008.7 and .6 )
Section Feeds

Traversing keys plus and minus

for geometry axis 1


for geometry axis 2
for geometry axis 3
Signal(s) to channel (PLC - > NCK)s
Signal(s) updated: cyclically
Signal(s) valid from SW release:
In JOG mode, the traversing keys plus and minus can be used to traverse the selected axis in
both directions.
Incremental traversing
With signal state 1, the axis starts to traverse the set increment. If the signal changes
to 0 status before the increment has been traversed, the traversing movement will be
aborted. If the signal state is 1 again, the traversing movement will be continued.
Until the increment is traversed completely, the traversing movement of the axis can
be stopped and continued several times as described.
Continuous traversing
If no INC dimension is selected, the axis will traverse as long as the traversing axis
remains pressed.
If both traversing signals (plus and minus) are set at the same time, no traversing movement is
carried out or the traversing movement is aborted.
The effect of the traversing keys can be disabled for each axis separately using the PLC interface signal Traversing key lock.
CAUTION: In contrast to machine axes, with geometry axes it is possible to traverse only
one geometry each simultaneously. If you try to traverse more than one
geometry axis using the traversing keys, alarm 20062 will be output.
no traversing
AUTOMATIC and MDA modes
The geometry axes cannot be traversed in JOG mode.
- if it is already traversed (as a machine axis) via the axial PLC interface;
- if another geometry axis is already traversed via the traversing keys.
Alarm 20062 Axis is already active is output.
IS Traversing keys plus and minus for machine axes (V380x0004.7 and .6)
IS Traversing key lock
for geometry axis 1 (V32001000.4)
for geometry axis 2 (V32001004.4)
for geometry axis 3 (V32001008.4)

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

9-177

Manual Traversing and Handwheel Traversing (H1)


9.6

Signal descriptions

V3200 1001.0 to .6
V3200 1005.0 to .6
V3200 1009.0 to .6
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 - - - > 1

Signal state 0 or edge


change 1 - - - > 0

Related to ....

Machine function INC1, INC10, INC100, INC1000, INC10000, INCvar, continuous


for geometry axis 1
for geometry axis 2
for geometry axis 3
Signal(s) to channel (PLC - > NCK)s
Signal(s) updated: cyclically
Signal(s) valid from SW release:
This input area is only used if the IS INC inputs in mode group area active (V2600 0001.0) is
not set.
The IS INC... defines how many increments the axis traverses per latch position when the traversing key is pressed or the handwheel is turned. When doing so, JOG mode must be active.
With INCvar, the value in the general SD 41010: JOG_VAR_INCR_SIZE will apply.
With Continuous, the appropriate axis can be traversed using the plus or minus traversing key
with holding down the traversing key as required.
Once the selected machine function is active, this is signaled to the PLC interface (IS Active
machine function INC1; ... ).
If several machine function signals (INC1, INC... or Continuous traversing) are selected at the
interface at the same time, no machine function is enabled internally in the control system.
Note:
The input IS INC... or Continuous to modify an active machine function must be present at
least one PLC cycle. It need not be present statically.
The appropriate machine function is not selected. No modification to the active machine function
is requested.
If an axis is just traversing an increment, the movement is aborted with deselection or switchover
of the machine function.
IS Active machine function INC1, ...
for geometry axis 1 (V33001001.0 ... .6)
for geometry axis 2 (V33001005.0 ... .6)
for geometry axis 3 (V33001005.0 ... .6)
IS INC inputs in mode group area active (V2600 0001.0)

Description of the signals provided from the channel


V3300 1000.0 to .2
V3300 1004.0 to .2
V3300 1008.0 to .2
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 - - - > 1

Signal state 0 or edge


change 1 - - - > 0
Related to ....

9-178

Handwheel active (1 to 3)

for geometry axis 1


for geometry axis 2
for geometry axis 3
Signal(s) from channel (NCK - > PLC)
Signal(s) updated: cyclically
Signal(s) valid from SW release:
These PLC interface signals specify if this geometry axis is assigned to handwheel 1, 2, 3 or to
no handwheel.
One axis can be assigned only one handwheel at a time.
If several interface signals Enable handwheel are set, the priority is Handwheel 1 before
Handwheel 2 before Handwheel 3.
If the assignment is active, the geometry axis can be traversed in JOG mode using the
handwheel.
This geometry axis is not assigned handwheel 1, 2 or 3.
IS Enable handwheel (V32000000.0 to .2, V32000004.0 to .2, V32000008.0 to .2

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

Manual Traversing and Handwheel Traversing (H1)


9.6

V33001000.7 and .6
V33001004.7 and .6
V33001008.7 and .6
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 - - - > 1

Signal state 0 or edge


change 1 - - - > 0

Application example(s)

Related to ....

V33001001.0, ..., .6
V33001005.0, ..., .6
V33001009.0, ..., .6
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 - - - > 1
Signal state 0 or edge
change 1 - - - > 0
Related to ....

Signal descriptions

Traversing commands plus and minus for geometry axis 1


for geometry axis 2
for geometry axis 3
Signal(s) from channel (NCK - > PLC)
Signal(s) updated: cyclically
Signal(s) valid from SW release:
A traversing movement is to be carried out in the axis direction concerned. The traversing command is initiated in different ways, depending on the operating mode.
- JOG mode: using the traversing key plus or minus
- REF submode: using the traversing key leading to the reference point
- AUTO/MDA modes: A program block that contains a coordinate value for the axis
concerned is carried out.
No traversing request is currently pending for the axis direction concerned or a traversing movement carried out has been completed.
 JOG mode:
- The traversing key is cancaled.
- When quitting traversing using the handwheel
 REF submode:
when the reference point is reached
 AUT/MDA modes:
- The program block has been executed (and the next following program block does not
contain a coordinate value for the axis concerned)
- Abortion by RESET, etc.
- IS Axis lock is provided
Release of clamping (in case of axes with clamping)
Note:
If the clamping is only released with the traversing command, no continuous path mode is possible for these axes.
IS Traversing key plus and ... minus for geometry axis 1 (V32001000.7 and .6 )
for geometry axis 2 (V32001004.7 and .6 )
for geometry axis 3 (V32001008.7 and .6 )

Active machine function INC1, ..., continuous


for geometry axis 1
for geometry axis 2
for geometry axis 3
Signal(s) from channel (NCK - > PLC)
Signal(s) updated: cyclically
Signal(s) valid from SW release:
A signal is fed back to the PLC interface to define which machine function is active for the geometry axes in JOG mode.
The appropriate machine function is not active.
IS Machine function INC1,...,continuous

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

for geometry axis 1 (V32000001.0 ... .6)


for geometry axis 2 (V32000005.0 ... .6)
for geometry axis 3 (V32000009.0 ... .6)

9-179

Manual Traversing and Handwheel Traversing (H1)


9.6

Signal descriptions

9.6.4

Axis/spindle - specific signals

Description of the signals provided to the axis/spindle


V380x0004.0 ... .2
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 - - - > 1

Signal state 0 or edge


change 1 - - - > 0
Application example(s)
Related to ....

V380x0004.4
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 - - - > 1
Signal state 0 or edge
change 1 - - - > 0
Application example(s)
Related to ....

V380x0004.5
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 - - - > 1

Signal state 0 or edge


change 1 - - - > 0
Signal inapplicable ......
Related to ....

9-180

Enable handwheel (1 ... 3)


Signal(s) to axis/spindle (PLC - > NCK)
Signal(s) updated: cyclically
Signal(s) valid from SW release:
These PLC interface signals are used whether the machine axis is assigned handwheel 1, 2, 3
or no handwheel.
One axis can be assigned only one handwheel at a time.
If several interface signals Activate handwheel are set, the priority is Handwheel 1 before
Handwheel 2 before Handwheel 3.
If the assignment is active, the machine axis can be traversed in JOG mode using the hand wheel.
This machine axis is not assigned handwheel 1, 2 or 3.
This interface signal can be used to lock the manipulation of the axis by turning the handwheel
from the PLC user program.
IS Handwheel active 1 to 3 (V390x0004.0 to .2)

Traversing key lock


Signal(s) to axis/spindle (PLC - > NCK)
Signal(s) updated: cyclically
Signal(s) valid from SW release:
The traversing keys plus and minus have no effect on the appropriate machine axis. For example, traversing the axis in JOG mode using the traversing keys on the MCP is not possible.
If the traversing key lock is enabled during a traversing movement, the machine axis is stopped.
The traversing keys plus and minus are enabled.
Depending on the operating status, traversing of the machine axis in JOG mode using the traversing keys can thus be locked from the PLC program.
IS Traversing key plus and Traversing key minus (V380x0004.7 and .6)

Rapid traverse override


Signal(s) to axis/spindle (PLC - > NCK)
Signal(s) updated: cyclically
Signal(s) valid from SW release:
If the PLC interface signal Rapid traverse override is provided together with the Traversing key
plus or the Traversing key minus, the selected machine axis will traverse at rapid traverse rate.
The rapid traverse velocity is defined in the machine data JOG_VELO_RAPID.
The rapid traverse override is active in JOG mode for the following variants:
- continuous traversing
- incremental traversing
With rapid traverse override active, the velocity can be manipulated using the axial feed override
switch.
The machine axis will traverse at the specified JOG velocity (SD: JOG_SET_VELO or MD:
JOG_VELO).
- AUTOMATIC and MDA modes
- Reference point approach (JOG mode)
IS Traversing key plus and Traversing key minus (V380x0004.7 and .6)
IS Axis - specific feed override (VB380x0000)

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

Manual Traversing and Handwheel Traversing (H1)


9.6

V380x0004.7 and .6
Interface signal
Edge evaluation: yes
Signal state 1 or edge
change 0 - - - > 1

Signal descriptions

Traversing keys plus and minus


Signal(s) to axis/spindle (PLC - > NCK)
Signal(s) updated: cyclically
Signal(s) valid from SW release:
In JOG mode, the traversing keys plus and minus can be used to traverse the selected axis in
both directions.
Incremental traversing
With signal state 1, the axis starts to traverse the set increment. If the signal
changes to 0 state before the increment has been traversed, the traversing
movement will be aborted. If the signal state is 1 again, the traversing movement will
be continued. Until the increment is traversed completely, the traversing movement
of the axis can be stopped and continued several times as described above.
Continuous traversing
If no INC dimension is selected, the axis will traverse as long as the traversing axis
is hold down.
If both traversing signals (plus and minus) are set at the same time, no traversing movement is
carried out or the traversing movement is aborted.
The effect of the traversing keys can be disabled for each axis separately using the PLC interface signal Traversing key lock.

Signal state 0 or edge


change 1 - - - > 0
Signal inapplicable ......
Application example(s)
Special cases, ......
Related to ....

V380x0005.0 ... .6
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 - - - > 1

Signal state 0 or edge


change 1 - - - > 0
Related to ....

No traversing
AUTOMATIC and MDA modes
The machine axis cannot be traversed in JOG mode if it is already traversed via the channel specific PLC interface (as a geometry axis). Alarm 20062 is output.
Indexing axes
IS Traversing key plus and ... minus for geometry axis 1 (V32001000.7 and .6 )
for geometry axis 2 (V32001004.7 and .6 )
for geometry axis 3 (V32001008.7 and .6 )
IS Traversing key lock (V380x0004.4 )

Machine function INC1, INC10, INC100, INC1000, INC10000, INCvar, continuous


Signal(s) to axis/spindle (PLC - > NCK)
Signal(s) updated: cyclically
Signal(s) valid from SW release:
This input area is only used if the IS INC inputs in mode group area active (V2600 0001.0) is
not set.
The IS INC... defines how many increments the axis traverses per latch position when the traversing key is pressed or the handwheel is turned. When doing so, JOG mode must be active.
With INCvar, the value in the general SD 41010: JOG_VAR_INCR_SIZE will apply.
With Continuous, the appropriate axis can be traversed using the plus or minus traversing key
with holding down the traversing key as required.
Once the selected machine function is active, this is signaled to the PLC interface (IS Active
machine function INC1; ... ).
If several machine function signals (INC1, INC... or Continuous traversing) are selected at the
interface at the same time, no machine function is enabled internally in the control system.
Note:
The input IS INC... or Continuous to modify an active machine function must be present at
least one PLC cycle. It need not be present statically.
The corresponding machine function is not selected.
While an axis traverses an incremental dimension, abortion or switching of the machine function
will also abort the movement.
IS Active machine function INC1, ... (V390x0005.0 ... .6)
IS INC inputs in mode group area active (V2600 0001.0)

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

9-181

Manual Traversing and Handwheel Traversing (H1)


9.6

Signal descriptions

Description of the signals provided from the axis/spindle


V390x0004.0 to .2
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 - - - > 1

Signal state 0 or edge


change 1 - - - > 0
Related to ....

V390x0004.7 and .6
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 - - - > 1

Signal state 0 or edge


change 1 - - - > 0

Application example(s)

Related to ....

V390x0005.0, ..., .6
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 - - - > 1
Signal state 0 or edge
change 1 - - - > 0
Related to ....

9-182

Handwheel active (1 to 3)
Signal(s) from axis/spindle (NCK - > PLC)
Signal(s) updated: cyclically
Signal(s) valid from SW release: 1.1
These PLC interface signals are used whether the machine axis is assigned handwheel 1, 2, 3
or no handwheel.
One axis can be assigned only one handwheel at a time.
If several interface signals Activate handwheel are set, the priority is Handwheel 1 before
Handwheel 2 before Handwheel 3.
If the assignment is active, the machine axis can be traversed in JOG mode using the handwheel.
This machine axis is not assigned handwheel 1, 2 or 3.
IS Enable handwheel (V380x0004.0 to .2)
IS Handwheel selected from HMI (V19000003, ff)

Traversing commands plus and minus


Signal(s) from axis/spindle (NCK - > PLC)
Signal(s) updated: cyclically
Signal(s) valid from SW release:
A traversing movement is to be carried out in the axis direction concerned. The traversing command is initiated in different ways, depending on the operating mode.
- JOG mode: using the traversing key plus or minus
- REF submode: using the traversing key leading to the reference point
- AUTO/MDA modes: A program block that contains a coordinate value for the axis
concerned is carried out.
No traversing request is currently pending for the axis direction concerned or a traversing movement carried out has been completed.
 JOG mode:
- The traversing key is cancaled.
- When quitting traversing using the handwheel
- REF submode: when the reference point is reached
 AUT/MDA modes:
- The program block has been executed (and the next following program block does not
contain a coordinate value for the axis concerned)
- Abortion by RESET, etc.
- IS Axis lock is provided
Release of the clamping of the axes (in case of axes with clamping) (e.g. with rotary tables).
Note: If the clamping is released only with the traversing command, no continuous - path
mode is possible for these axes.
IS Traversing key plus and Traversing key minus (V380x0004.7 and .6)

Active machine function INC1, ..., continuous


Signal(s) from axis/spindle (NCK - > PLC)
Signal(s) updated: cyclically
Signal(s) valid from SW release: 1.1
A signal is fed back to the PLC interface which machine function is active for the geometry axes
in JOG mode.
The appropriate machine function is not active.
IS Machine function INC1,...,continuous (V380x0005.0, ..., .6)

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

Manual Traversing and Handwheel Traversing (H1)


9.7

9.7

Data fields, lists

Data fields, lists

9.7.1

Interface signals

Number

.Bit

Name

Ref.

Signals from HMI to PLC


VB19001003
VB19001004
VB19001005

Axis number, machine/geometry axis

for handwheel 1
for handwheel 2
for handwheel 3

.0

INC inputs in operating mode area active

V3000 0000

.2

JOG mode

V3000 0002

.0 to .6

Machine function INC1 to continuous in operating mode area

V3100 0000

.2

Active mode JOG

V32001000
V32001004
V32001008

.2, .1, .0
.2, .1, .0
.2, .1, .0

Activate handwheel (3, 2, 1)

for geometry axis 1


for geometry axis 2
for geometry axis 3

V32001000
V32001004
V32001008

.4
.4
.4

Traversing key lock

for geometry axis 1


for geometry axis 2
for geometry axis 3

V32001000
V32001004
V32001008

.5

Rapid traverse override

for geometry axis 1


for geometry axis 2
for geometry axis 3

V32001000
V32001004
V32001008

.7 or .6
.7 or .6
.7 or .6

Traversing keys plus or minus

for geometry axis 1


for geometry axis 2
for geometry axis 3

V32001000
V32001004
V32001008

.0, ..., .6
.0, ..., .6
.0, ..., .6

Machine function INC1, ..., continuous

V33001000
V33001004
V33001008

.2, .1, .0
.2, .1, .0
.2, .1, .0

Handwheel active (3, 2, 1)

V33001000
V33001004
V33001008

.7 or .6
.7 or .6
.7 or .6

Traversing command plus or minus for geometry axis 1


for geometry axis 2
for geometry axis 3

V33001001
V33001005
V33001009

.0, ..., .6
.0, ..., .6
.0, ..., .6

Active machine function INC1, ..., continuous


for geometry axis 1
for geometry axis 2
for geometry axis 3

NCK - specific
V2600 0001
Mode- specific

Channel- specific

for geometry axis 1


for geometry axis 2
for geometry axis 3

for geometry axis 1


for geometry axis 2
for geometry axis 3

Axis/spindle- specific
VB380x0000

Feed override

V380x0000

.7

Override active

V380x0002

.2

Delete distance to go

V380x0004

.2, .1, .0

Enable handwheel (3, 2, 1)

V380x0004

.4

Traversing key lock

V380x0004

.5

Rapid traverse override

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

9-183

Manual Traversing and Handwheel Traversing (H1)


9.7

Data fields, lists

Axis/spindle- specific
V380x0004

.7 or .6

Traversing keys plus or minus

V380x0005

.0 to .6,

Machine function INC1 up to continuous in the axis area

V390x0000

.7 / .6

Position reached with exact stop coarse / fine

V390x0004

2, .1, .0

Handwheel active (3, 2, 1)

V390x0004

.7 or .6

Traversing command plus or minus

V390x0005

.0, ..., .6

Active machine function INC1 up to continuous

9.7.2

Machine data

Number

Identifier

Name

Ref.

General
10000

AXCONF_MACHAX_NAME_TAB [n]

Machine axis name [n = axis index]

11310

HANDWH_REVERSE

Defines traversing in the opposite direction

11320

HANDWH_IMP_PER_LATCH[n]

Handwheel pulses per latch position [handwheel index]

11346

HANDWH_TRUE_DISTANCE

Handwheel path or velocity specification

Chpt. 19

Channel- specific
20060

AXCONF_GEOAX_NAME_TAB [n]

Geometry axis in channel [n = geo. axis index]

Chpt. 19

20100

DIAMETER_AX_DEF

Geometry axes with transverse axis function

P1

G2

Axis/spindle- specific
32000

MAX_AX_VELO

Maximum axis velocity

32010

JOG_VELO_RAPID

Conventional rapid traverse

32020

JOG_VELO

Conventional axis velocity

32300

MAX_AX_ACCEL

Axis acceleration

B2

32420

JOG_AND_POS_JERK_ENABLE

Enable axis - specific jerk limitation

B2

32430

JOG_AND_POS_MAX_JERK

Axis - specific jerk

B2

35130

GEAR_STEP_MAX_VELO_LIMIT[n]

Maximum speed for gear stage/spindle

S1

9.7.3

Setting data

Number

Identifier

Name

Ref.

General
41010

JOG_VAR_INCR_SIZE

Size of variable increment with INC/handwheel

41110

JOG_SET_VELO

JOG velocity for linear axes

41130

JOG_ROT_AX_SET_VELO

JOG velocity for rotary axes

41200

JOG_SPIND_SET_VELO

JOG velocity for the spindle

9-184

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

Operating Modes, Program Mode (K1)

10.1

10

Brief description

Program mode
Program mode is provided if part programs or part program blocks are processed in either of
the modes AUTOMATIC or MDA. During the program execution, the program sequence can
be manipulated by PLC interface signals and commands.

Channel
A channel is a unit in which a part program can be processed.
The system assigns the channel an interpolator with related program execution. A certain
operating mode will apply.
The SINUMERIK 802D control system possesses one channel.

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

10-185

Operating Modes, Program Mode (K1)


10.2

Operating modes

10.2

Operating modes

Enabling
The desired operating mode is enabled via the interface signals in VB3000 0000. There is no
priority if several operating modes are selected at the same time:


JOG (high priority): Traversing of the axes by manual operation of the hand wheel or traversing keys. Channel - specific signals and interlocks are not taken into account.

MDA: Program blocks can be executed.

AUTOMATIC (low priority): Automatic execution of part programs

Check - back signal


The active mode is indicated via the interface signals in VB 3100 0000.

Possible machine functions


The following machine functions can be selected in JOG mode:


REF (reference point approach)

The desired machine function is activated by the IS REF (V300 00001.2). The display can
be seen in the IS Active machine function REF (V3100 0001.2).

Stop
The IS NC Stop (V3200 0007.3), IS NC Stop for axes and spindles (V3200 0007.4) or NC
Stop at block border (V3200 0007.2) can be used to provide a stop signal. Depending on the
stop signal selected either only the axes or, in addition, also the spindle or the axes are stopped at block end.

RESET
The IS Reset (V3000 0000.7) will abort the active part program.
The following actions are carried out after the IS Reset:


The part program preparation is stopped immediately.

Axes and spindles are stopped.

Any auxiliary functions of the current block not yet output at this moment are no longer
output.

The block pointer is reset to the beginning of the corresponding part program.

All reset alarms are deleted from the display.

The reset is completed if the IS Channel status: Reset (V3300 0003.7) is set.

Ready to operate
Readiness for operation is displayed by the IS 802 - Ready (V 3100 0000.3).

10-186

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

Operating Modes, Program Mode (K1)


10.2

10.2.1

Operating modes

Mode change

General
A mode change is requested and activated via the interface.

Note
The mode will only be changed internally in the control system if Channel status active
(IS V3300 0003.5) is no longer provided.

In the channel status Reset (IS V3300 0003.7), e.g. after pressing the RESET key, it is possible to switch over from one mode to another.
In the channel status Interrupted (IS V3300 0003.6), switching over is bound to certain
conditions (see Table 10 - 1).
If you quit AUTO to switch over to JOG, you must return to AUTO or press RESET. A change
AUTO - JOG - MDA is thus impossible. The same applies to MDA from which you can neither
directly nor indirectly change to AUTO unless the RESET status is not provided.
For the operating mode changes possible according to the current operating mode and the
channel status (Channel in reset or Channel interrupted), please refer to the following Table.
Table 10-1

Mode change depending on the channel status


AUTOMATIC

JOG

From

To

AUTO
previously
Reset

Interr.

AUTOMATIC

Reset
X

JOG

MDA

Interr.

MDA
MDA
previously
Interr.

Reset
X

X
X

Interr.

The positions marked with an X are possible mode changes.

Errors on mode change


If a mode change request has been denied by the system, an appropriate error message is
output. This error message can be cleared without changing the channel.

Mode change lock


The IS Mode change lock (V3000 0000.4) can be used to disable the mode change. The
signal acts such that the mode change request is already suppressed.

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

10-187

Operating Modes, Program Mode (K1)


10.2

10.2.2

Operating modes

Possible functions in the individual operating modes

Overview of functions
Which function can be selected in which operating mode and in which operating status, is to
be seen in the following Table.

Loading a program from external


using Services

sb sb

Execution of a part program/


block

Block search

Reference point approach per


part program command (G74)

sb

sb

sb

sb sb

Channel active JOG in MDA

Channel active JOG interrupted MDA mode

Channel active

Channel interrupted

Channel in RESET state MDA

Channel active

Channel interrupted JOG during MDA mode

Channel active

Channel interrupted JOG during AUTO interrupted

Channel active

Channel in Reset state JOG

Channel active

Functionalities

Channel interrupted

Possible functions in the individual operating modes

Channel in reset state AUTOMATIC

Table 10-2

sb sb
s

sb

s: Function cannot be started in this status


b: Function can be executed in this status

10-188

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

Operating Modes, Program Mode (K1)


10.2

10.2.3

Operating modes

Monitoring functions in the individual operating modes

Overview of monitoring functions


In the individual operating modes, various monitoring functions are active.

Channel active

Channel active JOG interrupted MDA mode

Channel active JOG in MDA

Channel in RESET state MDA

Channel interrupted

Channel active

Channel interrupted JOG during MDA mode

Channel active

Channel active

Channel interrupted JOG during AUTO interrupted

Channel in Reset state JOG

Channel active

Channel interrupted

Monitorings and interlockings

Channel in reset state AUTOMATIC

Table 10-3

Axis - specific monitoring functions or when positioning the spindle


SW limit switch +

SW limit switch -

HW limit switch +

HW limit switch -

Exact stop coarse/fine

Clamping tolerance

DAC limitation
(analog spindle)

Contour monitoring

Spindle- specific monitoring functions


Speed limit exceeded
Spindle stopped

Spindle synchronized

Speed within set range

Max. permissible speed


Encoder limit frequency

x
x

x: Monitoring is active in this status.

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

10-189

Operating Modes, Program Mode (K1)


10.2

10.2.4

Operating modes

Interlocks in the individual operating modes

Overview of interlocks
In the individual operating modes, various interlocks can be active.

Channel in reset state AUTOMATIC

Channel interrupted

Channel active

Channel in Reset state JOG

Channel active

Channel interrupted JOG during AUTO interrupted

Channel active

Channel interrupted JOG during MDA mode

Channel active

Channel in RESET state MDA

Channel interrupted

Channel active

Channel active JOG interrupted MDA mode

Channel active JOG in MDA

Which interlock can be enabled in which operating mode and in which operating status is to
be seen in the Table below:

802- Ready

Mode change lock

NC Start inhibited

Read- in disable

Spindle disable

Servo disable

Axis disable

Servo disable

Spindle lock

General interlocks

Channel- specific interlocks


Feed stop

Axis/specific interlocks

Spindle- specific interlocks

x: Interlock can only be enabled in this status

10-190

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

Operating Modes, Program Mode (K1)


10.3

10.3
10.3.1

Execution of a part program

Execution of a part program


Program mode and part program selection

Definition
Program mode means that a part program is carried out in the AUTOMATIC mode and/or
program blocks are carried out in MDA mode.

Program manipulation
During program mode, it is possible to manipulate the program mode from the PLC via interface signals. The manipulation is carried out using mode - specific or channel - specific interface signals.
The channel advises the PLC of its current program mode status.

Selection
The selection of a part program can only be carried out if the channel concerned is in the RESET
status.
The part program can be selected as follows:

10.3.2

via the operation (Machine operating area) / Program manager

via the PLC

by selecting a program via the program number in Program list (see Manual Operating and Programming..., Chapter 7)

by reselecting an active program via the PLC - HMI interface (see Section 19.5)

Starting the part program or part program block

START command, channel status


The channel - specific IS NC Start (V3200 0007.1), which is normally controled by an MCP
key NC Start, will start the program execution.
The START command will only be executed in the modes AUTOMATIC and MDA. To this
aim, the channel must be in the status Channel status: RESET (V3300 0003.7) or Channel
status: Interrupted (V3300 0003.6).

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

10-191

Operating Modes, Program Mode (K1)


10.3

Execution of a part program

Required signal statuss


The selected part program can only be enabled for execution with the START command.
The following enable signals will apply:


IS 802 - Ready must be set (V3100 0000.3)

IS Activate program test may not be set (V3200 0001.7)

IS NC START inhibited may not be reset (V3200 0007.0)

IS NC STOP at block border may not be set (V3200 0007.2)

IS NC Stop may not be set (V32000007.3)

IS NC Stop axes and spindle may not be set (V3200 0007.4)

IS EMERGENCY STOP may not be set (V2700 0000.1)

Axis or NCK alarm may not be present

Execution of the command


The part program or the part program block is executed automatically and the IS Channel
status active (V3300 0003.5) and the IS Program status: running (V3300 0003.0) are set.
The program is processed as long as the program end is reached and/or the channel is interrupted and/or aborted by a STOP or RESET command.

Alarms
The START command will not come into effect if this prerequisite is not fulfilled. In this case
one of the following alarms will occur: 10200, 10202, 10203

10.3.3

Part program interruption

Channel status
The STOP command can only be executed if the channel concerned is in the status Channel
active (V3300 0003.5).

STOP commands
There are various commands to stop the program execution and to set the channel status to
Interrupted. These are:

10-192

IS NC STOP at block border (V3200 0007.2)

IS NC STOP (V3200 0007.3)

IS NC STOP axes and spindle (V3200 0007.4)

IS Single block (V3200 0000.4)

Programming command M0 and/or M1 and the appropriate enabling

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

Operating Modes, Program Mode (K1)


10.3

Execution of a part program

Execution of the command


If the STOP command has been executed, the IS Program status: Stopped (V3300 0003.2)
and the IS Program status: Interrupted (V3300 0003.3) are set. If another START command
is provided, the interrupted part program can be continued from the interruption position.
Generally, the following actions can be executed after the STOP command has been provided:

10.3.4

Stopping the part program execution at the next block border (with NC Stop at the block
border, M0/M1 or single block); any other STOP commands will stop it immediately.

Any auxiliary functions of the current block which are not yet output at this moment will no
longer be output.

The axes are stopped and the part program execution is also stopped.

The block pointer remains stopped at the interruption position.

RESET command

Function
The RESET command (IS Reset (V3000 0000.7)) can be executed in each channel status.
This command cannot be interrupted by any other command.
A RESET command allows to abort an active part program and/or part program blocks. After
execution of the RESET command, the IS Channel status: Reset (V3300 0003.7) and the IS
Program status: Aborted (V3300 0003.4) are set.
It is now no longer possible to continue the part program from the interruption position. All
axes in the channel are at exact stop.
After the RESET command, the following actions are carried out:


The part program preparation is stopped immediately.

Axes and (if any) the spindle are decelerated.

Any auxiliary functions of the current block, which are not yet output at this moment, will
not be output any more.

The block pointer is reset to the beginning of the corresponding part program.

All alarms will be deleted from the display if they are not POWER ON alarms.

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

10-193

Operating Modes, Program Mode (K1)


10.3

Execution of a part program

10.3.5

Program control

Selection/activation
The user can control the execution of the part program from the operator interface. In the
Program control menu (AUTOMATIC mode, operating area Position), certain functions can
be selected, whereas some functions have an influcence on PLC interface signals. These
interface signals are merely to be understood as selection signals from the user interface.
They will not yet activate the selected function.
In order to render the selected functions active, these signal states must be transferred to a
different area. For a manipulation on the part of the PLC, these signals must be set directly.
Table 10-4

Program control

Function

Selection signal

Enable signal

Check - back signal

SKP Skip Block

V1700 0001.0

V3200 0002.0

DRY Dry Run Feed

V1700 0000.6

V3200 0000.6

ROV Feed Override

V1700 0001.3

V3200 0006.6

Preselection:
SBL1 - Single block coarse
SBL2 - Single block fine
Single block

user - specific

V3200 0000.4

M1 Programmed stop

V1700 0000.5

V3200 0000.5

V3300 0000.5

PRT Program test

V1700 0000.7

V3200 0001.7

V3300 0001.7

10.3.6

Program status

Program statuses
The status of the selected program for the particular channel is displayed in AUTOMATIC and
MDA modes at the interface. If you change to JOG moide with the program stopped, the program status Interrupted or, in case of Reset, Aborted is displayed.
The following program statuses are possible:


IS Program status: Aborted (V3300 0003.4)

IS Program status: Interrupted (V3300 0003.3)

IS Program status: Stopped (V3300 0003.2)

IS Program status: Running (V3300 0003.0)

Effects of commands/signals
The program status can be manipulated by activating various commands or interface signals.
The Table below illustrates the resulting program status (supposed status prior to the signal
-> Program status: Running).

10-194

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

Operating Modes, Program Mode (K1)


10.3

Table 10-5

Execution of a part program

Effects on the program status


States of program execution
Commands

IS Reset

Aborted

Interrupted

Stopped

Waiting

Running

IS NC Stop

IS NC Stop at block border

IS NC Stop for axes and spindles

IS Read - in disable

IS Feed stop, channel lock

IS Feed stop, axis lock

Feed override = 0%

IS Spindle stop

M2 in the block

M0/M1 in the block

IS Single block

Auxiliary function output to PLC,


but not yet acknowledged

10.3.7

Channel status

Channel statuses
The current status of the channel is imaged to the interface. Based on this status, the PLC
can initiate certain reactions or interlocks, which can be configured by the manufacturer. The
channel status is displayed in all operating modes.
The following channel states are possible:


IS Channel status: Reset (V3300 0003.7)

IS Channel status: Interrupted (V3300 0003.6)

IS Channel status: Active (V3300 0003.5)

Effects of commands/signals
The channel status can be manipulated by enabling various commands or interface signals.
The Table below shows the resulting channel status (supposed status prior to the signal ->
channel status: Active).
The Channel status: Active is achieved if a part program or part program block is executed
or the axes are traversed in JOG mode.

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

10-195

Operating Modes, Program Mode (K1)


10.3

Execution of a part program

Table 10-6

Effects on the channel status


Channel status after the command
Commands

Reset

IS Reset

Interrupted

Active

IS NC Stop

IS NC Stop at block border

IS NC Stop for axes and spindles

IS Read - in disable

IS Feed stop, channel lock

IS Feed stop, axis lock

Feed override = 0%
IS Spindle stop

M2 in the block

M0/M1 in the block

IS Single block

Auxiliary function output to PLC,


but not yet acknowledged

10.3.8

Reactions to operator or program actions

Reactions
The Table below contains a list of channel and program statuses that may occur after certain
operator or program actions.
The left part of the Table contains the channel and program statuses, as well as the operating
modes under which the initial situation must be searched. The right part of the Table contains
certain operating/program actions; the number of the situation is specified for each action in
brackets after the corresponding action has been carried out.
Table 10-7

Reactions to operator or program actions

Situation

Channel
status
R

Program status
A

Active mode
A

A
x

10-196

Operator or program action


(situation after the action)

J
RESET (4)

RESET (5)
x

RESET (6)
NC Start (13); mode change (5 or 6)

NC Start (14); mode change (4 or 6)


x

Direction key (15); mode change (4 or 5)


NC Start (14)

NC Start (15)

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

Operating Modes, Program Mode (K1)


10.3

Table 10-7

Reactions to operator or program actions


R

10

11

12

14

15

16

17

NC Start (13); mode change (10 or 11)


x

NC Start (16); mode change (9 or 11)


x

13

Direction key (17); mode change (9 or 10)

NC Start (13); mode change (10 or 11)

NC Stop (12)
x

NC Stop (7); at block end (5)


x

Channel status:
RAborted
UInterrupted
ARunning

10.3.9

Execution of a part program

NC Stop (8); at JOG end (6)


NC Stop (10); at block end (10)

NC Stop (11); at JOG end (11)

Operating modes:
AAUTOMATIC
MMDA
JJOG

Program status:
NAborted
UInterrupted
SStopped
WWaiting
ARunning

Example of time diagram for a program sequence

NC START (from PLC) ......


NC - STOP , (from PLC).........
IS .NC Start inhibited (V3200 0007.0)... ........
IS Read - in disable (V3200 0006.1).............................

IS Servo enable, axis (V380 x 0002.1)......................


IS Feed STOP, axis (V380x 0004.3)...........................
IS Servo enable, spindle (V380x 0002.1)...................
IS Spindle

STOP (V380x 0004.3)................................

IS Program status: Running (V3300 0003.0)..............


IS Program status: Interrupted (V3300 0003.4)..........
IS Program status: Stopped (V3300 0003.2)................

M0

IS Traversing command plus (V390x 0004.7).............


IS Exact stop fine (V390x 0000.7)..............................
IS Spindle stopped (V390x 0001.4)...........................
IS Spindle within set range (V390x 2001.5).................
Explanation:
Linking by PLC user program
t4: Block relaying to N20 with Read - in disable stopped,
t5: Program interrupted with RESET

t4
Spindle run - up

Axis running

t5
Program:

N10 G01 G90 X100 M3 S1000 F1000 M88


N20 M0

Fig. 10-1

Example of signals during program execution

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

10-197

Operating Modes, Program Mode (K1)


10.4

Program test

10.4
10.4.1

Program test
General remarks on program test

Objective
For testing a new part program, various control functions are provided. These functions considerably reduce any hazards to the machine during the test phase and also reduce the required time. It is possible to enable several program test functions at the same time.
The following test possibilities will be described in the following:

10.4.2

Program execution without axis movements

Program execution in single block mode

Program execution with dry run feed

Execution of certain program sections

Skipping of certain program parts

Graphic simulation

Program execution without axis movements (PRT)

Functionality
With the Program Test function active, the part program can be started and executed using
the IS NC Start (V32000007.1), i.e. including auxiliary function output, dwell times, etc. Merely the axes/spindle are simulated. The safety function of the software limit switches remains
active.
The position control is not interrupted so that the axes need not be referenced after switching - off of the function.
The user can thus check the programmed axis positions and the auxiliary function outputs of
a part program.
NOTE: The program execution without axis movements can also be enabled together with
the function Dry run feed.

Selection/enabling
This function is selected using the user interface in the menu Program control. With the selection, the IS Program test selected (V1700 0001.7) is set.
The function must be enabled by the PLC user program using the IS Enable program test
(V3200 0001.7).

10-198

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

Operating Modes, Program Mode (K1)


10.4

Program test

Display
As a check - back message that the program test function is active, PRT is displayed in the
status line of the operator interface and the IS Program test active (V3300 0001.7) is set in
the PLC.

10.4.3

Program execution in single block mode

Functionality
The user can use this function to execute a part program step by step and check the individual machining steps. If he has found the executed part program block to be correct, he can
request the next block. Progression to the next part program block is carried out via the IS
NC Start
(V3200 0007.1).
With the single block function activated, however, the execution of the part program will stop
after each program block. The program status will change to Program status: Stopped. The
channel status remains set active.

Single block type


The following single block types are distinguished:


Single block coarse


With this single block type, all blocks that initiate actions (traversing movements, auxiliary
function outputs, etc.) are executed separately. If the tool radius compensation is enabled
(G41,G42), the program execution will stop after each intermediate block inserted by the
control system. In case of computational blocks, however, the program execution will not
be stopped, since they do not initiate any actions.

Single block fine


With this single block type, all blocks of the part program (also the pure computational
blocks without traversing movements) are executed one after the other by NC Start.

Single block coarse is the default setting when the control system is turned on.

Caution
For a series of G33 blocks, single block is only active if DRY RUN FEED is selected.

Selection/enabling
As a rule, the selection signal comes from a user machine control panel.
This function must be enabled from the PLC user program via the IS Enable single block
(V3200 0000.4).
The selection Single block coarse or Single block fine is made on the user interface in the
Program control menu.

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

10-199

Operating Modes, Program Mode (K1)


10.4

Program test

Display
As a check - back message of active single block mode, SBL is displayed in the appropriate
field of the user interface.
Once the part program execution has completed a part program block in single block mode,
the IS Channel status: Interrupted (V3300 0003.6) and the IS Program status: Stopped
(V3300 0003.2) are set and the IS Channel status: Active (V3300 0003.5) and the IS Program status: Running (V3300 0003.0) are reset.

10.4.4

Program execution with Dry Run Feed (DRY)

Functionality
The part program can be started via the IS NC Start (V3200 0007.1). With the function enabled, the traversing rates that have been programmed in conjunction with G1, G2, G3, CIP,
CT, are replaced by the feed value stored in SD 42100: DRY_RUN_FEED. The dry run feed
will also be used instead of the programmed revolutional feed in program blocks with G95. If,
however, the programmed feed is greater than the dry run feed, the larger value will be used.

Caution
If the function Dry run feed is enabled, no workpiece machining must be carried out, since the
cutting rates of the tools may be exceeded and/or the workpiece or the machine tool may be destroyed due to the changed feed values.

Selection/enabling
The operation with dry run feed is selected in the operating area Position - > softkey Program control (AUTOMATIC mode). This selection will set the IS Dry run feed selected
(V17000000.7). In addition, the desired value of the dry run feed must be entered in the setting data menu. This will, however, not yet enable the function.
The function is enabled using the IS Enable dry run feed (V3200 0000.4) and is evaluated
with NC Start.
The dry run feed must have been entered in SD 42100: DRY_RUN_FEED before program
start.

Display
As a check - back message of active dry run feed, DRY is displayed in the status line of the
user interface.

10-200

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

Operating Modes, Program Mode (K1)


10.4

10.4.5

Program test

Block search: Execution of certain program sections

Functionality
To position the control system on a certain block (target block) of a part program, the Block
search function can be used.. When doing so, it can be selected whether or not during the
block search to the target block the same calculations are to be carried out as in normal program mode.
After the target block has been reached, the program can be started via the IS NC Start (to
be provided 2x) (V3200 0007.1). If necessary an automatic compensation movement of the
axes to the starting or end position of the target block is carried out. Then the program is continued.
Note: Make absolutely sure that a collision - free starting position and the appropriate technological values are provided and that the appropriate tools are enabled. If necessary first a
collision - free starting position must be approached using JOG mode. Select the target block
with due consideration of the selected block search type.

Selection/enabling
The block search function is selected from the operator interface in AUTOMATIC mode.
The block search function can be enabled for the following functions using the appropriate
softkey:


Block search with calculation at the contour


Is used to be able to approach the contour in any situation. NC Start is used to approach
the starting position of the target block or the end position of the block prior to the target block. This will be traversed up to the end position. The execution of this block is carried out true to the contour.

Block search with calculation at the block end point


is used to be able to approach the target position (e. g. tool change position) in any situation. The end point of the target block or the next programmed position is approached
using the interpolation type valid in the target block. This will not be carried out true to the
contour. Only the axes programmed in the target block will be approached.

Block search without calculation


is used for quick search in the main program.
No calculation is carried out. The control - internal values are in the states as prior to the
block search. Whether or not a processing can be carried out, depends on the program
and must be decided by the operator.
This block search type is especially suited to carry out fast syntax checks for new programs.

Interface signal
The IS


Block search active (V3300 0001.4)

Action block active (V3300 0000.3)

Approach block active (V3300 0000.4)

Last action block active (V3300 0000.6)

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

10-201

Operating Modes, Program Mode (K1)


10.4

Program test

are set according to the time sequence shown in Fig. 10 - 2.

Note
The IS Approach block active will only be set in case of Block search with calculation at the contour, since in case of Block search with calculation at the block end point no separate approach
block is generated (approach block is identical to target block).

Start
block
search

Searched
block
found

NC Start
Output action
blocks

Last action block

NC Start
Output approach block

Target
block in
main program part

Block search active


(V3300 0001.4)
Action block active
(V3300 0000.3)
Approach block
active
(V3300 0000.4)
Last action block active
(V3300 0000.6)

Fig. 10-2

Time sequence of interface signals

After the IS Block search with calculation at the block end point and from the moment Last
action block active until the part program execution is continued by NC Start, no automatic
repositioning is executed. The start point of the current axis position is NC Start, and the end
point results from the execution of the part program.

Action blocks
Action blocks contain the actions accumulated during Block search with calculation, such as
auxiliary function outputs, tool (T, D), spindle (S), feed programming.
During Block search with calculation (contour or block end point), actions, such as the output of M functions, are accumulated in so - called action blocks. These blocks are output with
NC Start after Searched block found.

Note
With the action blocks, the accumulated spindle programming (S value, M3/M4/M5, SPOS) will also
become active. It must be guaranteed by the PLC user program that the tool can be operated and
the spindle programming is reset via the IS Spindle reset(V380x0002.2).

10-202

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

Operating Modes, Program Mode (K1)


10.4

Program test

PLC actions after block search


To enable PLC actions to be activated after block search, the IS Last action block active is
provided. It is intended to make sure that all action blocks are executed and actions on side
of the PLC or the operator (e.g. mode change) are now possible. For example, the PLC can
carry out tool change before the movement is started.
By default, at this moment the alarm 10208 is output. This will tell the operator that NC Start
is required to continue the program.

Supplementary condition
The approach movement Block search with calculation at the block end point is carried out
using the interpolation type valid for the target block. Reasonably, it should be G0 or G1. With
other interpolation types, the approach movement can be aborted with alarm (e. g. circle end
point error with G2/G3).

Note
For further information on the function Block search, please refer to:
References:
Operation and Programming

10.4.6

Skipping part program blocks (SKP)

Functionality
To test new programs, it is useful to lock or skip certain part program blocks for program execution.
PROGRAM1

Main program or subroutine

N10 ...
N20 ...

Block being
processed

N30 ...
/N40 ...
/N50 ...

Blocks
N40 and N50 are skipped during the
program execution

N60 ...
N70 ...
N80 ...
N90 M2

Fig. 10-3

Skipping part program blocks

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

10-203

Operating Modes, Program Mode (K1)


10.4

Program test

Selection/enabling
The skip function is selected on the user interface from the menu Program control. The selection will set the IS Skip block (V1700 0002.0). In addition, a slash / must be put in front
of the block to be skipped (see Fig. 10 - 3). This will, however, not yet enable the function.
The activation of the function is carried out via the IS Enable block skip (V3200 0002.0).

Display
As a check - back message of the activated function Skip block, SKP is displayed in the
status line of the user interface.

10.4.7

Graphical simulation

Function
A selected and opened program can be simulated graphically on the screen of the control
system in the AUTOMATIC mode. The motions of the programmed axes are recorded as broken - line graphics after actuating NC Start.

Selection/deselection
The graphical simulation is accessible for the program selected via the operating area Program, Load program and using the Simulation softkey. At the same time, the IS Simulation active (V1900 0000.6) is set and is reset again when quitting the operating area Program or changing over to Edit.

Display
Various operating options are provided to show an entire workpiece or simply a magnified
section of the workpiece on the screen.
References:

Operation and Programming

PLC user program


The PLC user program must manipulate the desired behavior of the control system during
simulation by itself, for example:


Stopping the axes/spindle by changing to program test: Set IS Enable program test
(V3200 0001.7)

Abortion of the running program if Simulation is quitted by setting the IS Reset


(V300 00000.7), etc.

Display machine data


Various display machine data are provided for user - specific design of graphic simulation
(MD 283 to MD 292).
References:

10-204

Section 10.7.1 Display machine data

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

Operating Modes, Program Mode (K1)


10.5

Timer for program runtime

Note
In addition to the graphical simulation, the Record function is provided. This function can be
used to record the axes movements of a running program in the operating area Position - >
Softkey Record as a broken - line graphics on the screen. This function is available in AUTOMATIC mode. The display is carried out in the same way as with the graphical simulation.
References:

10.5

Operation and Programming

Timer for program runtime

Function
The function Program runtime provides timers that can be used for the monitoring of technological processes in the program or simply on the display.
These timers are read - only timers. There are timers that are always active; other timers are
activated via machine data.

Timers - always active




Time since the last booting of the CNC with default values ( in minutes ):
$AN_SETUP_TIME
With Power - up of control system with default values, the timer is automatically set to
zero.

Time since the last power - up of the control system ( in minutes ):


$AN_POWERON_TIME
In this case, the control system is automatically set to zero with each power up of the control.

Timers that can be disabled


These timers can be enabled using machine data (default setting).
The start is timer - specific. Each active runtime measurement is automatically interrupted
whe the program is stopped or if feed override=zero.
The behavior of the enabled time measurements when dry run feed and program test are
active can be defined by means of machine data.


Overall runtime of NC programs in automatic mode ( in seconds ):


$AC_OPERATING_TIME
The runtimes of all programs between NC start and program end / reset are summed up
in Automatic mode. The timer is set to zero with each power - up of the control system.

Runtime of the selected NC program ( in seconds ):


$AC_CYCLE_TIME
The runtime between NC start and program end/reset is measured in the selected NC
program. The timer is deleted when a new NC program is started.

Tool cutting time ( in seconds ):


$AC_CUTTING_TIME
The runtime of the path axes without active rapid traverse is measured in all NC programs
between NC start and program end / reset when the tool is active.
The measurement is additionally interrupted when the dwell time is active.
The timer is automatically set to zero with each power - up of the control system.
Power - up with default values will set the timer to zero automatically.

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

10-205

Operating Modes, Program Mode (K1)


10.6

Workpiece counter

Display
The contents of the timers is displayed on the screen in the operating area
OFFSET/PARAM - > Softkey Setting data - >PageDown (2nd page):
Run time
= $AC_OPERATING_TIME
Cycle time
= $AC_CYCLE_TIME
Cutting time
= $AC_CUTTING_TIME
Setup time
= $AN_SETUP_TIME
Power on time = $AN_POWERON_TIME
Cycle time is additionally displayed in AUTOMATIC mode in the operating area Position in
the Tips line.
References:

10.6

Operation and Programming

Workpiece counter

Function
The function Workpiece counter provides counters which can be used to count workpieces.
These counters exist as channel - specific system variables with read/write access from the
program or operator panel (observe the protection level for writing).
The range of values is: 0 to 999 999 999.
Channel - specific machine data MD 27880: PART_COUNTER and
MD 27882: PART_COUNTER_MCODE can be used to control the counter activation, the
time of resetting to zero and the counting algorithm.

Counters

10-206

Number of the required workpieces ( workpiece setpoint number ):


$AC_REQUIRED_PARTS
This counter can be used to define the number of workpieces at which the number of current workpieces $AC_ACTUAL_PARTS is set to zero.
MD 27880: PART_COUNTER (bit 1) can be used to activate the generation of the display
alarm 21800 Workpiece setpoint number reached and the output of the IS Workpiece
setpoint number reached (V330040002.1).

Total number of workpieces manufactured ( total actual number ):


$AC_TOTAL_PARTS
The counter indicates the number of all workpieces manufactured from the start time.

Number of current workpieces ( current actual number ):


$AC_ACTUAL_PARTS
This counter registers the number of all workpieces manufactured from the start time.
When the workpiece setpoint number is reached ( $AC_REQUIRED_PARTS ), the timer
is automatically set to zero ( provided that $AC_REQUIRED_PARTS is unequal to 0.).

Number of workpieces specified by the user:


$AC_SPECIAL_PARTS
This counter allows the user to carry out workpiece counting according to his own definition. An alarm output can be defined in case of identity with
$AC_REQUIRED_PARTS ( workpiece setpoint number ). The user must reset the counter
to zero by himself.

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

Operating Modes, Program Mode (K1)


10.6

Workpiece counter

As the starting time, the first output of the M command for counting after setting the counter
to zero is used. This M command is set for the appropriate counter in MD 27880: PART_COUNTER or
MD 27882: PART_COUNTER_MCODE.

Display
The contents of the counters is displayed on the screen in the operating area OFFSET/PARAM - > softkey Setting data - >PageDown (2nd page):
Part total
= $AC_TOTAL_PARTS
Part required = $AC_REQUIRED_PARTS
Part count
= $AC_ACTUAL_PARTS
$AC_SPECIAL_PARTS not available on the display
Part count is additionally displayed in AUTOMATIC mode in the operating area Position in
the Tips line.
References:

Operation and Programming

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

10-207

Operating Modes, Program Mode (K1)


10.7

10.7

Data descriptions (MD, SD)

Data descriptions (MD, SD)

10.7.1

Display machine data

283
MM_CTM_SIMULATION_DEF_X
MD number
Simulation of default value X
Default: 0
Min. input limit: - 10000
Max. input limit: 10000
Change valid: immediately
Protection level:
Unit: mm and/or inch
Data type: INTEGER
Valid from SW release:
Meaning:
This MD is used to define the size of the X coordinate of the display range. In Simulation, you will get to the default value set here after pressing the softkey TO ORIGIN.
Related to ...
MD 284: MM_CTM_SIMULATION_DEF_Y
MD 285: MM_CTM_SIMULATION_DEF_VIS_AREA

284
MM_CTM_SIMULATION_DEF_Y
MD number
Simulation of default value Z
Default: 0
Min. input limit: - 10000
Max. input limit: 10000
Change valid: immediately
Protection level:
Unit: mm and/or inch
Data type: INTEGER
Valid from SW release:
Meaning:
This MD defines the size of the 2nd coordinate (Y or Z) of the display range. In Simulation, you will get to the default value set here after pressing the softkey TO ORIGIN.
Related to ...
MD 283: MM_CTM_SIMULATION_DEF_X
MD 285: MM_CTM_SIMULATION_DEF_VIS_AREA

285
MM_CTM_SIMULATION_DEF_VIS_AREA
MD number
Simulation of default value for display range
Default: 100
Min. input limit: - 10000
Max. input limit: 10000
Change valid: immediately
Protection level:
Unit: mm and/or inch
Data type: INTEGER
Valid from SW release:
Meaning:
These machine data are used to define the size of the display range for the X coordinate.
The Z coordinate will be calculated from this value automatically.
Related to ...
MD 283: MM_CTM_SIMULATION_DEF_X
MD 284: MM_CTM_SIMULATION_DEF_Z

286
MM_CTM_SIMULATION_MAX_X
MD number
Simulation of max. display X
Default: 0
Min. input limit: - 10000
Max. input limit: 10000
Change valid: immediately
Protection level:
Unit: mm and/or inch
Data type: INTEGER
Valid from SW release:
Meaning:
This MD is used to define the size of the X coordinate of a second display range (e.g. in
case of larger workpieces).
In Simulation, you will get to the default value set here after pressing the MAX softkey.
Related to ...

10-208

MD 287: MM_CTM_SIMULATION_MAX_Z
MD 288: MM_CTM_SIMULATION_MAX_VIS_AREA

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

Operating Modes, Program Mode (K1)


10.7

287
MD number
Default: 0

MM_CTM_SIMULATION_MAX_Y
Simulation for max. display Z
Min. input limit: - 10000

Data descriptions (MD, SD)

Max. input limit: 10000

Change valid: immediately


Protection level:
Unit: mm and/or inch
Data type: INTEGER
Valid from SW release:
Meaning:
This MD defines the size of the 2nd coordinate (Y or Z) of a second display range.
In Simulation, you will get to the default value set here after pressing the MAX softkey.
Related to ...
MD 286: MM_CTM_SIMULATION_MAX_X
MD 288: MM_CTM_SIMULATION_MAX_VIS_AREA

288
MM_CTM_SIMULATION_MAX_VIS_AREA
MD number
Simulation for max. display range
Default: 1000
Min. input limit: - 10000
Max. input limit: 10000
Change valid: immediately
Protection level:
Unit: mm and/or inch
Data type: INTEGER
Valid from SW release:
Meaning:
This MD is used to define the second display range for the X coordinate. The Z coordinate will be calculated from this value automatically.
Related to ...
MD 286: MM_CTM_SIMULATION_MAX_X
MD 287: MM_CTM_SIMULATION_MAX_Y

289
MM_CTM_SIMULATION_TIME_NEW_POS
MD number
Simulation for actual - value updating rate
Default: 100
Min. input limit: 0
Max. input limit: 4000
Change valid: immediately
Protection level:
Unit: ms
Data type: WORD
Valid from SW release:
Meaning:
This MD is used to define in which intervals the simulation graphics is visualized for the
current processing on the machine tool.
Value = 0 means no updating.

290
MM_CTM_POS_COORDINATE_SYSTEM
MD number
Position of the coordinate system
Default: 2
Min. input limit: 0
Max. input limit: 7
Change valid: immediately
Protection level:
Unit: Data type: BYTE
Valid from SW release:
Meaning:
The position of the coordinate system can be changed as follows:

+X

+X
1

+Z

+Z
+Z

+Z
3

+X
+Z

+X
+Z
4

+X

+X

+
X
7

+Z

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

+X

+Z

10-209

Operating Modes, Program Mode (K1)


10.7

Data descriptions (MD, SD)

291
MM_CTM_CROSS_AX_DIAMETER_ON
MD number
Diameter display for transverse axes active
Default: 1
Min. input limit: 0
Max. input limit: 1
Change valid: immediately
Protection level:
Unit: Data type: BYTE
Valid from SW release:
Meaning:
0:
Inputs for absolute values as a radius value.
Zero point offsets always in radius,
tool lengths always in radius,
tool wear always in radius
1:

Position display in diameter,


distance to go in diameter,
absolute paths in diameter

292
MM_CTM_G91_DIAMETER_ON
MD number
Incremental infeed
Default: 0
Min. input limit: 0
Change valid: immediately
Protection level:
Data type: BYTE
Meaning:
0:
Input in radius
1:
Input in diameter

10-210

Max. input limit: 1


Unit: Valid from SW release:

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

Operating Modes, Program Mode (K1)


10.7

10.7.2

Data descriptions (MD, SD)

Channel - specific machine data

21000
MD number

CIRCLE_ERROR_CONST
Circle end point monitoring constant

Default: 0.01

Min. input limit: 0.0

Change valid after Power On

Max. input limit: ***

Protection level: 2/7

Data type: DOUBLE

Unit: mm

Valid from SW release:

Meaning:

This machine data describes the admissible absolute circle difference.


With circle programming, the radius from the programmed center point to the start point or to
the end point are usually not equal (the circle is overdetermined). The max. permissible
difference of these two radii accepted without an alarm is determined by the greater value in
the following data:
- MD: CIRCLE_ERROR_CONST
- Start radius multiplied with 0.001
This means that the tolerance for small circles is a fixed value (MD: CIRCLE_ERROR_CONST) and for large circles, it is proportional to the start radius.

Application example

MD 21000: CIRCLE_ERROR_CONST = 0.01 mm


With this MD value and a radius of 10 mm, the constant will apply, and with > 10 mm, the
proportional factor will apply.

27860
MD number

PROCESSTIMER_MODE
Enable program runtime measurement

Default: 0x7

Min. input limit: 0

Change valid after RESET

Protection level: 2/7

Data type: BYTE


Meaning:

Max. input limit: 0x3F (HEX)


Unit: -

Valid from SW release:


This machine data can be used to enable/disable the channel - specific timers.
Meaning:
Bit 0 = 0
Bit 0 = 1
Bit 1 = 0
Bit 1 = 1
Bit 2 = 0
Bit 2 = 1
Bit 3

No measurement of the overall runtime for all part programs


The measurement of the overall runtime for all part programs
is active ( $AC_OPERATING_TIME )
No measurement of the current program runtime
The measurement of the current program runtime is active
( $AC_CYCLE_TIME )
No measurement of the tool cutting time
The measurement of the tool cutting time is active
( $AC_CUTTING_TIME )
Reserved

Further bits only if bit 0, 1, 2 = 1:


Bit 4 = 0
No measurement with active dry run feed
Bit 4 = 1
Measurement also with active dry run feed
Bit 5 = 0
No measurement with program test
Bit 5 = 1
Measurement also with program test
Bit 6, 7
Reserved
Application example
Special cases, errors, .......

It is recommended to disable timers not needed permanently. This will have a positive influence
on the calculation time for other applications.

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

10-211

Operating Modes, Program Mode (K1)


10.7

Data descriptions (MD, SD)

27880
MD number
Default: 0x0
Change valid after RESET
Data type: DWORD
Meaning:

PART_COUNTER
Enable workpiece counters
Min. input limit: 0x0

Max. input limit: 0x0FFFF

Protection level: 2/7

Unit: -

Valid from SW release:


This machine date can be used to set the workpiece counters.
Meaning of the individual bits:
Bit 0 - 3: Enable $AC_REQUIRED_PARTS
---------------------------------------------Bit 0 = 1: Counter $AC_REQUIRED_PARTS is active
Further meaning: Bits 1 - 3 only if bit 0 =1:
Bit 0=1:
Alarm/IS output if $AC_ACTUAL_PARTS corresponds
to $AC_REQUIRED_PARTS
Bit 1 = 1: Alarm/IS output if $AC_SPECIAL_PARTS corresponds
to $AC_REQUIRED_PARTS
Bits 2, 3
Reserved
Bits 4 - 7: Enable $AC_TOTAL_PARTS
------------------------------------------Bit 4 = 1:
Counter $AC_TOTAL_PARTS is active
Further meaning: Bits 5 - 7 only if bit 4 =1:
Bit 5 = 0: Counter $AC_TOTAL_PARTS is incremented by amount 1,
if M02/M30 is output by IS
Bit 5 = 1: Counter $AC_TOTAL_PARTS is incremented by amount 1, when the
M command is output from MD 27882: PART_COUNTER_MCODE[0]
Bit 6 = 0: Counter $AC_TOTAL_PARTS also active with program test/block search
Bit 6 = 1: No execution of $AC_TOTAL_PARTS with program test/block search
Bit 7 Reserved
Bit 8 - 11: Enable $AC_ACTUAL_PARTS
-------------------------------------------Bit 8 = 1: Counter $AC_ACTUAL_PARTS is active
Further meaning: Bits 9 - 11 only if bit 8 =1:
Bit 9=1:
Counter $AC_ACTUAL_PARTS is incremented by amount 1,
if M02/M30 is output by IS
Bit 9 = 1: Counter $AC_ACTUAL_PARTS is incremented by amount 1, when the
M command is output from MD 27882: PART_COUNTER_MCODE[1]
Bit 10 = 0: Counter $AC_TOTAL_PARTS also active with program test/block search
Bit 10 = 1: No execution of $AC_TOTAL_PARTS with program test/block search
Bit 11
Reserved
Bit 12 - 15: Enable $AC_SPECIAL_PARTS
--------------------------------------------Bit 12 = 1: Counter $AC_SPECIAL_PARTS is active
Further meaning: Bits 13 - 15 only if bit 12 =1:
Bit 13=1: Counter $AC_SPECIAL_PARTS is incremented by amount 1,
if M02/M30 is output by IS
Bit 13 = 1: Counter $AC_SPECIAL_PARTS is incremented by amount 1, when the
M command is output from MD 27882: PART_COUNTER_MCODE[2]
Bits 14, 15 Reserved

Application example
Related to ...

10-212

MD 27882: PART_COUNTER_MCODE
IS Required parts reached (V3300 40001.1)

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

Operating Modes, Program Mode (K1)


10.7

27882
MD number

Data descriptions (MD, SD)

PART_COUNTER_MCODE[n]
n = 0 ... 2 , index for counter assignment
Workpiece counting using an M command

Default: (2, 2, 2)

Min. input limit: 0

Change valid after Power On


Data type: BYTE
Meaning:

Max. input limit: 99

Protection level: 2/7

Unit:

Valid from SW release:


If the workpiece counting is enabled via MD 27880: PART_COUNTER,
the counting pulse can be triggered using a special M command.
The defined values are taken into account only in this case.
Meaning:
The workpiece counters are incremented by 1 when the described M command is output with
the appropriate IS signal. In this case, the following applies:
$PART_COUNTER_MCODE[0] for $AC_TOTAL_PARTS
$PART_COUNTER_MCODE[1] for $AC_ACTUAL_PARTS
$PART_COUNTER_MCODE[2] for $AC_SPECIAL_PARTS

Application example
Related to ...

10.7.3

MD 27880: PART_COUNTER

Channel - specific setting data

42000

THREAD_START_ANGLE

SD number

Start angle for thread G33

Default: 0.0

Min. input limit: 0.0

Change valid: immediately

Max. input limit: ***

Protection level: 7/7

Data type: DOUBLE

Unit: degrees

Valid from SW release:

Meaning:

This setting data can be used to set the offset of the individual turns for multiple threads.
This SD can be modified from the part program using the command SF=... . If SF=... is programmed in the G33 block of the part program, the setting data will be active.

Further references

Operation and Programming

42010
SD number
Default: ( - 1, - 1)
Change valid: immediately
Data type: DOUBLE
Meaning:

THREAD_RAMP_DISP[n]
(index n = 0: Acceleration distance, n = 1: Braking distance)
Acceleration and braking behavior of feed axis on thread cutting G33
Min. input limit: - 1
Max. input limit: 999 999.
Protection level: 7/7
Unit: mm/inch
Valid from SW release:
Acceleration distance and braking distance of the feed axis on thread cutting:
- 1:
Starting/braking of the feed axis is carried out with the configured acceleration.
The jerk will act according to the currently programmed BRISK/SOFT.
0:
Start/braking of the feed axis on thread cutting is carried out following a step - like curve.
>0:
The max. acceleration/brake distance is specified. Under certain circumstances, the
specified path may lead to an acceleration overload of the axis.
Reset/part program end is used to activate the default setting.
Example:
THREAD_RAMP_DISP[0] = 2 acceleration distance 2 mm
Description of Functions, Section Feed

Further references

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

10-213

Operating Modes, Program Mode (K1)


10.7

Data descriptions (MD, SD)

42100

DRY_RUN_FEED

SD number

Dry run feed

Default: 5000
Change valid: immediately

Min. input limit: 0

Max. input limit: ***

Protection level: 7/7

Data type: DOUBLE

Unit: mm/min

Valid from SW release:

Meaning:

To test a part program with reference to the distance to be traversed (without a workpiece to
be machined), the operator can enable the function Dry run feed from the operator interface
(softkey Program control). The value of this setting data will then be accepeted instead of the
programmed feed value. Feed override values will not be modified.
The dry run feed value can be entered in the Setting Data menu.
The function is only active in the modes AUTOMATIC and MDA.

SD inapplicable to ......

dry run feed function not enabled

Application example(s)

Check of distances to be traversed with new part programs

Special cases, errors, ...

The function may not be enabled if a workpiece is to be machined. Due to the fact that dry run
feed is enabled, the max. cutting speed of the tool could be exceeded. This may destroy the
workpiece and the tool.

10-214

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

Operating Modes, Program Mode (K1)


10.8

10.8
10.8.1

Signal descriptions

Signal descriptions
Mode signals

V3000 0000.0
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 - - > 1
Signal state 0 or edge
change 1 - - > 0
Signal inapplicable ......
Related to ....

AUTOMATIC mode
Signal(s) to NCK (PLC ---> NCK)
Signal(s) updated: cyclically
AUTOMATIC mode is selected from PLC program.

V3000 0000.1
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 - - > 1
Signal state 0 or edge
change 1 - - > 0
Signal inapplicable ......
Related to ....

MDA mode
Signal(s) to NCK (PLC ---> NCK)
Signal(s) updated: cyclically
MDA mode is selected from the PLC program.

V3000 0000.2
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 - - > 1
Signal state 0 or edge
change 1 - - > 0
Signal inapplicable ......
Related to ....

JOG mode
Signal(s) to NCK (PLC ---> NCK)
Signal(s) updated: cyclically
JOG mode is selected from the PLC program.

V3000 0000.4
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 - - > 1
Signal state 0

Mode change lock


Signal(s) to NCK (PLC ---> NCK)
Signal(s) updated: cyclically
Signal(s) valid from SW release:
The mode currently active (JOG, MDA or Automatic) cannot be changed.

Signal(s) valid from SW release:

AUTOMATIC mode is not selected from PLC program.


to the signal Mode change lock is active.
IS Active mode: AUTOMATIC

Signal(s) valid from SW release:

MDA mode is not selected from the PLC program.


to the signal Mode change lock is active.
IS Active mode: MDA

Signal(s) valid from SW release:

JOG mode is not selected from the PLC program.


to the signal Mode change lock is active.
IS Active mode: JOG

The mode can be changed.

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

10-215

Operating Modes, Program Mode (K1)


10.8

Signal descriptions

V3000 0000.7
Interface signal
Edge evaluation: yes
Signal state 1 or edge
change 0 - - > 1

Signal state 0 or edge


change 1 - - > 0
Related to ....
Special cases, errors, ....

Reset
Signal(s) to NCK (PLC ---> NCK)
Signal(s) updated: cyclically
Signal(s) valid from SW release:
The channel should change to the RESET status. The current program is then in the program
status Aborted. All spindles and axes running will be decelerated along their acceleration
characteristics to a standstill without contour violation.The basic settings will be recovered
(e. g. G functions). The alarms will be cleared if they are not POWER ON alarms.
Channel status and program sequence are not influenced by this signal.
IS Channel RESET
IS All channels in RESET status
An alarm that cancels the IS Ready will ensure that the channel is no longer in the reset
status. In order to be able to switch the mode, RESET must be provided.

V3000 0001.2
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 - - > 1
Signal state 0 or edge
change 1 - - > 0
Signal inapplicable ......

Machine function REF


Signal(s) to NCK (PLC ---> NCK)
Signal(s) updated: cyclically
Signal(s) valid from SW release:
The machine function REF will be enabled in JOG mode.

V31000 000.0
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 - - > 1
Signal state 0 or edge
change 1 - - > 0

Active mode: AUTOMATIC


Signal(s) from NCK (NCK ---> PLC)
Signal(s) updated: cyclically
AUTOMATIC mode is active.

V3100 0000.1
Interface signal
Edge evaluation:
Signal state 1 or edge
change 0 - - > 1
Signal state 0 or edge
change 1 - - > 0

Active mode:MDA
Signal(s) from NCK (NCK ---> PLC)
Signal(s) updated: cyclically
MDA mode is active.

V3100 0000.2
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 - - > 1
Signal state 0 or edge
change 1 - - > 0

Active mode: JOG


Signal(s) from NCK (NCK ---> PLC)
Signal(s) updated: cyclically
JOG mode is active

10-216

The machine function REF will not be enabled.


if JOG mode is not active.

Signal(s) valid from SW release:

AUTOMATIC mode is not active.

Signal(s) valid from SW release:

MDA mode is active.

Signal(s) valid from SW release:

JOG mode is not active

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

Operating Modes, Program Mode (K1)


10.8

V3100 0000.3
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 - - - > 1
Signal state 0 or edge
change 1 - - - > 0

Special cases, errors, ......

V3100 0001.2
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 - - > 1
Signal state 0 or edge
change 1 - - > 0

10.8.2

Signal descriptions

802- READY
Signal(s) from NCK (NCK ---> PLC)
Signal(s) updated: cyclically
Signal(s) valid from SW release:
This signal is set after Mains Power On and all voltages have been established. The operating
mode group is now ready for operation, and part programs can be executed in the channel
and/or axes can be traversed.
The operating mode group / channel is not ready for service. Possible causes are:
- a serious axis or spindle alarm is present
- hardware fault
- mode group configured not correctly (machine date)
If Mode group ready changes to signal status 0,
- the axis and spindle drives are decelerated to a standstill at the maximum braking current;
- the signals from the PLC to the NCK are set to the active status (clear position).
An alarm that cancels the IS 802 - READY ensures that the channel is no longer in the RESET
status. To be able to switch over the operating mode, RESET (V30000000.7) must be provided.

Active machine function: REF


Signal(s) from NCK (NCK ---> PLC)
Signal(s) updated: cyclically
The machine function REF is active in JOG mode.

Signal(s) valid from SW release:

The machine function REF is not active.

Channel - specific signals

V3200 0000.4
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 - - > 1
Signal state 0 or edge
change 1 - - > 0
Application example(s)
Special cases, errors, ....

Related to ....
Further references

Enable Single block


Signal(s) to channel (PLC ---> NCK)
Signal(s) updated: cyclically
Signal(s) valid from SW release:
In AUTOMATIC mode, the program is run in single block mode; in MDA, any way only one
block can be entered.
No effect
To test a new program, it can first be run in single block mode to be able to check the individual program steps more exactly.
- If tool radius compensation is selected (G41,G42), intermediate blocks will be inserted if
necessary.
- With a series of G33 blocks, Single block is only active if Dry run feed is selected.
- With Single block coarse, pure computational blocks will not be executed in single block
mode; this is only possible in Single block fine. The preselection is carried out using the
Program control softkey.
IS Single block selected
IS Program status: Interrupted
Section 10.4

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

10-217

Operating Modes, Program Mode (K1)


10.8

Signal descriptions

V3200 000.5
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 - - > 1
Signal state 0 or edge
change 1 - - > 0
Related to ....

Enable M1
Signal(s) to channel (PLC ---> NCK)
Signal(s) updated: cyclically
Signal(s) valid from SW release:
In AUTOMATIC or MDA, M1 contained in the part program will result in a programmed stop.

V3200 0001.7
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 - - > 1

Enable program test


Signal(s) to channel (PLC ---> NCK)
Signal(s) updated: cyclically
Signal(s) valid from SW release:
Axis lock will be provided internally for all axes (not for the spindle). The machine axes will
therefore not move when a part program block or a part program is executed. However, the
axis movements are simulated on the user interface by changing axis position values. The
axis position values for the display are generated from the calculated setpoints.
In all remaining points, the part program execution is executed as usual.
The Program test function has no influence on the execution of the part program.

Signal state 0 or edge


change 1 - - > 0
Related to ....

V3200 0002.0
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 - - > 1
Signal state 0 or edge
change 1 - - > 0
Related to ....

10-218

M1 programmed in a part program will not result in a programmed stop.


IS M01 selected (V1700 0000.5)
IS M0/M1 active (V3300 0000.5)

IS Program test selected


IS Program test active

Skip block
Signal(s) to channel (PLC ---> NCK)
Signal(s) updated: cyclically
Signal(s) valid from SW release:
The blocks of the part program, which are marked with a slash (/), will be skipped. For a
series of blocks to be skipped, this signal will only be active if it is provided prior to decoding
the first block of this series, best before NC Start.
The marked program blocks will not be skipped.
IS Skip block selected

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

Operating Modes, Program Mode (K1)


10.8

V3200 0006.1
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 - - > 1
Signal state 0 or edge
change 1 - - > 0
Application example(s)

Signal descriptions

Read- in disable
Signal(s) to channel (PLC ---> NCK)
Signal(s) updated: cyclically
Signal(s) valid from SW release:
The data transfer to the interpolator will be disabled for the next block. This signal is only
active in AUTOMATIC and MDA modes.
The data transfer to the interpolator will be enabled for the next block. This signal is only active in AUTOMATIC and MDA modes.
If the execution of the auxiliary function must be completed for the execution of the
next NC block (e. g. for tool change), the automatic block change must be prevented by Read - in disable.

N21 G...
X ...M...

N20 T...






N20 T...
T

Related to ....

V3200 0006.4
Interface signal
Edge evaluation: yes
Signal state 1 or edge
change 0 - - > 1
Signal state 0 or edge
change 1 - - > 0
Special cases, errors, ......

N21
M

 Reading to clipboard
 Block executed
 Signal Read - in disable
 Data transfer
 Contents of interpolator
Output of auxiliary function
Data transfer to interpolator
Read - in disable for tool change
Polling point of read - in disable

Cancel Read - in disable


IS Program status: Running

Program level abortion


Signal(s) to channel (PLC ---> NCK)
Signal(s) updated: cyclically
Signal(s) valid from SW release:
With each edge change 0 -> 1, the currently processed program level (subroutine level) will
be aborted immediately. The part program will be continued on the next - higher program
level from the interruption position.
no effect
The main program level cannot be aborted using this IS, but only using the IS Reset.

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

10-219

Operating Modes, Program Mode (K1)


10.8

Signal descriptions

V3200 0007.0
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 - - > 1
Signal state 0 or edge
change 1 - - > 0
Application example(s)
Related to ....

V3200 0007.1
Interface signal
Edge evaluation: yes
Signal state 1 or edge
change 0 - - > 1

Signal state 0 or edge


change 1 - - > 0
Related to ....

V3200 0007.2
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 - - > 1
Signal state 0 or edge
change 1 - - > 0
Related to ....

10-220

NC Start inhibited
Signal(s) to channel (PLC ---> NCK)
Signal(s) updated: cyclically
IS NC Start is inactive.

Signal(s) valid from SW release: 1.1

IS NC Start is active.
This signal is used, e.g. to suppress that the program is executed once more due to a lack of
lubricant.
IS NC Start

NC Start
Signal(s) to channel (PLC ---> NCK)
Signal(s) updated: cyclically
Signal(s) valid from SW release
AUTOMATIC mode: The selected NC program is started or continued.
If data are transferred from the PLC to the NC in the program status Program interrupted,
these will be taken into account with NC start immediately.
MDA mode: The entered part program block are enabled for execution or continued.
No effect
IS NC Start inhibited

NC STOP at block border


Signal(s) to channel (PLC ---> NCK)
Signal(s) updated: cyclically
Signal(e) valid from SW release:
The current NC program is stopped after the current part program block has been executed
completely. As far as any other respects are concerned, the same as with NC Stop.
no effect
IS NC Stop
IS NC Stop axes and spindles
IS Program status: Stopped
IS Channel status: Interrupted

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

Operating Modes, Program Mode (K1)


10.8

V3200 0007.3
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 - - > 1

Signal state 0 or edge


change 1 - - > 0
Application example(s)

Signal descriptions

NC Stop
Signal(s) to channel (PLC ---> NCK)
Signal(s) updated: cyclically
Signal(s) valid from SW release:
The current NC program is stopped immediately, and the current block will not be completed.
Only the axes are stopped without contour violation.
Any distances to go will only be traversed after restart.
The program status will change to Stopped, and the channel status will change to
Interrupted.
no effect

With NC Start, the program will be continued from the interruption position.

IS NC-Stop
IS NC-Start
Program running
Axis running
Block executed
Special cases, errors, ....

The signal NC Stop must be provided at least one PLC cycle time.

Related to ....

IS NC Stop at block border


IS NC Stop for axes and spindles
IS Program status: Stopped
IS Channel status: Interrupted

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

10-221

Operating Modes, Program Mode (K1)


10.8

Signal descriptions

V3200 0007.4
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 - - > 1

Signal state 0 or edge


change 1 - - > 0
Signal inapplicable to .....
Special cases, errors......

NC Stop for axes and spindles


Signal(s) to channel (PLC ---> NCK)
Signal(s) updated: cyclically
Signal(s) valid from SW release:
The current NC program is stopped immediately, and the current block will not be completed.
Any distances to go will only be traversed after restart. Axes and spindle will be stopped.
These, however, will be stopped controlled.
The program status will change to Stopped, and the channel status will change to
Interrupted.
no effect
Channel status: Reset
Program status: Aborted
All axes and spindles that have not been triggered by a program or a program block (e.g. axes
are running because the traversing keys on the MCP have been pressed), will not decelerate to
a standstill with NC Stop axes plus spindles.
Press NC Start to continue the program from the interruption position.
The signal NC Stop Axes plus spindles must be provided at least one PLC cycle time.

Signal NC Stop: Axes


Signal NC Start
Program running
Axis running
Spindle running
Block executed
Related to ....

IS NC STOP at block border


IS NC STOP
IS Program status: Stopped
IS Channel status: Interrupted

V3300 0000.3
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 - - > 1
Application example(s)

Action block active


Signal(s) from channel (NCK ---> PLC)
Signal(s) updated: cyclically
Signal(s) valid from SW release:
Block search: Output with accumulated auxiliary function outputs is running (see Section
10.4.5)

V3300 0000.4
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 - - > 1
Application example(s)

Approach block active


Signal(s) from channel (NCK ---> PLC)
Signal(s) updated: cyclically
Signal(s) valid from SW release:
Block search with calculation / at contour: Approach block is running (see Section 10.4.5)

10-222

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

Operating Modes, Program Mode (K1)


10.8

V3300 0000.5
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 - - > 1

Signal state 0 or edge


change 1 - - > 0

Signal descriptions

M0/M1 active
Signal(s) from channel (NCK ---> PLC)
Signal(s) updated: cyclically
Signal(s) valid from SW release:
The part program block is executed, the auxiliary functions are output and
- M0 is stored in the user memory or
- M1 is stored in the user memory and IS Activate M01 is active
The program status changes to Stopped.
- With the IS NC Start
- In case of program abortion by Reset

Data transfer to the


user memory
Block executed
NC block with M0

M0

M change signal
(1 PLC cycle time)
IS M0/M1 active
IS NC Start
Related to ....

IS Enable M01 )
IS M01 selected

V3300 0000.6
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 - - > 1
Application example(s)

Last action block active


Signal(s) from channel (NCK ---> PLC)
Signal(s) updated: cyclically
Signal(s) valid from SW release:
Block search: Last block of the output with accumulated auxiliary function outputs (see Section 10.4.5)

V3300 0001.4
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 - - > 1
Signal state 0 or edge
change 1 - - > 0
Application example(s)

Block search active


Signal(s) from channel (NCK ---> PLC)
Signal(s) updated: cyclically
Signal(s) valid from SW release:
The function Block search is active. It has been selected and started from the user interface.
The function Block search is not active.
The Block Search function can be used to jump to a certain block in the part program and to
start the program execution only from this block.

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

10-223

Operating Modes, Program Mode (K1)


10.8

Signal descriptions

V3300 0001.5
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 - - > 1

M2/M30 active
Signal(s) from channel (NCK ---> PLC)
Signal(s) updated: cyclically
Signal(s) valid from SW release:
The NC block that contains M2 is executed completely. If the block also contains traversing
movements, the signal will be output only when the target position is reached.

Signal state 0 or edge


change 1 - - > 0

- No end of program or abortion of program


- State after starting the CNC
- Start of an NC program

Data transfer to
the user memory
Block executed
NC block with
M2

M2

M change signal
(1 PLC cycle time)
IS M2/M30 active
Application example(s)
Special cases, errors, ....

V3300 0001.7
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 - - > 1

Signal state 0 or edge


change 1 - - > 0
Related to ....

10-224

The PLC can use this signal to detect the end of program execution and react accordingly.
- The functions M2 and M30 have the same effect. It is recommended to use only M2.
-

The IS M2/M30 active is present at the end of the program statically.

Not intended for automatic follow - up functions, such as workpiece counting, bar feed, etc.
For these functions, M2 must be programmed in a separate block, and either the word M2
or the decoded M signal must be used.

The last block of a program may not contain any auxiliary functions that will result in Read In disable.

Program test active


Signal(s) from channel (NCK ---> PLC)
Signal(s) updated: cyclically
Signal(s) valid from SW release:
The program control Program test is active. Axis lock is internally provided for all axes (not
for a spindle). The machine axes will therefore not move when a part program block or a part
program is executed. However, the axis movements are simulated on the user interface by
changing axis position values. The axis position values for the display are generated from the
calculated setpoints.
In all remaining points, the part program execution is executed as normal.
The program control Program test is not active.
IS Enable program test
IS Program test selected

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

Operating Modes, Program Mode (K1)


10.8

V3300 0003.0
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 - - > 1
Signal state 0 or edge
change 1 - - > 0

Special cases, errors, ....

Signal descriptions

Program status running


Signal(s) from channel (NCK ---> PLC)
Signal(s) updated: cyclically
Signal(s) valid from SW release:
The part program has been started with the IS NC Start and is running.
- Program stopped by M00/M01 or NC Stop or mode change.
- The block has been executed in single block mode.
- End of program reached (M2)
- Abortion of program by Reset
- Current block cannot be executed
The IS Program status: Running will not change to 0 if the machining of the workpiece is
stopped by either of the following events:
- Output of feed disable or spindle lock
- IS Read - in disable
- Feed override to 0%
- Response of spindle and axis monitoring functions

V3300 0003.2
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 - - > 1
Signal state 0 or edge
change 1 - - > 0
Related to ....

Program status stopped


Signal(s) from channel (NCK ---> PLC)
Signal(s) updated: cyclically
Signal(s) valid from SW release:
The NC part program has been stopped either by NC Stop, NC Stop: Axes plus spindles,
NC Stop at block border, programmed M0 or M1 or single block mode.
Program status Stopped is not present.

V3300 0003.3
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 - - > 1

Program status interrupted


Signal(s) from channel (NCK ---> PLC)
Signal(s) updated: cyclically
Signal(s) valid from SW release:
When changing the mode from AUTOMATIC or MDA (in program status Stopped) to JOG,
the program status will change to Interrupted. The program can then be continued from the
interruption position in AUTOMATIC or MDA by pressing NC Start.
Program status Aborted is not present.

Signal state 0 or edge


change 1 - - > 0
Special cases, errors, ....

V3300 0003.4
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 - - > 1
Signal state 0 or edge
change 1 - - > 0
Related to ....

IS NC Stop
IS NC Stop: Axes plus spindles
IS NC Stop at block border

The IS Program status: Interrupted indicates that the part program can be continued by
restart.

Program status aborted


Signal(s) from channel (NCK ---> PLC)
Signal(s) updated: cyclically
Signal(s) valid from SW release:
The program is selected but not started, or the current program has been aborted with Reset.
Program status Aborted is not provided.
IS Reset

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

10-225

Operating Modes, Program Mode (K1)


10.8

Signal descriptions

V3300 0003.5
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 - - > 1
Signal state 0 or edge
change 1 - - > 0

V3300 0003.6
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 - - > 1

Signal state 0 or edge


change 1 - - > 0

Channel status active


Signal(s) from channel (NCK ---> PLC)
Signal(s) updated: cyclically
Signal(s) valid from SW release:
In this channel
- a part program or a block is currently executed in either of the modes Automatic or MDA
- at least one axis is traversed in JOG mode
Channel status Interrupted or channel status Reset is not present.

Channel status interrupted


Signal(s) from channel (NCK ---> PLC)
Signal(s) updated: cyclically
Signal(s) valid from SW release:
The NC part program in AUTOMATIC mode or the block in MDA mode has been interrupted
by NC Stop, NC Stop for axes and spindles, NC Stop at block border, programmed M0
or M1 or single block mode.
The part program or the interrupted traversing movement can be continued with NC START.
Channel status Active or channel status Reset is present.

V3300 0003.7
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 - - > 1
Signal state 0 or edge
change 1 - - > 0

Channel status Reset


Signal(s) from channel (NCK ---> PLC)
Signal(s) updated: cyclically
Signal(s) valid from SW release:
The signal will be set to 1 once the channel is in the RESET status, i.e. if no machining is
active.
The signal will be set to 0 once the channel is processed.
Execution of a part program or block search

V3300 4001.1
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 ---> 1

Required part number reached


Signal(s) from channel (NCK ---> PLC)
Signal(s) updated: cyclically
Signal(s) valid from SW release:
The preset number of parts to be produced is reached.

Signal state 0 or edge


change 1 ---> 0

V1700 0000.5
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 - - > 1
Signal state 0 or edge
change 1 - - > 0
Related to ....

10-226

Depending on the setting of MD 27880: PART_COUNTER:


Bit 1 = 0:
with $AC_REQUIRED_PARTS = $AC_ACTUAL_PARTS
Bit 1 = 1:
with $AC_REQUIRED_PARTS = $AC_SPECIAL_PARTS
The preset number of parts to be produced is reached.

M01 selected
Signal(s) von MMC ---> PLC
Signal(s) updated: cyclically
Signal(s) valid from SW release:
The program control Enable M1 has been selected from the user interface. The function will
thus not yet come into effect.
The program control Enable M1 has not been selected from the user interface.
IS Enable M01 )
IS M0/M01 active

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

Operating Modes, Program Mode (K1)


10.8

Signal descriptions

V1700 0000.6
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 - - > 1
Signal state 0 or edge
change 1 - - > 0
Related to ....

Dry run feed selected


Signal(s) von HMI ---> PLC
Signal(s) updated: cyclically
Signal(s) valid from SW release:
The program control Dry run feed has not been selected from the user interface. The function will thus not yet come into effect.
The program control Dry run feed has not been selected from the user interface.

V1700 0001.7
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 - - > 1
Signal state 0 or edge
change 1 - - > 0
Related to ....

Program test selected


Signal(s) von HMI ---> PLC
Signal(s) updated: cyclically
Signal(s) valid from SW release:
The program control Program test has not been selected from the user interface. The function will thus not yet come into effect.
The program control Program test has not been selected from the user interface.

V1700 0001.3
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 - - > 1
Signal state 0 or edge
change 1 - - > 0
Related to ....

Feed override for rapid traverse selected


Signal(s) von HMI ---> PLC
Signal(s) updated: cyclically
Signal(s) valid from SW release:
The program control Feed override for rapid traverse has been selected from the user interface. The function will thus not yet come into effect.
The program control Feed override for rapid traverse has not been selected from the user
interface.
IS Rapid traverse override active

V1700 0002.0
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 - - > 1
Signal state 0 or edge
change 1 - - > 0
Related to ....

Skip block selected


Signal(s) von HMI ---> PLC
Signal(s) updated: cyclically
Signal(s) valid from SW release:
The program control Skip block has been selected from the user interface. The function will
thus not yet come into effect.
The program control Skip block has not been selected from the user interface.

V1900 0000.6
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 - - > 1
Signal state 0 or edge
change 1 - - > 0
Related to ....

Simulation active
Signal(s) von HMI ---> PLC
Signal(s) updated: cyclically
Signal(s) valid from SW release:
The Simulation function has been selected from the user interface.

IS Enable dry run feed

IS Enable program test


IS Program test active

IS Enable Skip block

The Simulation function has not been selected from the user interface.

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

10-227

Operating Modes, Program Mode (K1)


10.9

10.9
10.9.1

Data fields, lists

Data fields, lists


Channel machine data

Basic machine data of the channel


Number

Identifier

Name

Ref.

Channel- specific
20050

AXCONF_GEOAX_ASSIGN_TAB[n]

Assignment geometry axis - channel axis


[GEO axis No.]: 0...2

Chpt. 19

20060

AXCONF_GEOAX_NAME_TAB[n]

Geometry axis in channel


[GEO axis No.]: 0...2

Chpt. 19

20070

AXCONF_MACHAX_USED[n]

Machine axis number valid in channel


[Channel axis No.]: 0...4

Chpt. 19

20080

AXCONF_CHANAX_NAME_TAB[n]

Channel axis name in the channel


[Channel axis No.]: 0...4

Chpt. 19

20100

DIAMETER_AX_DEF

Geometry axis with transversal axis function

P1

20700

REFP_NC_START_LOCK

NC start inhibited without reference point

R1

21000

CIRCLE_ERROR_CONST

Circle end point monitoring constant

Auxiliary function settings of the channel


Number

Identifier

Name

Ref.

Channel- specific)
22000

AUXFU_ASSIGN_GROUP[n]

Auxiliary function group


[AuxFuncNo in channel]
: 0...63

H2

22010

AUXFU_ASSIGN_TYPE[n]

Type of auxiliary function


[AuxFuncNo. in channel]
: 0...63

H2

22020

AUXFU_ASSIGN_EXTENSION[n]

Auxiliary function extension


[AuxFuncNo. in channel]
: 0...63

H2

22030

AUXFU_ASSIGN_VALUE[n]

Auxiliary function group


[AuxFuncNo in channel]
: 0...63

H2

22550

TOOL_CHANGE_MODE

New tool offset with M function

W1

Name

Ref.

Timers and counters of the channel


Number

Identifier

Channel- specific )
27860

PROCESSTIMER_MODE

Enable the program runtime measurement

27880

PART_COUNTER

Enable workpiece counters

27882

PART_COUNTER_MCODE[n]

Workpiece counting using M command , n = 0 ... 2

10-228

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Operating Modes, Program Mode (K1)


10.9

Data fields, lists

Display machine data


Number

Identifier

Name

Ref.

Display MD
283 ...
293

Display settings for the graphical simulation

10.9.2

Channel - specific setting data

Number

Identifier

Name

Ref.

Channel- specific
42000

THREAD_START_ANGLE

Start angle for thread

42010

THREAD_RAMP_DISP

Acceleration and braking distance of feed axis on


thread cutting G33

42100

DRY_RUN_FEED

Dry run feed

10.9.3

Interface signals

Mode group signals


Number

.Bit

Name

Ref.

Name

Ref.

PLC to NCK
V30000000

.0

AUTOMATIC mode

V30000000

.1

MDA mode

V30000000

.2

JOG mode

V30000000

.4

Mode change lock

V30000000

.7

Reset

V30000001

.2

Machine function REF

Number

.Bit

NCK to PLC
V31000000

.0

Active mode: AUTOMATIC

V31000000

.1

Active mode: MDA

V31000000

.2

Active mode: JOG

V31000000

.3

802- READY

V31000001

.2

Active machine function REF

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Operating Modes, Program Mode (K1)


10.9

Data fields, lists

Channel signals
Number

.Bit

Name

Ref.

Name

Ref.

PLC to NCK
V32000000

.3

Enable DRF

V32000000

.4

Enable Single block

V32000000

.5

Enable M01

V32000000

.6

IS Enable dry run feed

V32000001

.0

Enable Referencing

V32000001

.7

Enable Program test

V32000002

.0

Skip block

V32000006

.0

Feed lock

V32000006

.1

Read- in disable

V32000006

.2

Delete distance to go

V32000006

.3

Delete number of subroutine cycles

V32000006

.4

Program level abortion

V32000006

.6

Rapid traverse override active

V32000006

.7

Feed override active

V32000007

.0

NC START inhibited

V32000007

.1

NC Start

V32000007

.2

NC Stop at block border

V32000007

.3

NC Stop

V32000007

.4

NC Stop: Axes plus spindles

V32000007

.7

Reset

Number

.Bit

NCK to PLC
V33000000

.3

Action block active

V33000000

.4

Approach block active

V33000000

.5

M00/M01 active

V33000000

.6

Last action block active

V33000001

.0

Referencing active

V33000001

.4

Block search active

V33000001

.5

M2/M30 active

V33000001

.7

Program test active

V33000003

.0

Program status: Running

V33000003

.2

Program status: Stopped

V33000003

.3

Program status: Interrupted

V33000003

.4

Program status: Aborted

V33000003

.5

Channel status: Active

V33000003

.6

Channel status: Interrupted

V33000003

.7

Channel status: Reset

V33004001

.1

Required parts number reached

10-230

R1

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Operating Modes, Program Mode (K1)


10.9

Number

.Bit

Name

Data fields, lists

Ref.

MMC to PLC
V17000000

.5

M01 selected

V17000000

.6

Dry run feed selected

V17000001

.3

Feed override for rapid traverse selected

V17000001

.7

Program test selected

V17000002

.0

Skip block selected

V19000000

.6

Simulation active

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10-231

Operating Modes, Program Mode (K1)


10.9

Data fields, lists

notice

10-232

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11

Feed (V1)

11.1

Feedrate F

Functionality
The feedrate F is the tool path velocity of the tool along the programmed workpiece contour. The individual axis velocities result from the portion of the axis path in the total distance
to be traversed along the contour.
The feed F is active for the interpolation types G1, G2, G3, CIP,CT and remains stored in a
program until a new F word is programmed.
References:

Operation and Programming

Measuring unit for F: G94, G95


The unit of the F word is determined by G functions:


G94

F as the feed in mm/min or inch/min

|G95

F as the feed in mm/spindle rotation


or inch/rev. (is only useful if the spindle is running)

The inch unit system applies to G700 or to the system setting inch with
MD 10240: SCALING_SYSTEM_IS_METRIC =0.

Unit for F with G96, G97


For turning machines, the group that contains G94, G95, is extended by the functions G96,
G97 for the constant cutting rate (ON/OFF). These functions have an additional influence
on the S word.
With the function G96 enabled, the spindle speed is matched with the diameter of the workpiece (transverse axis) currently machined such that a programmed cutting rate S remains
constant at the tool edge (spindle speed by diameter = constant).
From block G96, the S word will be evaluated as the cutting rate. G96 is modally active until it
is canceled by another G function of the group (G94, G95, G97).
The feed F is always rated in the measuring unit mm/revolution or inch/revolution (as with
G95).

Maximum tool path velocity


The maximum tool path velocity results from the maximum velocities of the axes involved
(MD 32000: MAX_AX_VELO) and their portion in the total distance to be traversed. The maximum axis velocity defined in the MD may not be exceeded.

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11-233

Feed (V1)
11.1

Feedrate F

Feed override with circles CFC


When machining circle contours using milling tools and with the tool radius compensation
(G41/G42) enabled, the feedrate must be corrected at the cutter tool center to ensure that the
programmed F value acts at the circle contour. With the feed override CFC enabled, internal
and external machining are detected automatically.
CFTCP can be used to switch off the feed override.
References:

Operation and Programming

Interface signals
With revolutional feed active, the IS Revolutional feed active (V33000001.2) is set.
If the G96 function is enabled, the IS Constant cutting rate active (V390x 2002.0) is set for
the spindle.

Alarms


If no F word is programmed with G1, G2, G3, ... , alarm 10860 is output. No axis movement can be carried out. However, note SD 42110: DEFAULT_FEED.

If F0 is programmed, alarm 14800 is output.

If the spindle has stopped with G95 active, no axis movement can be carried out. No
alarm is output.

With the Dry run feed function enabled and the program started, the feedrates programmed in conjunction with G1, G2, G3, CIP and CT are replaced by the feedrate value defined in
SD 42100: DRY_RUN_FEED.
References: Section 10.4.4 Program execution with dry run feed

The velocity of the traversing movement of an axis in JOG mode is defined by machine
data/setting data. For a detailed description of the velocities including possible rapid traverse override, please refer to:
References: Chapter 9 Manual Traversing and Handwheel Traversing

Notes

11.1.1

Feed with G33 (thread cutting)

Velocity of the axes


For G33 threads, the velocity of the axes for the thread length results from the set spindle
speed and the programmed thread pitch. The limit frequency defined in MD 32000:
MAX_AX_VELO , however, cannot be exceeded.
The feed F will not apply in this case. It remains, however, stored.
The axis velocity, e.g. for a cylinder thread, results from the preset spindle speed (S ) and the
programmed thread pitch (e.g. K):
Fz [mm/min] = speed S [rpm] * thread lead K[mm/rev.]
References:

11-234

Operation and Programming

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Feed (V1)
11.1

Feedrate F

NC STOP, Single Block


NC STOP and Single Block are active only at the end of a velocity chain.

Information

11.1.2

The spindle override switch should remain unchanged when machining a thread.

The feed override switch has no meaning in a block that contains G33.

Feed with G63 (tapping with compensating chuck)

Feed F
With G63, a feedrate F must be programmed. It must match with the selected spindle speed
S (programmed or set) and with the thread lead of the tap:
Feed F[mm/min] = speed S [rpm] x thread lead [mm/rev.]
The compensating chuck compensates any path differences of the tap axis to a certain degree.
References:

11.1.3

Operation and Programming

Feed with G331, G332 (rigid tapping = tapping without compensating


chuck)
References:

Operation and Programming

Axis velocity
For G331/G332 - tapping - , the axis velocity for the thread length results from the active
spindle speed S and the programmed thread lead. The limit frequency defined in
MD 32000: MAX_AX_VELO, however, cannot be exceeded.
The feed F will not apply here. It remains, however, stored.
References:

Operation and Programming

Interface signal
With the G331/G332 function active, the IS Rigid tapping active (V390x 2002.3) is set for
the spindle.

Note
It is only possible to work without a compensating chuck if spindle and axis involved have
been matched another to one exactly. With G331/G332, parameter record n (0...5) of the axis
will automatically come into effect which is also active for the current gear stage of the
spindle (M40, M41 to M45 - see also Chapter 5 Spindle). As a rule, the axis of the more
inert spindle will also be matched accordingly.

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11-235

Feed (V1)
11.2

11.2

Rapid traverse G0

Rapid traverse G0

Application
The rapid traverse movement G0 is used for quick positioning of the tool, not for direct workpiece machining.
All axes can be traversed simultaneously. This results in a straight contour.
The maximum velocity (rapid traverse) is defined in the machine data
(MD 32000:MAX_AX_VELO ). If only one axis traverses, it will traverse at its rapid traverse.
If, for example, two path axes are traversed at the same time, the tool path velocity (resulting
velocity) is selected such that the largest tool path velocity results taking into account both
axes.
For example, if two axes have maximum velocity and have also to be traversed the same
distance, the tool path velocity will be 1.41 * max. axis velocity (geometrical total of the two
axis components).
The feedrate F will not apply with G0. It remains, however, stored.

Rapid traverse override


The operating range Position -> softkey Program control can be enabled in AUTOMATIC
mode so that the override switch for the feed is also active for rapid traverse. If the function is
active, ROV is displayed in the status line. The IS Feed override selected for rapid traverse (V1700 0001.3) is provided from the HMI to the PLC. This signal must be provided by
the PLC user program to the IS Rapid traverse override active (V3200 0006.6).

11-236

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Feed (V1)
11.3

11.3
11.3.1

Feed override

Feed override
Overview

Progr. F value

Progr. S value

X axis (radius)

IS Enable dry run feed

Stored
S value

G96

SD: DRY_RUN_FEED
(dry run
feed)

G95

G97

F value
(G94)

SG96
2**X

G95/G96/G97
G94

Maximum
*

Spindle override
from machine
control panel

PLC

IS Enable dry run feed

Spindle set speed

G94

G95
*

100%
Feed override
from machine control
panel 0 - xxx %

Tool path velocity

Fig. 11-1

11.3.2

PLC
IS: Feed override active
IS: Feed override active
IS: Override active

Possibilites of feed programming and feed control

Feed disable and feed/spindle stop

General
Feed disable and Feed/spindle stop will stop the axes. The path contour will be observed
(exception: G33 block).

Feed disable
The channel - specific interface signal Feed disable (V3200 0006.0) will stop all axes (geometry and additional axes) in all operating modes.
This feed disable is not active with active G33, but it will be active for G63, G331, G332.

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11-237

Feed (V1)
11.3

Feed override

Feed Stop for axes in the WCS


The interface signals Feed Stop (V3200 1000.3, V3200 1004.3 and V3200 1008.3) will stop
the geometry axes (axes in WCS) when traversing in the workpiece coordinate system in
JOG mode.

Axis - specific feed stop


The axis - specific interface signal Feed Stop (V380x0004.3) will stop the corresponding machine axis. For AUTOMATIC mode, the following applies:
If Feed Stop is provided for a path axis, all axes moved in the current block and involved in
the path group will be stopped.
In JOG mode, only the corresponding axis is stopped.
The axis - specific Feed Stop is active if G33 is enabled (but: In this case, contour deviations
result = thread errors!).

Spindle Stop
The interface signal Spindle Stop (V380x0004.3) is used to stop the spindle.
Spindle Stop is active with G33, G63 (but: In this case, contour deviations result = thread
errors!).

11.3.3

Feed override from the machine control panel

General
The operator can use the feed override switch to reduce or increase the traversed feedrate
relatively to the programmed feedrate as a percentage directly on site. The feedrates will be
multiplied with the override values.
The override possible for the feedrate is between 0 and 120%.
The rapid traverse override switch is used to run traversing programs more slowly when testing part programs.
The rapid traverse possible for the feedrate is between 0 and 100%.
The spindle override can be used to modify the spindle speed and the cutting rate (with G96).
The override possible is between 50 and 120%.
A modification is carried out with compliance of the machine - specific acceleration and velocity limits and without contour error.
The overrides will apply to the programmed values before the limitations (e. g. G26) come
into effect.

Channel - specific override and rapid traverse override


For feed and override, one enable signal and a bit each are provided for the override switch
in per cent.

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Feed (V1)
11.3

Feed override

IS Feed override (VB3200 0004)


IS Feed override switch active (V3200 0006.7)
IS Rapid traverse override (VB3200 0005)
IS Rapid traverse override active (V3200 0006.6)
The interface for the override (value) is provided from a machine control panel via the PLC to
the NC in the Gray code.
An active feed override will applies to all path axes. An active rapid traverse override will apply to all axes tha traverse at rapid traverse.
If no separate rapid traverse switch is provided, the feed override switch can be used whereby feed overrides exceeding 100% will be limited to 100% rapid traverse override.
Which override will be active, can be selected either via PLC or from the operator panel.
When selection is made through the control panel (display:ROV), the IS Feed override for
rapid traverse selected (V1700 0001.3) is set, transferred to the IS Rapid traverse override
active (V3200 0006.6), and the value is to be transferred from a machine control panel to the
IS Rapid traverse override (VB3200 0005) from the PLC user program.
The channel - specific feed and rapid traverse override is disabled if G33, G63 G331 and
G332 are active.

Axis - specific feed override


For each axis, one enable signal and a byte each are provided for the feed override factor in
per cent.
IS Feed override (VB380x 0000)
IS Override active (V380x 0000.7)
The axis - specific feed override is inactive if G33, G331, G331, G63 are enabled (internally
fixed to 100%).

Spindle override
For each spindle, one enable signal and one byte each are provided for the PLC interface
spindle override factor in per cent.
IS Spindle override (VB380x 0000)
IS Feed override active (V380x 0000.7)
Another IS Feed override valid for spindle (V380x 2001.0) is provided for the PLC user program to specify that the value of the IS Feed override (VB380x 0000) will apply.
The spindle override is active with G33, but should not be actuated for reasons of accuracy;
is also active with G331, G332. With G63, the spindle override is fixed to 100 %.

Override enabled
The set override values are active in all modes and for all machine functions, provided that
the IS Rapid traverse override active, Feed override active or Override active are set.
An override value of 0% will have the same effect as feed disable.

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11-239

Feed (V1)
11.4

Data descriptions (MD, SD)

Override disabled
If the override is disabled (above interface signals are set to 0), override factor 1 will be
used internally in the NC, i.e. the override will be 100%.
Note:
A special characteristic for this value is the 1st switch position of the Gray - coded interfaces.
Even if the IS Rapid traverse override active, Feed override active and Override active,
the override factor of the 1st switch position will be used and 0 % will thus be output as the
override value for the axes (has the same effect as Feed disable). Override value 50 % will
apply to the spindle if the IS Override active is not set.

11.4

Data descriptions (MD, SD)

Setting data, channel - specific


42110
SD number
Default: 0.0
Change valid: immediately
Data type: DOUBLE
Meaning:

SD inapplicable to ......

DEFAULT_FEED
Default value for feedrate
Min. input limit: 0.=
Protection level: 7/7

Max. input limit: ***


Unit:
mm/min, mm/rev.
Valid from SW release:
The setting data is evaluated at part program start, taking into account the feedrate type of the
default setting after turning on.
Default settings when turning on:
Turning: G95 - feedrate in mm/rev. of spindle
Milling: G94 - feedrate in mm/min
If no F word is programmed for the appropriate feedrate type with G1, G2, G2, ... and the SD
value is not zero, the feedrate from this SD will be used. Otherwise, an alarm is output with a
notice that the feedrate is missing.
Turning: G94 programmed
Milling: G95 programmed

Related to ....

11-240

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Feed (V1)
11.5

11.5

Signal descriptions

Signal descriptions

11.5.1

Channel - specific signals

V3200 0000.6
Interface signal

Enable dry run feed


Signal(s) to channel (PLC NCK)

Edge evaluation: no
Signal state 1 or edge
change 0 --->1

Signal state 0 or edge


change 1 --->0
Application example(s)
Related to ....

VB3200 0004
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 --->1

Signal(s) updated: cyclically

Feed override
Signal(s) to channel (PLC NCK)
Signal(s) updated: cyclically

Table 11-1
Switch
position

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
Related to ....

Signal(s) valid from SW release:

SD 42100: DRY_RUN_FEED will be used instead of the programmed feed (with G1, G2, G3,
CIP, CT).
The interface signal is evaluated on NC Start if the channel was in the RESET state.
When using the selection via PLC, the interface signal Enable dry run feed must be set from
the PLC user program.
The programmed feed will be used for traversing.
active after RESET state
Testing a workpiece at increased feedrate.
IS Dry run feed selected (V1700 0000.6)
SD 42100: DRY_RUN_FEED (dry run feed)

Signal(s) valid from SW release:

Gray coding for the feed override


Code

00001
00011
00010
00110
00111
00101
00100
01100
01101
01111
01110
01010
01011
01001
01000
11000
11001
11011
11010
11110
11111
11101
11100
10100
10101
10111
10110
10010
10011
10001
10000

Feed override factor


Max. input limit:

0.0
0.01
0.02
0.04
0.06
0.08
0.10
0.20
0.30
0.40
0.50
0.60
0.70
0.75
0.80
0.85
0.90
0.95
1.00
1.05
1.10
1.15
1.20
1.20
1.20
1.20
1.20
1.20
1.20
1.20
1.20

IS Feed override active (V3200 0006.7)

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11-241

Feed (V1)
11.5

Signal descriptions

VB3200 0005
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 --->1

Rapid traverse override


Signal(s) to channel (PLC NCK)
Signal(s) updated: cyclically

Table 11-2

Signal(s) valid from SW release:

Gray coding for the rapid traverse override

Switch
position

Code

Rapid traverse override


Max. input limit:

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

00001
00011
00010
00110
00111
00101
00100
01100
01101
01111
01110
01010
01011
01001
01000
11000
11001
11011
11010
11110
11111
11101
11100
10100
10101
10111
10110
10010
10011
10001
10000

0.0
0.01
0.02
0.04
0.06
0.08
0.10
0.20
0.30
0.40
0.50
0.60
0.70
0.75
0.80
0.85
0.90
0.95
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00

Related to ....

IS Rapid traverse override active

V3200 0006.0
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 --->1

Feed disable
Signal(s) to channel (PLC NCK)
Signal(s) updated: cyclically
Signal(s) valid from SW release:
The signal of a channel is active in all operating modes.
 The signal results in feed disable for all axes involved in interpolation provided G33
(thread) is not active.
All axes will be stopped with compliance of the path contour. If the feed disable (0 signal)
has been canceled, the interrupted part program will be continued.
 The position control remains stored, i.e. the following error will be reduced.
 If for an axis for which Feed Disable is provided, a traversing request is provided, this will
remain stored. The traversing request provided will be carried out directly at the moment
when Feed disable is canceled.

Signal state 0 or edge


change 1 --->0
Special cases, errors, ....

11-242

If the axis in question interpolates with other axes, this will also apply to these axes.
 The feed is enabled for all axes of this channel.
 If a traversing request (Traversing command) is provided for an axis or an axis group if
Feed disable is canceled, this will be carried out directly.
Feed disable is disabled if G33 is enabled.

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Feed (V1)
11.5

V3200 0006.6
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 --->1
Signal state 0 or edge
change 1 --->0

Special cases, errors,.....


Related to ....

V3200 0006.7
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 --->1
Signal state 0 or edge
change 1 --->0

Special cases, errors, ....


Related to ....

V3200 1000.3
and
V3200 1008.3
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 --->1

Signal state 0 or edge


change 1 --->0

V1700 0000.6
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 - - - > 1

Signal state 0 or edge


change 1 - - - > 0
Related to ....

Signal descriptions

Rapid traverse override active


Signal(s) to channel (PLC NCK)
Signal(s) updated: cyclically
Signal(s) valid from SW release:
The rapid traverse override 0 to max. 100 % entered in the PLC interface acts channel - specifically.
The rapid traverse override entered in the PLC interface will not be taken into account.
If the rapid traverse override is disabled, 100 % will be used internally in the NC as the override factor.
Note:
An exception for this value is the 1st switch position of the Gray coded interface. In this case,
this override factor is used even if Rapid traverse override is inactive, and 0 % is output as
the override value for the axes.
The rapid traverse override is disabled if G33 is active.
IS Rapid traverse override

Feed override active


Signal(s) to channel (PLC NCK)
Signal(s) updated: cyclically
Signal(s) valid from SW release:
The feed override 0 to max. 120 % entered in the PLC interface is active for the tool feed and
thus automatically for the corresponding axes.
In JOG mode, the feed override is directly active for the axes.
The feed override entered in the PLC interface will not be taken into account.
If feed override is active, 100 % will be used internally in the NC as the override factor.
Note:
An exception for this value is the 1st switch position of the Gray coded interface. In this case,
this override factor is used even if Rapid traverse override is inactive, and 0 % is output as
the override value for the axes.
The feed override is disabled if G33 is active.
IS Feed override

Feed Stop

Geo axes (axes in WCS)

Signal(s) to channel (PLC NCK)


Signal(s) updated: cyclically
Signal(s) valid from SW release:
The signal is only active in JOG mode (traversing the axes in the WCS).
 Signal results in Feed Stop of the corresponding axis. For a traversing axis, this signal
results in a controlled deceleration up to standstill (ramp stop). No alarm message is
provided in this case.
 The position control remains stored, i.e. the following error will be reduced.
 If for an axis for which Feed Stop is provided, a traversing request is provided, this will
remain. This traversing request will be carried out directly at the moment when Feed
Stop is canceled.
 The feed for the axis is enabled.
 If a traversing request (traversing command) is provided for the axis when Feed Stop
is canceled, this will be carried out directly.

Dry run feed selected


Signal(s) to channel (HMI PLC)
Signal(s) updated: cyclically
Signal(s) valid from SW release:
Dry run feed selected.
Instead of the programmed feed, the dry run feed entered in SD 42100: DRY_RUN_FEED
will be active.
If dry run feed is enabled from the operator panel, the signal will automatically be entered in the
PLC interface and transferred by the PLC basic program to the PLC interface signal Enable dry
run feed.
Dry run feed is not selected.
The programmed feed is active.
IS Enable dry run feed (V3200 0000.6)
SD: DRY_RUN_FEED (dry run feed)

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

11-243

Feed (V1)
11.5

Signal descriptions

V1700 0001.3
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 - - - > 1

Signal state 0 or edge


change 1 - - - > 0
Application example(s)

Feed override for rapid traverse selected


Signal(s) to channel (HMI PLC)
Signal(s) updated: cyclically
Signal(s) valid from SW release:
The feed override switch will also be used as the rapid traverse override switch.
Any overrides exceeding 100% will be limited to the maximum value of 100% rapid traverse
override.
The IS Feed override for rapid traverse selected will automatically be entered from the operator
panel in the PLC interface and transferred by the PLC basic program to the PLC interface signal
Rapid traverse override active.
Furthermore, the IS Feed override (VB3200 0004) will be copied from the PLC basic program
to the IS Rapid traverse override (VB3200 0005).
The feed override will not also be used as the rapid traverse override switch.
This signal is used if no separate rapid traverse override switch is provided.

Signals from channel


V3300 0001.2
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 - - - > 1
Application example(s)
Related to ....

11-244

Revolutional feed active


Signal(s) from channel (NCK PLC)
Signal(s) updated: cyclically
Signal(s) valid from SW release:
When programming G95 (rotation speed) in automatic mode.

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

Feed (V1)
11.5

11.5.2

Signal descriptions

Axis/spindle - specific signals

Signals to axis/spindle
VB380x 0000
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 ---> 1

Feed override (axis - specific)


Signal(s) to axis (PLC NCK)
Signal(s) updated: cyclically
Signal(s) valid from SW release:
The axis - specific feed override is specified from the PLC using the Gray code.

Switch
position

Code

Axial feed override


factor

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

00001
00011
00010
00110
00111
00101
00100
01100
01101
01111
01110
01010
01011
01001
01000
11000
11001
11011
11010
11110
11111
11101
11100
10100
10101
10111
10110
10010
10011
10001
10000

0.0
0.01
0.02
0.04
0.06
0.08
0.10
0.20
0.30
0.40
0.50
0.60
0.70
0.75
0.80
0.85
0.90
0.95
1.00
1.05
1.10
1.15
1.20
1.20
1.20
1.20
1.20
1.20
1.20
1.20
1.20

Table 11-3
Related to ....

Gray coding for the axis - specific feed override

IS Override active

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

11-245

Feed (V1)
11.5

Signal descriptions

VB380x 2003
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 ---> 1

Spindle override
Signal(s) to spindle (PLC NCK)
Signal(s) updated: cyclically
Signal(s) valid from SW release:
The spindle override is specified from the PLC using the Gray code.
The override value determines the percentage of the programmed speed setpoint provided
to the spindle.
Switch
position

Code

Spindle override factor

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

00001
00011
00010
00110
00111
00101
00100
01100
01101
01111
01110
01010
01011
01001
01000
11000
11001
11011
11010
11110
11111
11101
11100
10100
10101
10111
10110
10010
10011
10001
10000

0.5
0.55
0.60
0.65
0.70
0.75
0.80
0.85
0.90
0.95
1.00
1.05
1.10
1.15
1.20
1.20
1.20
1.20
1.20
1.20
1.20
1.20
1.20
1.20
1.20
1.20
1.20
1.20
1.20
1.20
1.20

Table 11-4

Gray coding for spindle override

Related to ....

IS Override active (V380x 0001.7)


IS Feed override active for spindle (V380x 2001.0)

V380x 2001.0
Interface signal

Feed override active for spindle (instead of spindle override)


Signal(s) from axis/spindle ( PLC ->NCK )

Edge evaluation: yes

Signal(s) updated: cyclically

Signal(s) valid from SW release:

Signal state 1 or edge


change 0 ---> 1

Instead of the spindle override value, the feed override value (VB38030000) will be used for
the spindle.

Signal state 0 or edge


change 1 ---> 0

The spindle override value will be used.

Related to ....

IS
IS
IS

11-246

Spindle override (VB380x 2003)


Feed override (VB380x 0000)
Override active (V380x 0001.7)

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

Feed (V1)
11.5

V380x 0001.7
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 ---> 1

Signal state 0 or edge


change 1 ---> 0

Special cases, errors, ....

Related to ....

V380x 0004.3
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 ---> 1

Signal state 0 or edge


change 1 ---> 0

Application example(s)

Signal descriptions

Override active
Signal(s) to axis/spindle (PLC NCK)
Signal(s) updated: cyclically
Signal(s) valid from SW release:
Feed override active:
 The axis - specific feed override 0 to max. 120 % entered in the PLC interface will be
taken into account.
Spindle override active:
 The spindle override 0 to max. 120 % entered in the PLC interface will be taken into
account.
The present axis - specific feed override or spindle override is inactive.
If the override is not active, 100 % will be used internally in the NC as the override factor.
Note:
An exception for this value is the 1st switch position of the Gray coded interface. In this case,
this override factor is used even if Override is inactive, and 0 % is output as the override
value for the axes (has the same effect as Feed disable); for the spindle correspondingly
50 %.
 In spindle mode Oscillation, the spindle override is always supposed to be 100 %.
 The spindle override effects the programmed values before the limitations
(e. g. G26) come into effect.
 The feed override is disabled if G33 is active.
IS Feed override and IS Spindle override

Feed Stop/Spindle Stop (axis - specific)


Signal(s) to axis/spindle (PLC NCK)
Signal(s) updated: cyclically
The signal is active in all operating modes.

Signal(s) valid from SW release:

Feed Stop:
 Signal results in Feed Stop of the corresponding axis. For a traversing axis, this signal
results in a controlled deceleration up to standstill (ramp stop). No alarm message is
provided in this case.
 This signal results in Feed Stop for all axes interpolating if Feed Stop is provided for one
of the path axes. In this case, all axes will be stopped, observing the path contour. After
canceling the Feed Stop signal, the interrupted part program will be continued.
 The position control remains stored, i.e. the following error will be reduced.
 If a traversing request is provided for an axis for which Feed Stop is provided, this will
remain stored. This traversing request will be carried out directly at the moment when
Feed Stop is canceled.
If the axis interpolates with other axes, this will also apply to these axes.
Spindle Stop:
 The spindle will be decelerated to a standstill along its deceleration characteristic.
 In positioning mode, the positioning process will be aborted by setting the signal Spindle
Stop. The behavior above applies to single axes.
Feed Stop:
 The feed for the axis is enabled.
 If a traversing request (traversing command) is provided for the axis when Feed Stop
is canceled, this will be carried out directly.
Spindle Stop:
 The speed is enabled for the spindle.
 If Spindle Stop is canceled, the spindle is accelerated to the previous speed setpoint
along its acceleration constant or, in positioning mode, the positioning is continued.
Feed Stop:
 The traversing movements of the machine axes will not be started with Feed Stop if,
e.g. certain operating states are provided on the machine which do not allow an axis
movement (e. g. door not closed).
Spindle Stop:
 to carry out a tool change.

Special cases, errors, ....

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

11-247

Feed (V1)
11.6

Data fields, lists

11.6

Data fields, lists

11.6.1

Interface signals

Number

.Bit

Name

Ref.

Channel- specific
V3200 0000

.6

Enable dry run feed

V3200 0004

Feed override

V3200 0005

Rapid traverse override

V3200 0006

.0

Feed disable

V3200 0006

.6

Rapid traverse override active

V3200 0006

.7

Feed override active

V3200 1000

.3

Feed stop, geometry axis 1

V3200 1004

.3

Feed stop, geometry axis 2

V3200 1008

.3

Feed stop, geometry axis 3

V1700 0000

.6

Dry run feed selected

V1700 0001

.3

Feed override selected for rapid traverse

V3300 0001

.2

Revolutional feed active

Axis/spindle- specific
VB380x 0000

Feed override

VB380x 2003

Spindle override

V380x 0001

.7

Override active

V380x 2001

.0

Feed override for spindle active

V380x 0004

.3

Feed Stop / Spindle Stop

V390x 2002

.0

Constant cutting rate active (spindle)

S1

V390x 2002

.3

Rigid tapping active (spindle)

S1

11.6.2

Machine data/setting data

Number

Identifier

Name

Ref.

General machine data


10240

SCALING_SYSTEM_IS_METRIC

Scaling system, metric

G1

Axis - specific machine data


32000

MAX_AX_VELO

Maximum axis velocity

G1

35100

SPIN_VELO_LIMIT

Maximum spindle speed

S1

K1

Channel- specific setting data


42100

DRY_RUN_FEED

Dry run feed

42110

DEFAULT_FEED

Default value for feedrate

11-248

SINUMERIK 802D, 802D base line


6FC5 697 - 2AA10- 0BP2 (11.03) (DF)

Continuous - Path Mode, Exact Stop


and LookAhead (B1)

12.1

12

Brief description
In the continuous-path mode, the CNC executes a part program block by block. Only if the
functions of the block currently executed have been completed, the next block is started. Various demands placed on machining and positoning require various block change criteria. Two
behaviors are to be found at the block borders for the path axes.
The first type, Exact stop, means that all path axes must have reached the given target position depending on an exact stop criterion before the next block change is initiated. To be able
to fulfill this criterion, the path axes must reduce their tool path velocity what, however, will
result in a delay of the block change. The second type, Continous-path mode, is used to try
to avoid decelerating of the tool path rate at the block border to be able to change to the next
block at the same tool path velocity (if possible).
LookAhead is a method, which is used in continuous-path mode to determine a velocity
control looking ahead for several NC program blocks.

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

12-249

Continuous-Path Mode, Exact Stop and LookAhead (B1)


12.2

12.2

General

General
Interpolating machine axes must have the same dynamic behavior, i.e. the same following
error must occur at a the same velocity.
Path axes are all machining axes that are controlled by an interpolator that determines the
path points so that


all involved axes will start at the same time;

each involved axis will traverse at the correct velocity ratio;

all axes will reach the programmed target position at the same time.

The accelerations of the individual axes may be different depending on the path to be traversed,
such as a circle.
Path axes may be geometry axes or supplementary axes (e.g. workpiece rotary axes involved in the
workpiece machining).

Velocity at zero-cycle blocks


Zero-cycle blocks are blocks whose path length is shorter than the path that can be covered
using the programmed set feedrate and the interpolation cycle (time). For accuracy reasons,
the velocity is reduced such that traversing along the path takes at least one interpolator cycle. The velocity is thus equal to or less than the quotient of the path length of the block divided by the IPO cycle.

Stopping for synchronization


Irrespective of whether exact stop or continuous-path mode is selected, the block change
may be delayed by synchronization processes and can thus cause a stop of the path axis. In
exact stop mode, the path axes are stopped at the end point of the current block. In continuous path mode, the path axes are stopped in this situation at the next block end point, where
they can be braked keeping their acceleration limits. A stop is carried out for synchronization


on PLC acknowledgement.
If the acknowledgement by the PLC is required for an auxiliary function output before or
after the end of a motion, the stop is carried out at block end.

if there are no more following blocks.


If following blocks cannot or not quickly enough be prepared (e.g. Execution from external
source), the stop is carried out at the last approachable block limit.

when emptying the buffer.


If it is required in the NC part program to synchronize the initial part of the program with the
main run (empty buffer, e.g. STOPRE), a block-related velocity reduction and/or an exact
stop is implicitly connected with it.

No contour errors occur when stopping for synchronization. However, the stop is not desired
especially in contiuous path mode, since a relief cut can occur.

12-250

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Continuous-Path Mode, Exact Stop and LookAhead (B1)


12.3

12.3

Exact Stop

Exact Stop
The Exact Stop function (G60, G9) is used to wait for the path axes running in to the programmed
block end point. If all path axes have reached the exact stop criterion, the block change is carried
out. The velocity at the block transition is nearly zero.

This means:


that the path axes at the block end point come nearly to a standstill without overshooting.

the machining time is exceeded due to the waiting time to achieve the exact stop criterion.

relief cutting may occur due to the waiting time to achieve the exact stop criterion.

The exact stop function is suited for exact traversing along contours.
Exact stop is not recommended if

the exact curve within the framework of a criterion (e.g. exact stop fine) may deviate from the
programmed criterion to make the machining faster.

absolute velocity tolerance is required.

Enabling Excact Stop


The Exact Stop function can be selected in the NC part program using the command G60 or
G9. G60 is modally active, G9 non-modal. G09 is used to interrupt continuous path mode.
The two exact stop functions are only active with the selected exact stop criterion (G601,
G602). The exact stop function is deselected using the continuous path mode function G64.

Exact stop criteria




Exact stop fine: G601


This criterion is used to monitor whether the distance of axis actual position from the set
position is within a certain range. The size of this distance is defined in MD 36010:
STOP_LIMIT_FINE (exact stop fine).

Exact stop coarse: G602


The same functionality as exact stop fine, but the monitoring window is defined in MD
36000: STOP_LIMIT_COARSE (exact stop coarse). To achieve a faster block change
compared with the criterion exact stop fine, the exact stop coarse window must be parameterized larger than the exact stop fine window.
Block change times
v
Actual value

with G602

t1=interpolator end

with G601
Set value

Exact stop coarse > Exact stop fine

t1

Fig. 12-1

Block change according to the exact stop criteria

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6FC5 697-2AA10-0BP2 (11.03) (DF)

12-251

Continuous-Path Mode, Exact Stop and LookAhead (B1)


12.4

Continuous path mode

Interpolator end
The interpolator end is reached when the interpolator has calculated the setpoint velocity of
the axes to the amount of zero for one interpolation clock pulse. However, the actual positions
of the path axes have not reached the target (following error).
The auxiliary functions contained in the block are transferred to the PLC with interpolator end,
irrespective of the continuous path mode and/or the active exact stop criterion of the exact
stop function, provided that these auxiliary functions are output after end of motion.

12.4
12.4.1

Continuous path mode


General
In the continuous path mode, the path velocity is not decelerated for block change at the end
of block to a velocity which allows to reach the exact stop criterion. The objective is to avoid a
major braking of the path axes at the block change point in order to switch over to the next
block at the same tool path velocity if possible. In order to achieve this objective, the LookAhead function is activated in addition to the selection of the continuous path mode (G64) (refer
to Section 12.5).
The continuous path mode causes :


a rounding of the contour.

shorter processing times due to missing braking and acceleration procedures, which are
required for reaching the exact stop criterion.

better cutting conditions due to the more uniform velocity characteristic.

Continuous path mode is useful if a contour is to be traversed rapidly.


Continuous path mode is not useful if:


a contour is to be traversed exactly.

an absolute constant velocity is required.

Implied exact stop


In some cases, an exact stop must be generated in continuous path mode to be able to carry
out the following actions. In such situations, the path velocity is braked down to zero.

12-252

If auxiliary functions are output prior to the traversing motion, the previous block is only
completed when the selected exact stop criterion is reached.

If auxiliary functions are output after the traversing motion, these are output after interpolator end of the block.

If an executable block does not contain any traversing information for the path axes, the
previous block is completed when the selected exact stop criterion is reached.

A block is completed at interpolator end, if the switch-over of the acceleration profile


BRISK/SOFT is carried out in the following block.

If the function Empty buffer (STOPRE) is programmed in the part program, the previous
block is completed when the selected exact stop criterion is reached.

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Continuous-Path Mode, Exact Stop and LookAhead (B1)


12.4

Continuous path mode

Velocity = 0 in the continuous path mode


Irrespective of the implied exact stop, the path motion is braked down to zero at the block end,
if:


the time for the positioning of a spindle is longer using SPOS than the traversing time of
the path axes. The block change is carried out when the exact stop fine of the spindle to
be positioned is reached.

a synchronization is required (see Section 12.2).

Auxiliary function output during traversing


If the traversing time is not sufficient due to the programmed path length and the velocity of
the block with auxiliary function output, the tool path velocity for the block is pre-emptively
reduced in such a way that the acknowledgement of the auxiliary function can be provided
within a PLC cycle time. If the acknowledgement is not carried out within a PLC cycle time,
the following prepared block cannot be executed, and the axes are stopped immediately with
setpoint specification = 0 (without taking into account the acceleration limits). If also in long
blocks the velocity acknowledgement is not provided by the end of the block, in which it was
not necessary to reduce the velocity due to the PLC acknowledgement time, the velocity is
retained by the end of the block and is reduced as described above. If the acknowledgement
is provided during the braking process, no acceleration to the desired speed is carried out.

12.4.2

Velocity reduction according to the overload factor

Function
This function reduces the traversing rate in continuous path mode such that the non-tangential block transition can be overrun in one interpolator clock pulse, keeping the acceleration
limit and taking into account the overload factor. The velocity reduction causes sudden axisspecific velocity changes if the contour characteristic at the block end is not tangential. The
synchronous axes involved in traversing will also be involved in these sudden velocity changes. The sudden velocity change avoids a reduction of the traversing rate to zero. The sudden
velocity change is carried out if the axial velocity with the axis acceleration has been reduced
to a velocity from which the new setpoint value can be reached by the sudden velocity
change. The amount of the sudden change of the setpoint can be limited using the overload
factor criterion. Since the amount of the sudden change is axis-related, the smallest amount
of the sudden change is taken into account at the block transition of the path axes active during block change. In case of an almost tangential block transition, the path velocity is not reduced, if the admissible axes accelerations are not exceeded. This allows to overrun very
small bends in the contour.

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

12-253

Continuous-Path Mode, Exact Stop and LookAhead (B1)


12.4

Continuous path mode

Overload factor
The overload factor limits the sudden velocity change (further referred to as velocity jump) of
the machine axis at the block transition. To make sure that the velocity jump does not exceed
the axis load, the jump is deduced from the acceleration of the axis. The overload factor specifies by what amount the acceleration of the machine axis can be exceeded for an IPO clock
pulse, which is stored in MD 32300: MAX_AX_ACCEL (axis acceleration). The velocity stroke
is the product of the axis acceleration * (overload factor -1) * interpolator clock pulse. The
overload factor is 1.2.
Factor 1.0 means that only tangential transitions can be overrun at an endless velocity. In the
case of any other transitions, the velocity will be reduced to zero due to the setpoint settings.

Selection and deselection of the velocity reduction


The modal selection of continuous path mode with velocity reduction can be carried out according to the overload factor in each NC part program block using program code G64 (BRISK
active, not SOFT).
The continuous path mode G64 can be

12.4.3

interrupted by selecting the exact stop G9 block by block;

deselected by selecting exact stop G60.

Velocity reduction for jerk limitation on the path

Note
This function is not available with the 802D base line.

Introduction
The jerk limitation on the path is another method for controling the continuous path mode.
Whereas Velocity reduction according to overload factor (see Section 12.4.2) limits the
change in the velocity, the Jerk limitation on the path as described here limits acceleration
jumps (jerks).
In contour elements consisting of partial pieces (e.g. circle - straight line transitions), acceleration jumps occur at the block transition in continuous path mode.
References:

Section Acceleration.

Jerk reduction
Jerks can be reduced by reducing the tool path velocity at block transitions with path elements
having various bends of different kind. A smoother transition is achieved between the contour
elements.

12-254

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Continuous-Path Mode, Exact Stop and LookAhead (B1)


12.4

Continuous path mode

Jerk limit
The user defines the maximum jerk using MD 32432: PATH_TRANS_JERK_LIM (maximum
axis-specific jerk of a path axis at the block transition), which is allowed to occur in a path
axis at block transition.

Enabling
The jerk limitation at block transitions becomes active if continuous path mode with G64 and
acceleration behavior SOFT are programmed. MD 32432: PATH_TRANS_JERK_LIM must
have a positive value.

12.4.4

Machine axis- specific jerk limitation

Note
This function is not available with the 802D base line.

Function
The axis-specific machine data MD 32431: MAX_AX_JERK[..] can be used to set the acceleration change for each machine axis separately, as it is already done for the acceleration limitation using machine data MD 32300: MAX_AX_ACCEL[..]. MD 32431: MAX_AX_JERK[..] is
active for the axes interpolated by the path and for which SOFT (jerk-free acceleration curve)
is active within the block.
Generally, a distinction is made between the axis acceleration curve within a block and at the
transition between two blocks.

Advantages
To use axis-specific machine data for the path has the following advantages:


The dynamic properties of the axes are directly taken into account by interpolation and can
be utilized completely for each indiividual axis.

The limitation of the jerk per axis is kept not only in linear blocks, but also in curved contours.

References:

Section Acceleration.

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

12-255

Continuous-Path Mode, Exact Stop and LookAhead (B1)


12.5

LookAhead

12.5

LookAhead

Function
LookAhead is a procedure in continuous path mode (G64), which can pre-emptively determine the velocity control beyond the current block for several NC part program blocks.
Without LookAhead: If the programmed blocks contained only very small distances to be traversed, a velocity was reached per block which allowed braking of the axes at the block end
point, observing the acceleration limits. This meant that the programmed velocity was not reached at all,
although a sufficient number of prepared blocks with almost tangential path
transitions was present.
With LookAhead function: It is possible to carry out the acceleration and deceleration phases
over several blocks with almost tangential block transitions and thus to obtain a higher feedrate for small distances. In this way, there is a pre-emptive braking with regard to the velocity
limitations, so that a violation of the acceleration and velocity limits is avoided.
Feed
G64 continuous path mode with Look Ahead
Programmed feed F
F1

G60 - exact stop

N1
Fig. 12-2

N2

N3

N4

N5

N6

N7

N8 N9

N10 N11

N12 Block distance

Comparison of the velocity behavior G60 and G64 with short paths in the blocks

LookAhead takes into account foreseeable velocity limitations such as




velocity limitation in the block

acceleration limitation in the block

velocity limitation at the block transition

synchronization with block change at the block transition

exact stop at the block end upon completion

Method of operation
The LookAhead functionality is only available for the path axes and not for the spindle.

12-256

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Continuous-Path Mode, Exact Stop and LookAhead (B1)


12.5

LookAhead

For safety reasons, the velocity at the block end of each block prepared is first deemed to be
zero, since the following block or an exact stop block could be very small and the axes are to
have reached standstill at the block end point. In a sequence of blocks with a high setpoint
velocity and very short path distances, the velocity in the individual blocks can be increased
depending on the current predicted velocity value, in order to reach the required setpoint velocity, and can then be reduced again, to allow the velocity at the block end point of the last predicted following block to become zero. In this way, you will get a saw-tooth velocity profile,
which can be avoided by reducing the setpoint velocity in the predicted block number (firmly
preset).

Velocity profiles
Apart from the firmly foreseeable velocity limitations, LookAhead can also include the programmed velocity. This allows to pre-emptively attain the smaller velocity beyond the current
block.

Following block velocity


A possible velocity profile includes the detection of the following block velocity. On the basis of
the information from the current and the following NC blocks, a velocity profile is calculated,
from which the required velocity reductions for the current override are deducted. The maximum value of the velocity profile found is limited by the maximum path velocity. This function
allows to start a velocity reduction in the current block taking into account the override, so that
the smaller velocity of the following block can be reached at the beginning of the following
block. If the reduction of the velocity takes longer than the traversing time of the current block,
the speed is further reduced in the following block. The velocity control is always only taken
into account only for the following block.

Selection and deselection of LookAhead


LookAhead is selected by selecting continuous path mode G64 and canceled by G60/G9.

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

12-257

Continuous-Path Mode, Exact Stop and LookAhead (B1)


12.6

Data descriptions (MD, SD)

12.6
12.6.1

Data descriptions (MD, SD)


Channel - specific machine data

29000
LOOKAH_NUM_CHECKED_BLOCKS
MD number
Number of LookAhead blocks
Default: 35
Min. input limit: ***
Max. input limit: ***
Change valid after NEW_CONF
Protection level: 1/7
Unit: Data type: DWORD
Valid from SW release:
Meaning:
Max. number of blocks used with LookAhead for pre-emptive velocity control
Related to ....

12.6.2

Axis - specific machine data

32432**
MD number
Default:

PATH_TRANS_JERK_LIM
Max. axis-specific jerk with path movement at the block transition
1000.00 m/s3
Min. input limit: 0.0
Max. input limit: ***
2777.77 rev./s3
Change valid after NEW_CONF
Protection level: 3/3
Unit: m/s3, rev./s 3
Data type: DOUBLE
Meaning:
MD inapplicable ......
Application example(s)
Related to ....

Valid from SW release:


The control system will limit the jerk (acceleration jump) at the block transition from discontinuously
curved contour elements to the preset value.
Exact stop
Continuous path mode, acceleration type SOFT
MD 32431: MAX_AX_JERK (max. axis-specific jerk with path movement)
It is recommended to set both MDs to the same value.

** This machine data is not available with the 802D base line.

12-258

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Continuous-Path Mode, Exact Stop and LookAhead (B1)


12.7

12.7
12.7.1

Signal descriptions
Channel - specific signals

V3300 00004.3
Data block
Edge evaluation: no
Signal state 1 or edge
change 0 - - -> 1

12.7.2

Signal descriptions

All axes are stopped


Signal(s) from channel (NCK -> PLC)
Signal(s) updated: cyclically
Signal(s) valid from SW release:
All axes of the channel are stopped with interpolator end. No further traversing motions are present.

Axis - specific signals

V390x 0000.6
Data block
Edge evaluation: no
Signal state 1 or edge
change 0 - - -> 1

Signal state 0 or edge


change 1 - - -> 0

Signal inapplicable .....


Related to ....

V390x0000.7
Data block
Edge evaluation: no
Signal state 1 or edge
change 0 - - -> 1
Signal state 0 or edge
change 1 - - -> 0
Signal inapplicable ...
Related to ....

Position reached with exact stop coarse


Signal(s) from axis/spindle (NCK -> PLC)
Signal(s) updated: cyclically
Signal(s) valid from SW release:
The axis is at the appropriate exact stop and no interpolator is active for the axis; furthermore,
- the control system is in reset state (Reset key and/or program end).
- the axis has been programmed last as a positioning spindle.
- the path movement has been terminated by NC stop.
- the spindle is in position-controlled mode and at a standstill.
- the axis is switched from speed-controlled mode to position-controlled mode using the IS Position measuring system.
The axis is not at the appropriate exact stop or the interpolator is active for the axis or
- the path movement has been terminated by NC stop.
- the spindle is in speed-controlled mode.
- Parking mode is active for the axis.
- the axis is switched from position-controlled mode to speed-controlled mode using the IS Position measuring system.
MD 36000: STOP_LIMIT_COARSE (exact stop coarse)

Position reached with exact stop fine


Signal(s) from axis/spindle (NCK -> PLC)
Signal(s) updated: cyclically
See IS Position reached with exact stop coarse.

Signal(s) valid from SW release:

See IS Position reached with exact stop coarse

MD 36010: STOP_LIMIT_FINE (exact stop fine)

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

12-259

Continuous-Path Mode, Exact Stop and LookAhead (B1)


12.8

Data fields, lists

12.8
12.8.1

Data fields, lists


Interface signals

Number

.Bit

Name

Ref.

Channel-specific
V33000004

.3

All axes are at standstill

Axis/spindle-specific
V390x0000

.6

Position reached with exact stop coarse

V390x0000

.7

Position reached with exact stop fine

12.8.2

Machine data

Number

Identifier

Name

Ref.

Channel-specific
29000

LOOKAH_NUM_CHECKED_BLOCKS

Number of LookAhead blocks

Axis/spindle-specific
32431**

MAX_AX_JERK

Max. axis-specific jerk for path movement

B2

32432**

PATH_TRANS_JERK_LIM

Max. axis-specific jerk for path movement at


block transition

36000

STOP_LIMIT_COARSE

Exact stop coarse

A3

36010

STOP_LIMIT_FINE

Exact stop fine

A3

36020

POSITIONING_TIME

Delay time for exact stop fine

A3

** This machine data is not available with the 802D base line.

12-260

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Output of Auxiliary Functions to the PLC (H2)

13.1

13

Brief description

Auxiliary functions
In addition to axis positions and interpolation types, technological functions (feed, spindle
speed, gear step) and functions to control any additional facilities on the machine tool (sleeve
forward, open gripper, clamp chuck) can be specified for the machining of workpieces in the
part program. To this aim, auxiliary functions are provided.
Auxiliary functions are divided into:


Miscellaneous function M

Spindle function S

Auxiliary function H

Tool number T

Tool offset D

Feed F (With SINUMERIK 802D, F is not output to the PLC.)

Output of auxiliary functions to the PLC


The auxiliary function output is used to tell the PLC in due time when the part program wants
to perform, e.g. certain switching actions on the machine tool to be carried out by the PLC.
This is carried out by transferring the appropriate auxiliary functions, including their parameters, to the PLC. The processing of the values and signals transferred must be carried out by
the PLC user program. The individual forms of auxiliary function configuration, programming
and modes of functioning will be described in the following Section.

Auxiliary function groups


Auxiliary functions can be summarized in groups.

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

13-261

Output of Auxiliary Functions to the PLC (H2)


13.2

Programming of auxiliary functions

13.2

Programming of auxiliary functions

General structure of an auxiliary function


Identifier[address extension]=value
The identifiers permitted for auxiliary functions are: M, S, H, T, D, F.
An address extension is only provided for the H function. The address extension must be integer. With direct specification of the address extension using a numerical value, the brackets
may be omitted.
The value for the individual auxiliary functions is defined differently (INT = integer or REAL =
fractional decimal number (floating point)).
Table 13-1
Function

Overview of auxiliary functions; programming


Address extension
(integer)

Value

Explanation

Meaning:

Range

Range

Type

Meaning:

for selected M
functions:

1 ... 2

0 ... 99

INT

Function

Spindle no.
S

Spindle no.

1 ... 2

0 ... 3.4028 ex 38

REAL

Spindle speed

any

0 ... 99

3.4028 ex 38

REAL

any

0-32000

INT

Tool selection

0-9

INT

Tool offset selection

0.001999 999.999

REAL

Feedrate

Certain numbers is assigned a fixed function; the


address extension exists
only for spindle-specific
M functions

Number
per
block

1
These functions have no
effect in the NCK and
must be realized exclusively by the PLC.

1
D0 deselection,
default value D1

1
1

Max. 10 auxiliary functions may be programmed in a block. If the specified ranges or values
for address extension are exceeded or a wrong data type is taken into account, alarm 14770
Auxiliary functions incorrectly programmed is output. The following Table shows some programming examples for H functions.
If the permissible number of auxiliary functions per block is exceeded, alarm 12010 is output.
Table 13-2

13-262

Programming examples for H functions

Programming

H function output to the PLC

H5

H0=5.0

H=5.379

H0=5.379

H17=3.5

H17=3.5

H5.3=21

Error, alarm 14770

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Output of Auxiliary Functions to the PLC (H2)


13.3

Transfer of values and signals to the PLC interface

Block change
The NCK can carry out a new auxiliary function output to the PLC only after the PLC has acknowledged all auxiliary functions transferred.
A block is only considered completed if the programmed movement has been completed and
the auxiliary function has been acknowledged. To this aim, the NCK stops the execution of the
part program (if necessary) to ensure that no auxiliary functions get lost from the view of the
PLC user program.

13.3

Transfer of values and signals to the PLC interface

Transfer time
Auxiliary functions output at the end of the block (e.g. M2) are only output if all axes and
SPS movements of the spindle are completed.
If several auxiliary functions with different output types (prior to, during, at the end of the movement) are programmed in a block that contains movements, the individual auxiliary functions are output depending on their particular output type.
In a block without traversing movements, the auxiliary functions are output immediately as a
block.

Continuous -path mode


A path movement only remains continuously if the auxiliary function is output during the movement and has been acknowledged from the PLC prior to the end of the path.
References:

Chapter Continuous-Path Mode, Exact Stop, LookAhead

Interface signals
Provision of the signals from the NCK to the PLC: see Section 13.8 Signal descriptions

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

13-263

Output of Auxiliary Functions to the PLC (H2)


13.4

13.4

Division of auxiliary functions into groups

Division of auxiliary functions into groups

Functionality
The auxiliary functions of the M, H, D, T and S types, which are to be output, can be divided
into auxiliary function groups using machine data.
One auxiliary function may be assigned only one group.
Only one auxiliary function may be programmed per group. Otherwise, alarm 14760 is output.

Configuration
A max. of 64 auxiliary function groups can be defined.
These 64 auxiliary functions groups can be assigned max. 64 auxiliary functions. The auxiliary
functions that are assigned default values (groups 1 to 3) will not be taken into account.
The actual number of auxiliary functions, which have been distributed over the groups, are
entered in the NCK-specific MD 11100: AUXFU_MAXNUM_GROUP_ASSIGN (number of
auxiliary functions distributed over the AUXFUNC groups). To this aim, level 2 password must
be set. Then the control system must be turned off and turned on again (POWER ON). Only
now the following machine data with index n greater than zero are available, and further values can be entered.
An auxiliary function assigned is defined in the following machine data:
MD 22000: AUXFU_ASSIGN_GROUP[n]
Auxiliary function group
MD 22010: AUXFU_ASSIGN_TYPE[n]
Auxiliary function type
MD 22020: AUXFU_ASSIGN_EXTENSION[n]
Auxiliary function extension
MD 22030: AUXFU_ASSIGN_VALUE[n]
Auxiliary function value

Defaulted auxiliary function groups


Group 1:
The auxiliary functions M0, M1 and M2 (M17, M30) are assigned to group 1 by default. The
output is always carried out at the block end.
Group 2:
The M functions M3, M4 and M5 (M70) are assigned to group 2 by default. The output is always carried out before the motion.
Group 3:
The S function is assigned to group 3 by default. This group and all further groups are output
in parallel with the movement.

User-defined groups
All further groups (user-defined) are output with the movement.
The output settings can only be modified with Expert mode access (protection level 1).

Non -grouped auxiliary functions


The output of auxiliary functions that are not contained in groups is carried out with the movement.

13-264

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Output of Auxiliary Functions to the PLC (H2)


13.5

Behavior on block search

Configuration sample
Distribute 8 auxiliary functions over 7 groups:
Group 1: M0, M1, M2 (M17, M30) - by default, should be kept
Group 2: M3, M4, M5 (M70) - by default, should be kept
Group 3: S functions - by default, should be kept
Group 4: M78, M79
Group 5: M80, M81
Group 6: H1=10, H1=11 H1=12
Group 7: all T functions
The password for protection level 2 is set. Make the appropriate entry in MD 11100:
AUXFU_MAXNUM_GROUP_ASSIGN = 8. Then turn off the control system and turn it on
again or use the appropriate softkey to power up the control and program the remaining machine data; then reboot the control system.
Table 13-3

Entries in the machine data for the sample above

Index n

MD 22000
(GROUP)

MD 22010
(TYPE)

MD22020
(EXTENSION)

MD22030
(VALUE)

78

79

80

81

10

11

12

-1

13.5

Behavior on block search

Block search with calculation


With block search with calculation, all auxiliary functions assigned to a group are collected
and output at the end of the block search prior to the restart block (except for group 1: M0,
M1,...).
In any case the last auxiliary function of a group is output.
All auxiliary functions collected are output as normal auxiliary functions in a separate block
prior to the movement.
Important: To collect all auxiliary functions during a block search, they must be assigned to
an auxiliary function group!

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

13-265

Output of Auxiliary Functions to the PLC (H2)


13.6

13.6

Description of the auxiliary functions

Description of the auxiliary functions

13.6.1

M function

Application
The M functions can be used to enable most varied switching operations on the machine via
part program.

Scope of functions

13.6.2

A number of 5 M functions is possible per part program block.

Range of values of M functions: 0 to 99; integer

A minor part of M functions is assigned a fixed functionality defined by the control manufacturer (see Users Guide Operation and Programming). The remaining functions are
free for use by the machine manufacturer.

T function

Application
The T function can be used by the PLC to load the tool required for a certain section of the
machining program. Whether a tool change is to be carried out directly using the T command
or using a following M6 command can be set using MD 22550: TOOL_CHANGE_MODE..
The programmed T function can be interpreted either as a tool number or as a location number.
References:

Section Tool compensation

Scope of functions
A maximum of 1 T function is possible per part program block.

Special feature
T0 is reserved for the following function: Remove current tool from the tool holder and do not
change a new tool.

13.6.3

D function
The D function can be used to select the tool compensation for the active tool. The tool compensations are described in detail:
References:

13-266

Operation and Programming

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Output of Auxiliary Functions to the PLC (H2)


13.6

13.6.4

Description of the auxiliary functions

H function

Application
The H functions can be used to transfer various values from the part program to the PLC. The
assignment of the functions is left up to the user.

Scope of functions

13.6.5

3 H functions are possible per part program block.

Range of values of the H functions: Floating point data (such as arithmetic parameters R)

Adreerweiterung 0 bis 99 (H0=... bis H99=...) mglich

S function
The S function is used to set the speed for the spindle with M3 or M4. For lathes with G96
(constant cutting rate), the cutting value is set.
References:

Operation and Programming

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

13-267

Output of Auxiliary Functions to the PLC (H2)


13.7

13.7
13.7.1

Data descriptions (MD, SD)

Data descriptions (MD, SD)


General machine data

11100
AUXFU_MAXNUM_GROUP_ASSIGN
MD number
Number of auxiliary functions distributed over the AUXFUNC groups
Default: 1
Min. input limit: 1
Max. input limit: 64
Change valid after Power On
Protection level: 2/2
Unit: Data type: BYTE
Valid from SW release:
Meaning:
The number of auxiliary functions, which have been distributed over the groups, are to be
entered in the MD. Only the customer-specific auxiliary functions are taken into account,
not the predefined auxiliary functions.
Application example(s)
Related to ....
MD 22010: AUXFU_ASSIGN_TYPE[n]

13.7.2

Channel - specific machine data

22000
AUXFU_ASSIGN_GROUP[n]
MD number
Auxiliary function group [ aux. fu. no. in channel ]: 0...63
Default: 1
Min. input limit: 1
Max. input limit: 64
Change valid after Power On
Protection level: 2/7
Unit: Data type: BYTE
Valid from SW release:
Meaning:
see MD: AUXFU_ASSIGN_TYPE [n] (auxiliary function type)
Application example(s)

13-268

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Output of Auxiliary Functions to the PLC (H2)


13.7

Data descriptions (MD, SD)

22010
AUXFU_ASSIGN_TYPE[n]
MD number
Auxiliary function type [aux. fu. no. in channel]: 0...63
Default: Min. input limit: Max. input limit: 1 character
Change valid after Power On
Protection level: 2/7
Unit: Data type: STRING
Valid from SW release:
Meaning:
This MD (auxiliary function type), MD 22020: AUXFU_ASSIGN_EXTENSION[n] (auxiliary
function extension), MD 22030: AUXFU_ASSIGN_VALUE[n] (auxiliary function value) and
MD 22000: AUXFU_ASSIGN_GROUP[n] (auxiliary function group) are used to assign an
auxiliary function type (M, H, T, D, S) the appropriate extension and to assign the auxiliary
function value an auxiliary function group.
Example:
M 0 = 99 => group 5 (corr. to M100)

Auxiliary function type


Auxiliary function extension
Auxiliary function value
Auxiliary function group
MD: AUXFU_ASSIGN_TYPE[0] = M
MD: AUXFU_ASSIGN_EXTENSION[0] = 0 ; only for type H; also other values
MD: AUXFU_ASSIGN_VALUE[0] = 99
MD: AUXFU_ASSIGN_GROUP[0] = 5
; ( 5th group)

M00, M01, M02, (M17 and M30) are assigned to group 1 by default. M3, M4, M5 and are
assigned to group 2 by default.

Application example(s)
Special cases, errors, ......
Related to ....

Index [n] of the machine data always designates the auxiliary function number in the channel: 0-63.
All auxiliary functions assigned to auxiliary function groups must be numbered in the ascending order.
[0]1st auxiliary function
[1] 2nd
,,
...
All machine data required for assigning an auxiliary function to an auxiliary function group
must have the same index [
n].
see Section 13.4
If the auxiliary function value of an auxiliary function is less than 0, all auxiliary functions of this
type and extension are assigned to a group.
MD 11100: AUXFU_MAXNUM_GROUP_ASSIGN

22020
AUXFU_ASSIGN_EXTENSION[n]
MD number
Auxiliary function extension [Aux. fu. in channel]: 0...63
Default: 0
Min. input limit: 0
Max. input limit: 99
Change valid after Power On
Protection level: 2/7
Unit: Data type: BYTE
Valid from SW release:
Meaning:
See MD 22010: AUXFU_ASSIGN_TYPE [n] (auxiliary function type)
Application example(s)

22030
AUXFU_ASSIGN_VALUE[n]
MD number
Auxiliary function value [Aux. fu. in channel]: 0...63
Default: 0
Min. input limit: ***
Max. input limit: ***
Change valid after Power On
Protection level: 2/7
Unit: Data type: DWORD
Valid from SW release:
Meaning:
If the value in this MD is less than 0, all auxiliary functions of this type and of this address extension are assigned to this group.
further see MD 22010: AUXFU_ASSIGN_TYPE[n] (auxiliary function type)
Application example(s)
see Section 13.4

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

13-269

Output of Auxiliary Functions to the PLC (H2)


13.8

13.8

Signal descriptions

Signal descriptions

V2500 0004. 0 to .4
V2500 0006.0
V2500 0008.0
V2500 0010.0
V2500 0012.0 to .2
Interface signal
Edge evaluation: no
Signal state 1

M funct. changes 1 to 5
S funct. change 1
T funct. change 1
D funct. change 1
D funct. changes 1 to 3
Signal(s) from channel (NCK - -> PLC)
Signal(s) updated: cyclically
Signal(s) valid from SW release:
An M, S ,T, D, H information has been output to the interface together with a new value and the
corresponding change signal. The change signal indicates that the corresponding value is valid.
The change signals are only valid for one PLC cycle, i.e. if the signal is 1, a change is pending
for this cycle.

Signal state 0
The value of the appropriate information is not valid.
VD2500 2000
Interface signal
Edge evaluation: no
Signal state 1

Signal state 0
Application example(s)
Special cases, errors,
......

VB2500 1000 to
VB2500 1012
Interface signal
Edge evaluation: no
Signal state 1
Signal state 0
Application example(s)
Related to ...

VD2500 3000
VD2500 3008
VD2500 3016
VD2500 3024
VD2500 3032
VD2500 3012
VD2500 3020
VD2500 3028
VD2500 3036
Interface signal
Edge evaluation: no
Signal state 1

Signal state 0
Related to ....

13-270

T function1
Signal(s) from channel (NCK - -> PLC)
Signal(s) updated: job-controlled
Signal(s) valid from SW release:
from NCK
Once the T change signal is provided, this machine data provides the T function programmed in
an NC block.
Range of values of T function: 0-32000; integer
The T function remains stored until it is overwritten by a new T function.
after power up of the PLC.
Before a new auxiliary function is entered, the remaining functions are deleted.
Control of automatic tool selection.
With T0, the current tool is removed from the tool mount and no new tool is changed (default
configuration of machine manufacturer).

Decoded M signals: M0 - M99


Signal(s) from channel (NCK - -> PLC) Synchronous actions (S5)|Signals
Signal(s) updated: cyclically
Signal(s) valid from SW release:
The dynamic M signal bits are set using decoded M functions.
In case of a general auxiliary function output, the dynamic M signal bits are acknowledged by
the PLC system program after the user program has been passed completely.
Spindle CW/CCW rotation, coolant ON/OFF.
IS M function for spindle (DINT), axis-specific (VD370x 0000)

M function 1
M function 2
M function 3
M function 4
M function 5
Extended address of M function 1
Extended address of M function 2
Extended address of M function 3
Extended address of M function 4
Extended address of M function 5
Signal(s) from channel (NCK - -> PLC)
Signal(s) updated: job-controlled from
Signal(s) valid from SW release:
NCK
This machine data provides up to 5 M functions programmed in a block at a time once the M
change signals are provided.
Range of values of the M functions: 0 to 99; integer
Range of values of the extended address: 1 ... 2; integer (spindle number)
The M functions remain stored until they are overwritten by new M functions.
after power up of the PLC.
Before a new auxiliary function is entered, the remaining functions are deleted.
IS M function for the spindle (DINT), axis-specific (VD370x 0000)

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Output of Auxiliary Functions to the PLC (H2)


13.8

VD2500 4000
VD2500 4008
VD2500 4004
VD2500 4012
Interface signal
Edge evaluation: no
Signal state 1

Signal state 0
Related to ....

VD2500 5000
Interface signal
Edge evaluation: no
Signal state 1

Signal state 0
Application example(s)
Special cases, errors, ......

VD2500 6000
VD2500 6008
VD2500 6016
VW2500 6004
VW2500 6012
VW2500 6020
Interface signal
Edge evaluation: no
Signal state 1

Signal state 0
Application example(s)

Signal descriptions

S function 1
S function 2
Extended address of S function 1
Extended address of S function 2
Signal(s) from channel (NCK - -> PLC)
Signal(s) updated: job-controlled from
Signal(s) valid from SW release:
NCK
The programmed S function is made available here in an NC block (speed or cutting value for
G96), as soon as the S change signal is present.
Range of values of S function: floating point (REAL format/4-byte))
The S function is kept, until it is overwritten by a new S function.
after power up of the PLC.
Before a new auxiliary function is entered, the remaining functions are deleted.
IS S function for the spindle (REAL), axis-specific (VD370x 0004)

D function 1
Signal(s) from channel (NCK - -> PLC)
Signal(s) updated: job-controlled from
Signal(s) valid from SW release:
NCK
Once the D change signal is provided, this machine data provides the D function programmed in
an NC block.
Range of values of D function: 0-9; integer
The D function remains stored until it is overwritten by a new D function.
after power up of the PLC.
Before a new auxiliary function is entered, the remaining functions are deleted.
D0 is reserved for the deselection of the current tool offset.

H function 1
H function 2
H function 3
Extended address of H function 1
Extended address of H function 2
Extended address of H function 3
Signal(s) from channel (NCK - -> PLC)
Signal(s) updated: job-controlled from
Signal(s) valid from SW release:
NCK
This machine data provides up to 3 H functions programmed in a block at a time once the H
change signals are provided.
Range of values of H function: Floating point (REAL-Format/4-byte)
Range of values of the extended address: 0 to 99; integer
The H functions remain stored until it is overwritten by a new H function.
after power up of the PLC.
Before a new auxiliary function is entered, the remaining functions are deleted.
Switching operations on the machine.

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

13-271

Output of Auxiliary Functions to the PLC (H2)


13.9

Data fields, lists

13.9

Data fields, lists

13.9.1

Interface signals

Number

.Bit

Name

Ref.

Channel-specific
V2500 0000

.0 to .4

M function 1 change to M function 5 change

V2500 0006

.0

S function 1 change

V2500 0008

.0

T function 1, change

V2500 0010

.0

D function 1, change

V2500 0012

.0 to .2

H function 1 change to H function 3 change

VD2500 2000

T function 1 (DInt)

VD2500 3000

M function 1 (DInt)

VD2500 3004

Extended address of M function 1 (byte)

VD2500 3008

M function 2 (DInt)

VD2500 3012

Extended address of M function 2 (byte)

VD2500 3016

M function 3 (DInt)

VD2500 3020

Extended address of M function 3 (byte)

VD2500 3024

M function 4 (DInt)

VD2500 3028

Extended address of M function 4 (byte)

VD2500 3032

M function 5 (DInt)

VD2500 3036

Extended address of M function 5 (byte)

VD2500 4000

S function 1 (REAL format)

VD2500 4004

Extended address of M function 2 (byte)

VD2500 4008

S function 2 (REAL format)

VD2500 4012

Extended address of M function 2 (byte)

VD2500 5000

D function 1 (DInt)

VB2500 6004

Extended address of H function 1 (dual)

VD2500 6000

H function 1 (REAL format)

VB2500 6012

Extended address of H function 2 (dual)

VD2500 6008

H function 2 (REAL format)

VB2500 6020

Extended address of H function 3 (dual)

VD2500 6016

H function 3 (REAL format)

V2500 1000

.0 - .7

Dynamic M function: M00-M07

V2500 1001

.0 - .7

Dynamic M function: M08-M15

V2500 1012

.0 - .7

Dynamic M function: M96- M99

VD370x 0000

M function for the spindle (DINT), axis-specific

S1

VD370x 0004

S function for the spindle (REAL), axis-specific

S1

to

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Output of Auxiliary Functions to the PLC (H2)


13.9

13.9.2
Number

Data fields, lists

Machine data
Identifier

Name

11100

AUXFU_MAXNUM_GROUP_ASSIGN

Number of auxiliary functions distributed over the AUXFUNC groups

22000

AUXFU_ASSIGN_GROUP[n]

Auxiliary function group

22010

AUXFU_ASSIGN_TYPE[n]

Auxiliary function type

22020

AUXFU_ASSIGN_EXTENSION[n]

Auxiliary function extension

22030

AUXFU_ASSIGN_VALUE[n]

Auxiliary function value

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6FC5 697-2AA10-0BP2 (11.03) (DF)

Ref.

13-273

Output of Auxiliary Functions to the PLC (H2)


13.9

Data fields, lists

notice

13-274

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Tool: Compensation and Monitoring (W1)

14.1

14

Overview: Tool and tool compensation

Characteristics
With the SINUMERIK 802D control system, tool compensation data can be taken into account
for various tool types (drill, milling tool, turning tool, ...).


Length compensation

Radius compensation

Storage of the tool compensation data in the tool offset memory


-

Tool identification by T numbers from 0 to 32000

Definition of a tool with a maximum of 9 cutting edges (compensation data blocks)


using a T number

Cutting edge is described by tool parameters:


- Tool type
- Geometry: Length
Wear: Length
- Geometry: Radius
Wear: Radius
- Cutting edge position (with turning tools)

Tool change can be selected: either immediately using a T command or using M6

Tool radius compensation


-

The compensation is active for all interpolation types: Linear and circular

The compensation can be selected on external corners: Transition circle (G450) or


intersection point of the equidistants (G451)

Automatic detection of outer/inner corners

Detailed description:
References:

Operation and Programming

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Tool: Compensation and Monitoring (W1)


14.2

14.2

Tool

Tool

Selecting a tool
The T function is used to select a tool in the program. Whether the new tool is loaded immediately using the T function or using M6, depends on the setting in MD 22550:
TOOL_CHANGE_MODE (new tool compensation with M function).

Range of values for T


The T function may have integer values from T0 (no tool) to T32000 (tool with number 32000).
A maximum of 32 tools can be stored in the CNC at a time.

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Tool: Compensation and Monitoring (W1)


14.3

14.3

Tool compensation

Tool compensation

Tool compensation using the D function


A tool may have up to 9 cutting edges. The 9 cutting edges are assigned to the D functions
D1 to D9.
A maximum of 64 tool compensation data blocks can be stored, which divide over the individual tools.
The cutting edge is programmed using D1 (edge 1) to D9 (edge 9). The tool cutting edge always refers to the tool currently active. An active tool cutting edge (D1 to D9) without active
tool (T0) will not be active. A cutting edge D0 will cancel all tool compensations of the tool currently active.

Edge selection during tool change


After programming a new tool (new T number) and changing this tool, the cutting edge can be
selected using the following options:
1. Programm the cutting edge number.
2. Do not program the cutting edge number. D1 is active automatically.

Enabling the tool compensation


D1 to D9 are used to enable the tool compensation for the tool edge of the tool currently active. The tool length compensation and the tool radius compensation, however, come into effect at different times:


The tool length compensation (TLC) will be realized with the first traversing movement of
the axis for which the TLC is to be active. This traversing movement must be a linear interpolation (G0, G1).

The tool radius compensation (TRC) will be active by programming G41/G42 in the active
plane (G17, G18 or G19). The TRC with G41/G42 may only be carried out in a program
block that contains G0 (rapid traverse) or G1 (linear interpolation).

For a detailed description of the tool compensation including tool radius compensation, see:
References:

Operation and Programming, Chapter Tool and Tool Compensation

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14-277

Tool: Compensation and Monitoring (W1)


14.4

14.4

Tool monitoring

Tool monitoring

Note
This function is not available with the 802D base line.

14.4.1

Overview: Tool monitoring

General
The tool monitoring is activated via the following machine data - provided that the required
option exists:
MD 18080: MM_TOOL_MANAGEMENT_MASK - bit 1 =1
MD 20310: TOOL_MANAGEMENT_MASK - bit 1 =1
The Tool monitoring function does not require an active tool management; with SINUMERIK
802D, it offers the following monitoring methods of the active cutting edge of the active tool:


Monitoring of the tool life

Monitoring of the workpiece count

All of the above mentioned monitoring functions can be activated for a tool simultaneously.

Monitoring counter
Monitoring counters have been implemented for each monitoring method. The monitoring counters run from a set value > 0 towards zero. If a monitoring counter reaches the value <= 0,
the limit value is deemed to be reached; an appropriate alarm message is issued and an interface signal is output.
First, another interface signal is output when a cutting edge of a tool has reached the prewarning limit specified for this tool.

System variable for monitoring type and status

14-278

$TC_TP8[t] - status of the tool with number t:


Bit 0 =1: tool is active
=0: replacement tool
Bit 1 =1: tool is enabled
=0: not enabled
Bit 2 =1: tool is disabled
=0: not disabled
Bit 3 : reserved
Bit 4 =1: Prewarning limit reached
=0: not reached

$TC_TP9[t] - type of the monitoring function for the tool with number t :
= 0:
no monitoring
= 1:
life time of the monitored tool
= 2:
count of the monitored tool

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Tool: Compensation and Monitoring (W1)


14.4

Tool monitoring

These system variables can be read / written in the NC program and be addressed via the
operation (HMI). Since the Tool management function package is not available with the
SINUMERIK 802D, it is the operators/programmers own responsibility to manage these system parameters.
For the operation (HMI), see the following references: Operation and Programming

System variable for tool monitoring data


Table 14-1

Tool monitoring data

Identifier

Description

Data Type

Default

$TC_MOP1[t,d]

Prewarning limit Tool life in minutes

REAL

0.0

$TC_MOP2[t,d]

Remaining tool life in minutes

REAL

0.0

$TC_MOP3[t,d]

Count prewarning limit

INT

$TC_MOP4[t,d]

Remaining count

INT

...

...

$TC_MOP11[t,d] Desired tool life

REAL

0.0

$TC_MOP13[t,d] Desired count

REAL

0.0

t for tool number T, d for D number

System variable for active tool


The following can be read in the NC program via a system variable:


$P_TOOLNO - number of the active tool T

$P_TOOL - active D number of the active tool

Interface signals
Some monitoring states are provided to the PLC/user:


Tool prewarning limit reached (V5300 0000.0)

Tool limit value reached (V5300 0000.1)

T number for tool prewarning limit (VD5300 1000)

T number for tool limit value (VD5300 1004)

The workpiece counter can be turned off from the PLC:




Turn off workpiece counter (V3200 0013.5)

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14-279

Tool: Compensation and Monitoring (W1)


14.4

14.4.2

Tool monitoring

Tool life monitoring


The tool life is monitored for the tool cutting edge currently in use (active cutting edge D of the
tool T currently active).
Once the path axes traverse (G1, G2. G3, ... but not with G0), the remaining tool life
($TC_MOP2[t,d] ) of this too cutting edge is updated. If during machining the remaining tool
life of a cutting tool is managed under the value of Tool life prewarning limit"
($TC_MOP1[t,d] ), the IS Tool prewarning limit reached (V5300 0000.0) and the IS T number for tool prewarning limit are set (VD5300 1000).
If the remaining tool life <= 0 , an alarm is output, as well as the IS Tool limit value reached
(V5300 000.1) and T number for tool limit value (VD5300 1004) are set. Following, the tool
will change to the Disabled status and can now no longer be reprogrammed until the Disabled status is not canceled. Now, the operator must intervene and either replace the tool or
make sure that a tool is available for machining again.

$A_MONIFACT system variable


Using the $A_MONIFACT system variable (REAL data type), it is possible to let the monitoring clock slower or faster. This factor can be set before using the tool, e.g. to take into account the different wear according to the workpiece material used.

After power-up of the control system, Reset/end of program, the factor $A_MONIFACT
has the value 1.0; real time is active.
Examples showing how the system variable is taken into account:
$A_MONIFACT=1 1 minute of real time = 1 minute of tool life which is decremented
$A_MONIFACT=0.1 1 minute of real time = 0.1 minute of tool life which is decremented
$A_MONIFACT=5 1 minute of real time = 5 minutes of tool life which are decremented

Updating the setpoint using RESETMON( )


The function

RESETMON(state, t, d, mon)
will set the actual value to the setpoint:
- either for all cuttting edges of a certain tool or only for one certain edge
- either for all or only for a certain monitoreing type

transfer parameters:
INT state
Status of the command execution:
= 0
Successful execution
= -1
The cutting edge with the specified D number does not exist.
= -2
The tool with the specified T number t does not exist.
= -3
The specified tool t does not provide a defined monitoring function.
= -4
The monitoring function is not enabled, i.e. the command will not be carried
out.

14-280

INT

t
=0
<> 0

Internal T number:
for all tools
for this tool ( t < 0 : generating the absolute amount |t|)

INT

d
optional: D number of the tool with the number t:
>0
for this D number
without d / = 0 all cutting edges of tool t

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Tool: Compensation and Monitoring (W1)


14.4

INT

Tool monitoring

mon

optional: bit-coded parameter for monitoring type (values analogous to


$TC_TP9):
= 1:
Life time
= 2:
Count
without mon or = 0: All actual values of the monitoring functions enabled for tool t are
set to the setpoints.

Notes:

14.4.3

RESETMON( ) is ineffective with the interface signal Program test active set.

The variable for the status checkback message state must be defined at the beginning
of the program using a DEF statement:
DEF INT state
It is also possible to define a different name for the variable (instead of state, but at
least 15 characters, starting with 2 letters). The variable is only available in the program
where it was defined.
This also applies to mon. If a specification is required here at all, this can also be transferred directly as a number (1 or 2).

Workpiece count monitoring


The active cutting edge of the tool currently active is monitored for the workpiece count.
The monitoring of the workpiece count includes all tool cutting edges used to manufacture a
workpiece. If the count changes as a result of a specification by the operator, the monitoring
data of all tool cutting edges which have become active since the last workpiece counting will
be adapted accordingly.

Updating the count via operation or SETPIECE( )


The workpiece count can be updated either via operation (HMI) or using the SETPIECE( )
language command in the NC program.
Using the SETPIECE function, the user can update the count monitoring data of the tools involved in the machining process. All tools which have been enabled since the last activation
of SETPIECE are acquired with their D numbers. If a tool is active at the moment when
SETPIECE is called, this is also taken into account.
Once a block containing path axis motions is executed after SETPIECE( ), this tool will also
be taken into account for the next SETPIECE call.
SETPIECE(x ) ;
x : = 1... 32000

x:=0

Number of the workpieces produced since the last execution of the


SETPIECE function. The count for the remaining count ($TC_MOP4[t,d] )
will be reduced by this value.
Cancels all counters for the remaining count ($TC_MOP4[t,d] ) for the tools/
D number involved in the machining since then.
Alternatively, it is recommended to reset the counters via the operation
(HMI).

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14-281

Tool: Compensation and Monitoring (W1)


14.4

Tool monitoring

Example:
N10 G0 X100
N20 ...
N30 T1
N40 M6 D2
N50 SETPIECE(2)
N60 X... Y...
N100 T2
N110 M6 D1
N120 SETPIECE(4)
N130
N200
N210
N220

X... Y...
T3
M6 D2
SETPIECE(6)

N230 X... Y...


N300 SETPIECE(0)
N400 M2

;$TC_MOP4[1,2 ] (T1,D2) is decremented by 2

;$TC_MOP4[2,1 ] (T2,D1) and $TC_MOP4[1,2 ] are


decremented by 4

;$TC_MOP4[3,2 ] (T3,D2) and $TC_MOP4[2,1 ] (T2,D1) and


$TC_MOP4[1,2 ] are decremented by 6
;deletion of all $TC_MOP4[t,d ] above

Notes:
-

The command SETPIECE( ) does not act in block search.

Programming $TC_MOP4[t,d] directly is only recommended in a simple case. This


would require to program a subsequent block containing the STOPRE command.

Updating the setpoints


Updating the setpoints, i.e. setting of the remaining quantity counters ($TC_MOP4[t,d]) to the
desired count ($TC_MOP13[t,d]), is usually carried out via operation (HMI). This, however,
can also be carried out, as already described for the tool life monitoring, via the RESETMON
function ( state, t, d, mon).
Example:
DEF INT state

; Definition of a variable for the status checkback message at the beginning


of the program

...
N100 RESETMON(state,12,1,2) ;Setpoint update of the workpiece counter for T12, D1
...

14.4.4

Examples for tool life monitoring


1. Activate the tool monitoring function (provided that the tool monitoring function
(option) is installed:
MD 18080: MM_TOOL_MANAGEMENT_MASK = 0x02
MD 20310: TOOL_MANAGEMENT_MASK= 0x02
2. Tool life monitoring for tool 2, cutting edge 1 in the NC program:
$TC_TP9[2,1]=1
; activation of tool life monitoring
$TC_MOP1[2,1]=100
; prewarning limit in minutes
$TC_MOP2[2,1]=245
; remaining tool life in minutes
$TC_MOP11[2,1]=800
; tool life setpoint in minutes

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Tool: Compensation and Monitoring (W1)


14.4

Tool monitoring

Another example for the tool life monitoring for the active tool with active D number in the
NC program:
$TC_TP9[$P_TOOLNO,$P_TOOL]=1
; activation of tool life monitoring
$TC_MOP1[ $P_TOOLNO,$P_TOOL]=200 ; prewarning limit in minutes
$TC_MOP2[ $P_TOOLNO,$P_TOOL]=602 ; remaining tool life in minutes
$TC_MOP11[$P_TOOLNO,$P_TOOL]=700 ; tool life setpoint in minutes

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6FC5 697-2AA10-0BP2 (11.03) (DF)

14-283

Tool: Compensation and Monitoring (W1)


14.5

14.5

Special cases of tool compensations

Special cases of tool compensations


With SINUMERIK 802D, SW 2.0 and higher, the following special cases are offered for the
tool compensation.

Influence of setting data


Using certain setting data, the operator / programmer may influence how the length compensation value of the tool used will be taken into account:


SD 42940: TOOL_LENGTH_CONST
(assignment of the tool length compensations to the geometry axes)

SD 42950: TOOL_LENGTH_TYPE
(assignment of the tool length compensations irrespective of the tool type)

Note: The changed setting data will come into effect with the next cutting edge selection.

Tool length and plane change (SD 42940: TOOL_LENGTH_CONST)


Value of the setting data equal to 0:
The behavior is according to the standard definition: The lengths 1 to 3, both in the geometry
and for the wear, are assigned as fixed values to the abscissa, ordinate or applicate according
to the G17 to G19 currently active and according to the relevant tool type. If the active G17 to
G19 changes, the axis assignment will also change to the lengths 1 to 3, since abscissa, ordinate and applicate will thus be assigned to other geometry axes.
Detailed explanations:

References:

Operation and Programming

Value of the setting data unequal to 0:


The assignment of the tool lengths 1 to 3 both for the geometry and for the wear to the geometry axes is carried out according to the SD value and will not be changed when changing
the machining plane (G17 to G19).
The assignment of the tool lengths 1 to 3 to the geometry axes for turning tools (tool types
500 to 599) results from the value of the setting data SD 42940 according to the table below:
Plane/Value
17
18*)
19
-17
-18
-19

Length 1
Y
X
Z
X
Z
Y

Length 2
X
Z
Y
Y
X
Z

Length 3
Z
Y
X
Z
Y
X

*) Each value unequal to 0, which is not equal to one of the six values mentioned above, is
evaluated as the value with 18.
In the case of values with a negative sign, the assignment with regard to length 3 is always
the same; the lengths 1 and 2 are changed, compared with the assignment with the relevant
positive values.

14-284

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Tool: Compensation and Monitoring (W1)


14.5

Special cases of tool compensations

The table below shows the assignment of the tool lengths 1 to 3 to the geometry axes for a
drill / milling tool (tool types 100 to 299):
Plane/Value
17*)
18
19
-17
-18
-19

Length 1
Z
Y
X
Z
Y
X

Length 2
Y
X
Z
X
Z
Y

Length 3
X
Z
Y
Y
X
Z

*) Each value unequal to 0, which is not equal to one of the six values mentioned above, is
evaluated as the value with 17.
In the case of values with a negative sign, the assignment with regard to length 1 is always
the same; the lengths 2 and 3 are changed, compared with the assignment with the relevant
positive values.
Note:
The representation in the tables is based on the assumption that the geometry axes 1 to 3 are
designated X, Y, Z. The assignment of a compensation to an axis depends not on the axis
identifier, but on the axis sequence order (1st, 2nd, 3rd geometry axis).

Length compensation for tool type (SD 42950: TOOL_LENGTH_TYPE)


Value of the setting data equal to 0:
The behavior is according to the standard definition: The lengths 1 to 3 both for the geometry
and for the wear are assigned to the real tool type (milling tool / drill or turning tool).
Detailed explanation:

References:

Operation and Programming

Value of the setting data unequal to 0:


The assignment of the tool lengths is carried out irrespective of the real tool type.
Value 1:
Length assignment always as with milling tools
Value 2:
Length assignment always as with turning tools

Notes


The influence of these two setting data only refers to tool lengths; the tool radius is not
concerned.

If SD 42940: TOOL_LENGTH_CONST is set to a value not euqal to 0 and the value in


SD 42950: TOOL_LENGTH_TYPE is equal to 1 or 2, the value specified in the table for
SD 42940 will apply to the tool type now assigned (milling or turning tool).

Example
SD 42940: TOOL_LENGTH_CONST =18
SD 42950: TOOL_LENGTH_TYPE =2

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14-285

Tool: Compensation and Monitoring (W1)


14.5

Special cases of tool compensations

Explanation:
The behavior of the active tool with regard to the length compensation is as a turning tool
(-> SD 42950 =2).
In all planes G17 to G19, the length assignment is carried out as with G18 (-> SD 42940=18):
Length 1 -> X axis
Length 2 -> Z axis
if a Y axis exists:
Length 3 -> Y axis
The tool radius acts according to the real tool type and according to the plane currently active.

14-286

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Tool: Compensation and Monitoring (W1)


14.6

14.6

Data descriptions (MD, SD)

Data descriptions (MD, SD)

18080**
MM_TOOL_MANAGEMENT_MASK
MD number
Memory reservation for the tool monitoring
Default: 0x0
Min. input limit: 0x0
Max. input limit: 0xFFFF
Change valid after Power On
Protection level: 2/2
Unit: Data type: DWORD
Valid from SW release: 2.0
Meaning:
Value = 0:
No memory will be reserved; no tool monitoring possible
Value = 0x2: monitoring data/memory will be provided
(only possible with the Tool monitoring option)
Related to ....

MD 20310: TOOL_MANAGEMENT_MASK

** This machine data is not available with the 802D base line.
20310**
TOOL_MANAGEMENT_MASK
MD number
Activation of tool monitoring
Default: 0x0
Min. input limit: 0x0
Max. input limit: 0xFFFF
Change valid after Power On
Protection level: 2/2
Unit: Data type: DWORD
Valid from SW relase: 2.0
Meaning:
Wert = 0:
No tool monitoring
Wert = 0x2:
Tool monitoring activated
(only possible with the Tool monitoring option)
Related to ....

MD 18080: MM_TOOL_MANAGEMENT_MASK

** This machine data is not available with the 802D base line.

20360
TOOL_PARAMETER_DEF_MASK
MD number
Definition of tool parameters
Default: 0
Min. input limit: 0
Max. input limit: 0x01
Change valid after Power On
Protection level: 2/2
Unit: Data type: DWORD
Valid from SW release: 1.1
Meaning:
Bit 0=0: With turning tools, the wear parameter of the transverse axis X is taken into account as
a radius value.
Bit 0=1: With turning tools, the wear parameter of the transverse axis X is taken into account as
a diameter value.
Special cases, errors, ......

22550
TOOL_CHANGE_MODE
MD number
New tool compensation with M function
Default: 0
Min. input limit: 0
Max. input limit: 1
Change valid after Power On
Protection level: 2/2
Unit: Data type: BYTE
Valid from SW release:
Meaning:
A tool is selected in the program using the T function. Whether the new tool is changed
immediately using the T function, depends on the setting in this MD:
0:
The new tool is loaded immediately using the T function. For turning machines with tool
revolver, in most cases, this setting is used.
1:
The new tool is prepared for loading using the T function. In case of machines equipped with
a tool magazine, this setting is used mainly to bring the new change to the tool change
position in parallel to the machining time (without interrupting the machining time). The M
function is used to remove the old tool from the spindle and to load the new tool into the
spindle. According to DIN 66025, this tool change is programmed using the M function M6.
Related to ....

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14-287

Tool: Compensation and Monitoring (W1)


14.6

Data descriptions (MD, SD)

Setting data
42940
SD number
Default: 0
Change valid: immediately
Data type: DWORD
Meaning:

TOOL_LENGTH_CONST
When changing the machining plane (G17 to G19), keep the assignment of the tool lengths 1 to 3
to the geometry axes as it is
Min. input limit: 0
max. Eingabegrenze: 19
Protection level: 3/3
Unit: Valid from SW release: 2.0
If this setting data is unequal to zero, the assignment of the tool lengths 1 to 3 (length, wear) to the
geometry axes will not be changed when changing the machining plane (G17 to G19). The assignment of the tool length components to the geometry axes results from the value of the setting data,
as specified in the tables below. The assignment makes a distinction between turning tools (tool
types 500 to 599) and other tools (drilling/milling tools). The representation in the tables is based
on the assumption that the geometry axes 1 to 3 are designated X, Y and Z. The assignment of a
compensation to an axis, however, depends not on the axis identifier, but on the sequence order of
the geometry axes.

The assignment of the tool lengths to the geometry axes for turning tools (tool types
500 to 599) results from the value of the setting data SD 42940 according to the table
below:
Plane/Value Length 1
Length 2
Length 3
17
Y
X
Z
18*)
X
Z
Y
19
Z
Y
X
-17
X
Y
Z
-18
Z
X
Y
-19
Y
Z
X
The table below shows the assignment of the tool lengths 1 to 3 to the geometry axes
for drill / milling tool (tool types 100 to 299):
Plane/Value Length 1
Length 2
Length 3
17*)
Z
Y
X
18
Y
X
Z
19
X
Z
Y
-17
Z
X
Y
-18
Y
Z
X
-19
X
Y
Z
Related to ....

SD 42950: TOOL_LENGTH_TYPE

42950
SD number
Default: 0
Change valid: immediately
Data type: DWORD
Meaning:

TOOL_LENGTH_TYPE
Assignment of the tool length compensation irrespective of the tool type
Min. input limit: 0
Max. input limit: 2
Protection level: 3/3
Unit: Valid from SW release: 2.0
0:
The assignment is carried out according to the default settings. A distinction is made between turning tools (tool types 500 to 599) and drilling/milling tools (tool types 100 to 299).
1:
The assignment of the tool length components is carried out irrespective of the real tool type,
always as with milling tools.
2:
The assignment of the tool length components is carried out irrespective of the real tool type,
always as with turning tools.

Related to ....

SD 42940: TOOL_LENGTH_CONST

14-288

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Tool: Compensation and Monitoring (W1)


14.7

14.7

Signal descriptions

Signal descriptions

V1900 5001.0
Interface signal
Edge evaluation: yes
Signal status 1 or edge
transition 0 - - -> 1
Signal status 0 or edge
transition 1 - - -> 0

V3200 0013.5
Interface signal
Edge evaluation: nein
Signal state 1 or signal
transition 0 ---> 1
Signal state 0 or signal
transition 1 ---> 0
Related to ....

V5300 0000.0
Interface signal
Edge evaluation: yes
Signal state 1/ value
Signal state 0

V5300 0000.1
Interface signal
Edge evaluation: yes
Signal state 1 / value
Signal state 0

VD5300 1000
Interface signal
Edge evaluation: yes
Signal state 1/ value
Signal state 0

VD5300 1004
Interface signal
Edge evaluation: yes
Signal state 1 / value
Signal state 0

Update tool list


Signal(s) from the channel (PLC->NCK)
Signal(s) updated: cyclically
Tool display is refreshed

Signal(s) valid from SW release: 2.0

No effect

Disable workpiece counter


Signal(s) to channel (PLC ---> NCK)
Signal(s) updated: cyclically
Signal(s) valid from SW release: 2.0
With the tool monitoring enabled, the workpiece count monitoring is disabled.
No effect

Tool prewarning limit reached


Signal(s) from channel (NCK ---> PLC)
Signal(s) updated: job-controlled
Signal(s) valid from SW release: 2.0
from NCK
The prewarning limit for a tool to be monitored was reached.
The T number is provided in VD5300 1000.
No prewarning limit reached

Tool limit value reached


Signal(s) from channel (NCK ---> PLC)
Signal(s) updated: job-controlled
from NCK
The limit value for a tool to be monitored was reached.
The T number is provided in VD5300 1004.
No limit value reached

Signal(s) valid from SW release: 2.0

T number for tool prewarning limit


Signal(s) from channel (NCK ---> PLC)
Signal(s) updated: job-controlled
Signal(s) valid from SW release: 2.0
from NCK
The T number for which the tool prewarning limit is set will be provided.
No tool number transmitted

T number for tool limit value


Signal(s) from channel (NCK ---> PLC)
Signal(s) updated: job-controlled
Signal(s) valid from SW release: 2.0
from NCK
The T number for which the tool prewarning limit is set will be provided.
No tool number transmitted

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

14-289

Tool: Compensation and Monitoring (W1)


14.8

Data fields, lists

14.8

Data fields, lists

14.8.1

Interface signals

Number

.Bit

Name

Ref.

Channel-specific
V2500 0008

.0

T function 1, change

H2

V2500 0010

.0

D function 1, change

H2

VD2500 2000

T function 1

H2

VD2500 5000

D function 1

H2

V2500 1000

.6

M6

H2

V3200 0013

.5

Disable workpiece counter

V5300 0000

.0

Tool prewarning limit reached

V5300 0000

.1

Tool limit value reached

VD5300 1000

T number for tool prewarning limit

VD5300 1004

T number for tool limit value

14.8.2

Machine data

Number

Identifier

Name

Ref.

General
18080**

MM_TOOL_MANAGEMENT_MASK

Memory reservation for tool monitoring

Channel-specific
20310**

TOOL_MANAGEMENT_MASK

Activation of the tool monitoring

20360

TOOL_PARAMETER_DEF_MASK

Definition of tool parameters

22550

TOOL_CHANGE_MODE

New tool compensation with M function

** This machine data is not available with the 802D base line.

14-290

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Measuring (M5)

15.1

15

Brief description

Channel -specific measuring


In a part program block, a measuring cycle (with or without deleting the distance to go) is programmed. In addition, a trigger event (edge of sensor) is programmed, initiating the measuring
process. The statements apply to all axes programmed in this block. The program that contains the measuring process are executed in AUTOMATIC mode and can be used either for
workpiece or tool measurement.

Tool measurement in JOG


In particular, for measuring tools on turning and milling machines, a prompting system has
been implemented in the SINUMERIK 802D, which is active in JOG mode and assists the
operator in performing the measuring sequence. This sequence includes the channel-specific
measurement. The required functionality must be integrated in the PLC user program. The
measured correction values of the tool will be available in the tool offset memory at the end of
the measuring process.
Which operator actions are to be carried out exactly is contained in:
References:
Operation and Programming

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

15-291

Measuring (M5)
15.2

Hardware requirements

15.2

Hardware requirements

15.2.1

Probes that can be used

General
To acquire tool and workpiece dimensions, a switching sensing probe is required, which provides a constant signal (no pulse) in case of a deflection.
The probe must switch nearly free from bouncing. This is generally possible by a mechanical
adjustment of the probe.
Various manufacturers offer different designs of probes on the market. The probes are therefore divided into three groups, depending on the number of directions in which a probe can be
deflected (see Fig. 15-1).

Multi-directional
probe

Fig. 15-1

Bi-directional
probe

Mono-directional
probe

Probe types

Table 15-1

Probe assignment

Tracer type

Turning machines

Milling and machining


centers

Tool measurement

Workpiece measurement

Workpiece measurement

multi-directional

bi-directional

mono-directional

Whereas for turning machines a bi-directional probe can be used, for milling and machining
centers a mono-probe can also be used for workpiece measurement.

Multi -directional probes (3D)


This type can be used for tool and workpiece measurement without any restrictions.

15-292

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Measuring (M5)
15.2

Hardware requirements

Bi -directional probes
For the workpiece measurement in milling and machining centers, this type is treated as a
mono-probe. For turning machines, this type can be used for workpiece measurement.

Mono -directional probes


On milling and machining centers, this type can be used for workpiece measurement with
slight restrictions.
To measure in different axis directions/axes, it must be possible to position the spindle using
the NC fnction SPOS. The sensing probe must be aligned according to the measuring task to
be performed.

Switching behavior
The MD 13200:MEAS_PROBE_LOW_ACTIVE[0] is used to announce the signal level of the
connected sensor (extended / withdrawn ) to the control system.

15.2.2

Connecting the probe

Connection to the 802D/drive 611UE


With the SINUMERIK 802D, the probe is connected to the drive 611UE on the terminals
X453 (input I0.A) for drive A and/or on X454 (input I0.B) for drive B in case of two-axis modules. For single-axis modules, only drive A is available.
All measuring inputs of the axis drive modules must be linked electrically with each other and
connected to the probe.
Parameterize the input of each axis drive using the function Probe (parameter P660=80)
when starting up the drive using the SimoCom U tool.
For the sensor, use an external voltage (24V), not that of the drive.
The connection including the reference potential, is explained and described in detail in:
References:
Start-Up Guide
References:
SIMODRIVE 611 UE, Description of Functions

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

15-293

Measuring (M5)
15.2

Hardware requirements

Button for
POWER
ON -RESET

Motor encoder
Drive A
X411
FAULT
LED rot

Motor encoder
Drive B
X412

Option module
PROFIBUS-DP3

X423

Signaling terminals
X421
AS1
AS2
Terminals for supply and
pulse enable

Terminals drive B

P24

X454

M24
9
663
X431

19
Analog outputs
75.A
16.A
75.B
16.B
15
(reference)

X441

X34
M DAU1 DAU2
Terminals of drive A
56.A
14.A
24.A
20.A
65.A
9
I0.A
I1.A
O0.A
O1.A

Fig. 15-2

15-294

X453

Serial
interface
(RS232)
X471

56.B
14.B
24.B
20.B
65.B
9
I0.B
I1.B
O0.B
O1.B

Encoder interface TTL encoder


1
P_Encoder
X472
2
M_Encoder
3
A
4
*A
5
reserved
6
B
7
*B
8
reserved
9
P_Encoder
10 R
11 M_Encoder
12 *R
13 reserved
14 reserved
15 reserved

Display
and
operating unit
Unit bus
X351

Elements on the front panel SIMODRIVE 611 UE; the sensing probe is connected to X453/X454

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Measuring (M5)
15.3

15.3
15.3.1

Channel-specific measuring

Channel-specific measuring
Measuring mode

Measuring commands MEAS and MEAW


The measuring process is enabled from the part program. A trigger event and a measuring
mode are programmed. Two measuring modes are provided:


MEAS: Measuring with deleting the distance to go


Example: N10 G1 F300 X300 Z200 MEAS=-1
Trigger event is the falling edge (-) of probe (1): from the status when extended to the status when withdrawn

MEAW: Measuring without deleting the distance to go


Example: N20 G1 F300 X300 Y100 MEAW=1
Trigger event is the rising edge (+) of probe (1): from the status when extended to the status when withdrawn

The measuring block is completed when the sensing probe signal is arrived or the position is
reached. The measuring job can be canceled using RESET.
References:

Operation and Programming

Note
If a geometry axis (axis in WCS) is programmed in a measuring block, the measured values for all
geometry axes will be stored.

15.3.2

Measurement results

Reading measurement results in the program


The results of the measurement command can be read in the part program using system variables.


System variable $AC_MEA[1]


Polling the status signal of the measuring job.
The variable is deleted at the beginning of a measurement. Once the probe reaches the
trigger criterion (rising or falling edge), the variable is set. Thus the realization of the measuring job can be checked in the part program.

System variable $AA_MM[<axis>]


Access to the result of measurement in the machine coordinate system.
Reading in the part program and in the synchronous actions. <axis> stands for the name
of the measuring axis (X, Y, ...).

System variable $AA_MW[axis]


Access to the measurement result in the workpiece coordinate system. Reading in the part
program and in the synchronous actions. <axis> stands for the name of the measuring axis
(X, Y, ...).

References:

Operation and Programming

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

15-295

Measuring (M5)
15.4

Measuring accuracy and testing

PLC service display


The measuring signal can be checked using the diagnostics menu PLC status:
IS Probe 1 actuated (V2700 0001.0).
The IS Measurement active (V390x 0002.3) can be used to display the current measuring
status of the axis (measuring block with this axis running).

15.4

Measuring accuracy and testing

15.4.1

Measuring accuracy

Accuracy:
The runtime of the measuring signal is determined by the hardware used. The delay times are
in the s range, plus reaction time of the probe when using the SIMODRIVE 611UE.
The measuring uncertainty results from:
Measuring uncertainty = runtime of measuring signal x traversing velocity
Correct results can only be guaranteed for traversing velocities, at which not more than 1 trigger signal per position controller cycle arrives.

15.4.2

Sensing probe function test

Example of a function test


It is recommended to carry out the function test of the sensing probe using an NC program.
%_N_PRUEF_MESSTASTER_MPF
;test program for probe connection
N10
N20

;R10
;R11

Flag for selection state


MESSWERT_IN_X

N30

T1 D1

;Preselect tool compensation for probe

N40
N50

ANF: G0 G90 X0 F150


MEAS=1 G1 X100

;Start position and measuring velocity


;Measuring at measuring input 1 in the X axis

N60

STOPRE

N70
N80

R10=$AC_MEA[1]
;Switching signal at 1st measuring input
IF R10==0 GOTOF FEHL1 ;Evaluation of the signal

N90
N95

R11=$AA_MW[X]
M0

;Reading in the meas. value in the workpiece coordinates

N100 M2
N110 FEHL1: MSG (Probe does not switch!)
N120 M0
N130 M2

15-296

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Measuring (M5)
15.4

Measuring accuracy and testing

Example: Repeat accuracy


This program allows to determine the measuring scatterband (repeat accuracy or repeatability) of the entire measuring system (machine-probe-signal transmission).
In the example, the X axis is measured 10 times and the measured value is taken over into
the workpiece coordinates.
So -called random size deviations can be noticed, which are not subject to a particular trend.
%_N_PRUEF_GENAU_MPF
N05 ;R11
N06 R12=1
N10 ; R1 bis R10
N15 T1 D1
N20
N25
;N30
N35
N37
N40
N50
N60
N65
N70
N80
N90
N95

Switching signal
;Counter
MEASURED VALUE_IN_X
;Initial conditions, preselect tool compensation
for probe
ANF: G0 X0 F150
;Prepositioning in the measuring axis
MEAS=+1 G1 X100
;Measuring at the 1st measuring input on rising
switching edge, in the X axis
STOPRE
;Stop decoding for later evaluation of the result
(is carried out automatically when reading MEA)
R11= $AC_MEA[1]
;Switching signal at 1st read measuring input
IF R11==0 GOTOF FEHL1 ;Check switching signal
R[R12]=$AA_MW[X]
;Read measured value in workpiece coordinates
R12=R12+1
IF R12<11 GOTOB ANF
;Repeat 10 times
M0
M02
FEHL1: MSG (Probe does not switch)
M0
M02

After selecting the parameter display, the results of the measurement R1 to R10 can be read.

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

15-297

Measuring (M5)
15.5

15.5

Tool gauging in JOG

Tool gauging in JOG

Note
This function is not available with the 802D base line.

Gauging principle
The operator will traverse the tool to the sensing probe in JOG mode using the traversing keys
or the handwheel. When the sensing probe switches, the movement is automatically stopped,
the control system will internally switch to AUTOMATIC mode, and a measuring program is
started. The measuring program controls the actual measuring process using a second sensing probe approach and another positioning process. At the end, the tool compensation values are entered and JOG mode is active again.
Advantage: The compensation values entered before measuring the tool can deviate from the
real values completely. The tools need not be premeasured.
Note: No wear measurement is carried out, but always a re-measurement of the tool.
In JOG mode, the operator can use softkeys and screen forms to make inputs. These assist
him in the tool measurement.
References:

Operation and Programming

Important
The PLC user program must be created with the appropriate sequences. Only then the required functionality will be available.
When approaching the sensing probe, be especially careful. The sensing probes have only a
limited extension travel. If this travel is exceeded, the probes can be damaged or even be
destroyed! Observe the instructions of the manufacturers!
In particular, reduce the approach velocity such that it is always possible to stop in time. Rapid traverse override must not be active.
The screen forms displayed and the sequence are dependent on the technology. Correspondingly, the following tool types can be measured:

Turning technology


Turning tool (geometry length 1 and geometry length 2)

Drill (geometry length 1)

Milling technology

15-298

Milling tool (geometry length 1 and geometry radius)

Drill (geometry length 1)

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Measuring (M5)
15.5

Tool gauging in JOG

Tool offsets
The screen forms contain first the active tool T and the active offset number D for the target of
the measured result entry. Either a different tool can be specified from the PLC via the interface or the operator enters a different tool T and/or the offset number D.

Important
If a tool or an offset number other than the active values has been entered, this has to be announced to the NC when using this tool/tool offset after measuring; this can be done, e.g. by
programming and start in MDA mode. Only then the control system can take into account the
correct tool offsets.

A length compensation determined by measurement is automatically entered in the Geometry component of the active/specified tool compensation D of the active/specified tool, and the
associated components Wear and Adapter are deleted.
When measuring the cutter radius, it is assumed that no further offset is available in the axes
of the cutter radius plane (values in the axes of the Adapter component, as well as geometry
length 2 and 3 are equal to zero).
The result for the radius is entered in the Geometry component. The associated components
Adapter and Wear of both axes of the plane are deleted.

Sensing probes
The sensing probe for tool measurement is either a stationary sensing probe or it is swiveled
to the work area using a mechanical facility. In the case of a rectangular design of the sensing
probe plate, the edges must be aligned paraxially. The tool/calibration tool is traversed against
the sensing probe. Before a measurement is carried out, the sensing probe must be calibrated, i.e. the exact sensing probe switching points with reference to the machine zero must be
known to the control system.

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

15-299

Measuring (M5)
15.5

Tool gauging in JOG

Preparatory work, calibrating the sensing probe




Select JOG mode.

Use the Settings softkey to enter the following values in the window, which opens:
Retraction plane, safety clearance, JOG feed, variable incremental dimension and direction of rotation of the spindle fo general use in JOG and for tool measurement.

Press another softkey Sensor data to enter the following values in the window, which
opens:
-

Feedrate for automatic sensor approach in the measuring program

Sensor switching points (The appropriate values are set automatically when calibrating.
If exact values are known, these can be entered manually. No calibration is thus required.)

The softkeys Measure tool -> Adjust sensor and the window, which opens, are used to
prompt the operator when performing the sequence required to calibrate the sensor. In this
case, the tool used is the calibration tool with the dimensions exactly known and entered.
With the milling technology, the calibration tool is one of the type milling cutter; with the
turning technology, the tool is a turning tool with edge radius zero. The entered edge position is not taken into account here.
The internal sequence when calibrating is the same as when measuring. The measurement results, however, are written to the data for the sensor switching points - not to the
tool offsets.

Note: The internal NC programs for measuring or calibrating have been designed such that
the measurement is carried out when a rising edge of the sensor occurs.

Measuring sequence

15-300

JOG mode is selected. The measuring feedrate is entered. The sensor is calibrated and/or
the exact sensor switching points are entered.

The measuring sequence is performed using the softkeys Measure tool and further softkeys, depending on the tool type.

When the softkey Measure tool is pressed, the IS Measurement in JOG active
(V1700 0003.7) is transferred from HMI to the PLC. The PLC can preset another T number
than the active one via the IS T number for tool measurement in JOG (VD1900 5004)
and provide this to the HMI. If the sensor switches to the sensor when traversing the selected axis, the NCK will output the IS Sensor 1 active (V27000001.0). As a response, the
PLC will set the IS Feed disable (V3200 0006.0) and the NCK will stop the movement.
The feed disable is kept as long as a traversing key is pressed in JOG mode and the IS
Measurement active in JOG
(V1700 0003.7) is set. The PLC will the provide the IS Reset (V3000 000.7). The traversing movement in JOG is thus canceled.
HMI will detect that the sensor has switched and will provide the order to the PLC for switching over to AUTOMATIC mode (IS AUTOMATIC mode;V1800 0000.0) after the traversing key has been pressed (with handwheel travel - immediately). The PLC will transfer
this to the NCK (V3000 0000.0).
The NCK will enable the AUTOMATIC mode (IS Active mode: AUTOMATIC (V3100
0000.0)) what is displayed on the HMI screen. The PLC will cancel the IS Feed disable
(V3200 0006.0). In the following, the HMI provides the IS Mode change disable (V1800
0000.4) to the PLC. If the PLC has detected this signal (is present only over one PLC cycle), the PLC will provide the IS Mode change disable (V3000 0000.4) to the NCK.
HMI has loaded an NC measuring program into the NCK. This will be enabled now. This
measuring program will automatically calculate the direction of approaching the sensor and
the traversing distance including safety clearance.
HMI will give the PLC the order to start the measuring program via the IS Start measuring

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Measuring (M5)
15.6

Supplementary conditions

in JOG (V1800 0000.6). The signals in the range V1800 are present only over one PLC
cycle. Ths IS Start measuring in JOG is therefore buffered in the PLC. The NC measuring program is started from the PLC via the output of the IS NC START (V3200 0007.1)
to the NCK.
The NC program will reposition the axis, reapproach the sensor, measure and then retract.
The HMI will then output the request for switching back to JOG mode (V1800 0000.2) to
the PLC. As a response, the PLC will reset the IS Mode change disable (V3000 0000.4).
The PLC will output the JOG mode (V3000 0000.2) to the NCK and the NCK will return the
IS Active mode JOG (V3100 0000.2).
Use the softkey Next step to select the next approach direction/axis for retraction to the
sensor. The further procedure is analogously - until all directions/axes are traversed.
At completion of measuring or calibration of the sensor, deselect the function using the
Back softkey. This will reset the IS Measuring in JOG active (V1700 0003.0). Analogously, it is reset when quitting the operating area.
The IS Reset (V3000 0000.7) can be used to cancel the Automatic program, and the
Back softkey can be used to quit measuring in JOG mode. This will also clear the IS
Feed disable (V3200 0006.0) and the IS Mode change disable (V3000 0000.4), which
are possibly still set and/or also clear any signals written to a buffer.

PLC user program


The required functionality according to the sequence in the PLC user program, as it has been
described above, must be provided by the user.
The toolbox for SINUMERIK 802D, which is supplied by SIEMENS, contains an appropriate
user example in PLC 802D Library, V01.05 and higher. This can be used. When doing so, it is
essential to call PLC_INI (SBR32) and MCP_NCK (SBR38) in OB1, since these transfer signals of the subroutine MEAS_JOG (SBR43) to NCK/HMI.

15.6

Supplementary conditions


Use of the SIMODRIVE 611 UE drives, controller module in the A version and higher, with
the associated firmware V03.04.03

SINUMERIK 802D, SW 1.1 and higher

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

15-301

Measuring (M5)
15.7

15.7

Data descriptions (MD, SD)

Data descriptions (MD, SD)

361
MD number
Default: 0
Change valid: immediately
Data type: BOOLEAN
Meaning:

MEAS_TOOL_CHANGE
Input enable for T/D no. with tool gauging
Min. input limit: 0
Protection level: 3/3

373
MD number
Default: 0
Change valid: immediately
Data type: BOOLEAN
Meaning:

SMM_MEAS_SAVE_POS_LENGTH2
Enable Tool gauging Save Pos softkey for all values
Min. input limit: 0
Protection level: 2/2

Max. input limit: 1


Unit: -

0: T/D number input disabled


1: T/D number input enabled

Max. input limit: 1


Unit: -

Controls the Dave Pos. softkey with the Tool gauging manually function
0: The Save Pos. softkey is only active when measuring length 1
1: The Save Pos. softkey is generally active

13200
MEAS_PROBE_LOW_ACTIVE[0]
MD number
Switching behavior of sensing probe
Default: 0
Min. input limit: 0
Max. input limit: 1
Change valid after Power On
Protection level: 3/3
Unit: Data type: BOOLEAN
Valid from SW release:
Meaning:
0:
when not extended
0V
when extended
24 V
1:
when not extended
24 V
when extended
0V

15-302

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Measuring (M5)
15.8

15.8

Signal descriptions

Signal descriptions

V1700 0003.7***
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 - - -> 1

Signal state 0 or edge


change 1 - - -> 0

Measuring in JOG active


Signal(s) to PLC (HMI ---> PLC)
Signal(s) updated: cyclically
Signal(s) valid from SW release: 1.1
The function Tool measurement in JOG is activated from HMI.
Note: When switching over to AUTOMATIC mode when this function is performed, the signal
remains set. HMI will keep the JOG screen on the display; only the display of the currently active mode will change.
The function Tool measurement in JOG is not active.

*** This interface data is not available with the 802D base line.
V1800 0000.0
Interface signal
Edge evaluation: yes
Signal state 1 or edge
change 0 - - -> 1
Signal state 0
Signal not applicable to...

AUTOMATIC mode
Signal(s) to PLC (HMI ---> PLC)
Signal(s) updated: cyclically
AUTOMATIC mode is selected from HMI.
The signal status 1 is present only over one PLC cycle.
AUTOMATIC mode is not selected from HMI.
the signal Mode change disable

Signal(s) valid from SW release: 1.1

V1800 0000.1
Interface signal
Edge evaluation: yes
Signal state 1 or edge
change 0 - - -> 1
Signal state 0
Signal not applicable to....

MDA mode
Signal(s) to PLC (HMI ---> PLC)
Signal(s) updated: cyclically
Signal(s) valid from SW release: 1.1
MDA mode is selected form HMI.
The signal status 1 is present only over one PLC cycle.
MDA mode is not selected from HMI.
the signal Mode change disable

V1800 0000.2
Interface signal
Edge evaluation: yes
Signal state 1 or edge
change 0 - - -> 1
Signal state 0
Signal not applicable to ...

JOG mode
Signal(s) to PLC (HMI ---> PLC)
Signal(s) updated: cyclically
Signal(s) valid from SW release: 1.1
JOG mode is selected from HMI.
The signal status 1 is present only over one PLC cycle.
JOG is not selected from HMI.
the signal Mode change disable

V1800 0000.4
Interface signal
Edge evaluation: yes
Signal state 1 or edge
change 0 - - -> 1
Signal state 0

Mode change disable


Signal(s) to PLC (HMI ---> PLC)
Signal(s) updated: cyclically
Signal(s) valid from SW release: 1.1
Request from HMI: The currently active mode (JOG, MDA or Automatic) must not be changed.
The signal status 1 is present only over one PLC cycle.
The mode can be changed.

V1800 0000.6***
Interface signal
Edge evaluation: yes
Signal state 1 or edge
change 0 - - -> 1
Signal state 0

Start measuring in JOG


Signal(s) to PLC (HMI ---> PLC)
Signal(s) updated: cyclically
Signal(s) valid from SW release: 1.1
Order frm HMI to PLC to start the measuring program by pressing NC Start.
The signal status 1 is present only over one PLC cycle.

*** This interface data is not available with the 802D base line.

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

15-303

Measuring (M5)
15.8

Signal descriptions

V1800 0001.2
Interface signal
Edge evaluation: yes
Signal state 1 or edge
change 0 - - -> 1
Signal state 0
Signal not applicable ....

Machine function REF


Signal(s) to PLC (HMI ---> PLC)
Signal(s) updated: cyclically
The machine function REF is selected in JOG mode.
The signal status 1 is present only over one PLC cycle.
The machine function REF will not be selected.
if JOG mode is active.

V1900 5002.0
Interface signal
Edge evaluation: no
Signal status 1 or edge
transition 0 - - -> 1
Signal status 0 or edge
transition 1 - - -> 0

Enable tool gauging in JOGmode


Signal(s) from NCK (PLC HMI)
Signal(s) updated: cyclically
Signal(s) valid from SW release: 2
The Measuring function can be activated in the JOG mode.

VD1900 5004
Interface signal
Edge evaluation: no
Value > 0
(DWORD)
Value = 0
Signal not applicable ....

Measuring not possible in JOG.

T number for tool measurement in JOG


Signal(s) to HMI ( PLC--->HMI)
Signal(s) updated: cyclically
Signal(s) valid from SW release: 1.1
Specification of the T number from the PLC for entering the measurement results at the HMI.
The number entered in the HMI screen form is used as the offset number.
No specification of the T number from the PLC
if the IS Measuring in JOG active (V1700 0003.7) is not set

V2700 0001.0
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 - - -> 1
Signal state 0 or edge
change 1 - - -> 0

Probe 1 actuated
Signal(s) from NCK (NCK PLC)
Signal(s) updated: cyclically
Probe 1 is actuated.

V390x 0002.3
Interface signal
Edge evaluation: no
Signal state 1 or edge
change 0 - - -> 1

Measurement active
Signal(s) from axis/spindle (NCK PLC)
Signal(s) updated: cyclically
The function Measuring is active.

Signal state 0 or edge


change 1 - - -> 0

15-304

Signal(s) valid from SW release: 1.1

Signal(s) valid from SW release:

Probe 1 is not actuated.

Signal(s) valid from SW release:

This shows the current measuring status of the axis (measuring block with this axis running).
The function Measuring is not active.

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Measuring (M5)
15.9

15.9

Data fields, lists

Data fields, lists

15.9.1

Interface signals

Number

.Bit

Name

Ref.

HMI signals (from HMI to PLC)


V1700 0003

.7***

Measurement in JOG active

V1800 0000

.0

AUTOMATIC mode (request from HMI)

V1800 0000

.1

MDA mode (request from HMI)

V1800 0000

.2

JOG mode (request from HMI)

V1800 0000

.4

Mode change disable (request from HMI)

V1800 0000

.6***

Start measuring in JOG (request from HMI)

V1800 0001

.2

Machine function REF (request from HMI)

HMI signals (from PLC to HMI)


VD1900 5004

T number for tool measurement in JOG (specification from the PLC)

General (from NCK to PLC)


V2700 0001

.0

Probe 1 actuated.

Axis/spindle-specific (from axis to PLC)


V390x 0002

.3

Measurement active

*** This interface data is not available with the 802D base line.

15.9.2

Machine data

Number

Identifier

Name

Ref.

General machine data


13200

MEAS_PROBE_LOW_ACTIVE

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Switching behavior of probe

15-305

Measuring (M5)
15.9

Data fields, lists

notice

15-306

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Compensation (K3)

16.1

16

Brief description

Compensations
With the SINUMERIK 802D, the following compensations can be enabled axis-specifically:


Backlash compensation

Interpolatory compensation LEC


(compensation of leadscrew error and measuring system error)

Following error compensation (dynamic feedforward control)

The compensation functions can be set for each machine separately using axis-specific machine data.

Position display
The standard actual and set value display does not take into account the compensation values and displays the position values of an ideal machine. The compensation values are displayed in the operating area System in the screen form Service Axes under Abs. comp.
value meas. system 1.

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

16-307

Compensation (K3)
16.2

16.2

Backlash compensation

Backlash compensation

Effect
With axes/spindles provided with indirect measuring systems, the mechanical backlash results in a falsification of the distance to be traversed. For example, with direction reversal, an
axis travels will traverse too few or too much by the amount of the backlash (see Fig. 16-1).

Compensation
To compensate the backlash, the axis-specific actual value is corrected by the backlash
amount with each direction reversal of the axis/spindle.
During the start-up, this amount can be entered in
MD 32450: BACKLASH (backlash) for each axis/spindle.

Activation
After reference point approach, the backlash compensation is always active in all operating
modes.

Positive backlash
The encoder advances the machine part (e.g. table). To make sure that the actual position
acquired by the encoder advances the real position of the table, the table traverses too shortly
(see Fig. 16-1). In this case, a positive backlash compensation value must be entered (= normal case).

Table
Backlash

Encode
r

Encoder actual value advances the real actual value (table): Table traverses too short
Fig. 16-1

Positive backlash (normal case)

Negative backlash
The encoder lags behind the machine part (e.g. table); the table travels too far. A negative
compensation value must be entered.

Large backlash compensation values


In case of direction reversal of the axis concerned, the user may provide the backlash compensation value divided into several segments. This avoids that a sudden setpoint change on
the axes results in specific axis errors.

16-308

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Compensation (K3)
16.3

Interpolatory compensation

The contents of the axis-specific MD 36500: ENC_CHANGE_TOL determine the increment,


by which the backlash compensation value (MD 32450: BACKLASH) is added.
Note that the backlash compensation will only be taken into account after n servo cycles ( n=
MD32450 / MD 36500). If the time is too long, zero speed monitoring alarms may result.
If MD 36500: ENC_CHANGE_TOL is greater than MD 32450: BACKLASH, the compensation
is carried out in one servo cycle.

16.3
16.3.1

Interpolatory compensation
General

Terms and definitions


Compensation value: Difference between the axis position measured by the position encoder and the desired programmed axis position (= axis position of the ideal machine). The compensation value is often also called offset value.
Intermediate point: A position of the axis and the related compensation value.
Compensation table: Table of intermediate points

Compensation table
Since measurement deviations of ball screw spindle and measuring system have a direct influence on the accuracy of the workpiece machining, they must be compensated by appropriate position-dependent compensation values. The compensation values are determined
according to the measured error curve and entered in the control system in the form of compensation tables during the start-up. For each compensation relation, a separate table must
be created.
The input of compensation values and additional table parameters are carried out using special system variables.

Input of the compensation table


The compensation tables can be loaded into the buffered NC user memory in two different
ways:


The compensation values are loaded by starting an NC program that contains the compensation tables.

The compensation data can also be loaded by transferring the compensation tables from a
PC via the serial interface of the HMI.

Note
The compensation tables can be output via the serial interface of the HMI from the operating area
System -> Data I/O -> Data selection / Data ... / Compensation: Leadscrew error and downloaded after editing.

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

16-309

Compensation (K3)
16.3

Interpolatory compensation

Linear interpolation between intermediate points


The traversing distance to be compensated and defined by start and end positions will be divided into several segments of the same size (the number depends on the error curve form)
(see Fig. 16-2). In the following, the actual positions limiting these segments will be referred
to as intermediate points. During the start-up, the corresponding offset value must be entered for each intermediate point. The offset (or compensation) value acting between 2 intermediate points is generated from the corresponding compensation values of the adjacent intermediate points (i.e. adjacent points are linked by a straight line) by a linear interpolation.
Compensation
value

Error curve
Compensation curve

Linear interpolation

n
n+1
Intermediate point

Fig. 16-2

n+2

n+3

Position of
the axis

Linear interpolation between the intermediate points

Compensation value at the reference point


The compensation table should be structured such that the compensation value is zero at the
reference point.

16.3.2

Leadscrew error compensation (LEC)

Function
The leadscrew error compensation / measuring system error compensation (LEC) is an axisspecific compensation.
With the LEC, the axis-specific actual position value is modified by the corresponding compensation value at the interpolation cycle and directly traversed by the machine axis. A positive compensation value results in a movement of the corresponding machine axis in the negative direction.
The size of the compensation value is not limited and is not monitored. To avoid inadmissible
high velocities and accelerations of the machine axis due to the compensation, the compensation value should be selected correspondingly small. Otherwise, in case of large compensation values, other axis monitoring functions may result in alarm messages (e.g. contour monitoring, speed setpoint limitation).

16-310

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Compensation (K3)
16.3

Interpolatory compensation

Activation


The compensation values are stored in the NC user memory and are active after Power
ON.

The function has been activated for the machine axis desired
(MD 32700: ENC_COMP_ENABLE [0] = 1).

The axis has been referenced (IS Referenced/synchronized 1 V390x0000.4 set).

If these conditions are fulfilled, the axis-specific actual position value will be modified by the
corresponding compensation value and traversed by the machine axis immediately.
If the reference is then lost, e.g. since the encoder frequency has been exceeded (IS Referenced/synchronized 1 = 0), the compensation processing will be switched off.

Compensation table
The position-related compensations for the corresponding axis are stored in the compensation table in the form of system variables. A maximum of 125 intermediate points (N = 0...124)
is possible.
To this aim, the following measuring-system specific parameters must be defined for the table
(see Fig.16-3):


Compensation value for intermediate point N of the compensation table:


$AA_ENC_COMP [0,N,AXi]= ...
with: AXi = machine axis name, e.g. X1, Y1, Z1 ; N = intermediate point index
The compensation value for each individual intermediate point (axis position) must be entered in the table. The size of the compensation value is not limited.

Note
The first and the last compensation values remain active over the entire traversing range, i.e.
these compensation values should be 0 if the compensation table does not extend over the
entire traversing range.

Intermediate point spacing: $AA_ENC_COMP_STEP[0,AXi]= ...


The intermediate point spacing defines the spacing between the compensation values of
the corresponding compensation table (AXi, see above).

Starting position: $AA_ENC_COMP_MIN[0,AXi]= ...


The starting position is the axis position at which the compensation table for the axis in
question starts (intermediate point 0).
The compensation value pertaining to the starting position is $AA_ENC_COMP[0,0,AXi]
For all positions less than the starting position, the compensation value of intermediate
point 0 is used (does not apply to tables with module).

End position: $AA_ENC_COMP_MAX[0,AXi]= ...


The end position is the axis position at which the compensation table for the corresponding
axis ends (intermediate point k < 125).
The compensation value pertaining to the end position is $AA_ENC_COMP[0,k,AXi)]
For all positions greater than the end position, the compensation value of intermediate
point k is used (exception: table with modulo function). Compensation values greater than
k are inactive.

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

16-311

Compensation (K3)
16.3

Interpolatory compensation

Compensation with modulo function: $AA_ENC_COMP_IS_MODULO[0,AXi] = 1


If the compensation with modulo function is activated, the compensation table is repeated
cyclically, i.e. the compensation value at $AA_ENC_COMP_MAX ( intermediate point
$AA_ENC_COMP[0,k,AXi]) is directly followed by the compensation value at
$AA_ENC_COMP_MIN (intermediate point $AA_ENC_COMP[0,0,AXi]).
In case of rotary axes with modulo 360, it is recommended to use 0 degrees as the
starting position ($AA_ENC_COMP_MIN) and 360 degrees as the end position
($AA_ENC_COMP_MAX). These two compensation values must be entered with the
same amount.

Caution
When entering the compensation values, it should be made sure that all intermediate points is
assigned a compensation value within the defined range (i.e. that no gaps occur). Otherwise,
for these intermediate points the compensation value will be used, which has remained from
previous entries in these places.

Note

 In MD 10240: SCALING_SYSTEM_IS_METRIC=0, table parameters that contain positional


information are interpreted in inches.
An automtic conversion of the position data can be achieved by manual switch -over (see Section 3.2.2 Switching over the scaling system manually).

 The compensation table can only be loaded if MD 32700: ENC_COMP_ENABLE=0 is set. If this
value is set =1, the compensation will be enabled, thus enabling write protection (output of alarm
17070).

Example
The following example shows the specification of compensation values for machine axis X1
as a program.
%_N_AX_EEC_INI
CHANDATA (1)
$AA_ENC_COMP[0,0,X1]= 0.0 ;1st compensation value (intermediate point 0) +0mm
$AA_ENC_COMP[0,1,X1]= 0.01 ;2nd compensation value (intermediate point 1) +10mm
$AA_ENC_COMP[0,2,X1]= 0.012
;3rd compensation value (intermediate point 2)
+12mm
...
$AA_ENC_COMP[0,120,X1]= 0.0
;last compensation value (intermediate point 120)
$AA_ENC_COMP_STEP[0,X1]= 2.0
;intermediate point spacing 2.0 mm
$AA_ENC_COMP_MIN[0,X1]= -200.0
;compensation starts at -200.0 mm
$AA_ENC_COMP_MAX[0,X1]= 40.0
;compensation ends at +40.0 mm
$AA_ENC_COMP_IS_MODULO[0,X1] = 0;compensation without modulo function
M17
Values for more than 125 interpolation points will cause alarm 12400 Element missing.

16-312

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Compensation (K3)
16.3

Error curve
Compensation curve
(linear interpolation between the intermediate points)
Compensation values of compensation table

Compensation value
Start position
($AA_ENC_COMP_MIN)

End position
($AA_ENC_COMP_MAX)

Intermediate point spacing


($AA_ENC_COMP)
-200-207
-198
0

Interpolatory compensation

Compensation value of
intermediate point 5
Reference point

-196 -194
2

38

40

119

120
Intermediate points

Linear interpolation

Fig. 16-3

Axis position

Parameters of the compensation table (system variables for LEC)

16.3.3

Special features of interpolatory compensation

Measuring
The function Measuring provides the compensated actual positions (ideal machine) required
by the user or programmer.

Software limit switches


The software limit switches also monitor the ideal position values (i.e. the actual position values corrected by the LEC and the backlash compensation).

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

16-313

Compensation (K3)
16.4

16.4
16.4.1

Following error compensation (feedforward control)

Following error compensation (feedforward control)


General

Axis-specific following errors


The feedforward control allows to reduce the following error nearly to zero. The feedforward
control is therefore also called following error compensation.
In particular, in case of acceleration processes at contour bends, e.g. circles and corners, this
following error results in an undesired velocity-dependent contour error.
The SINUMERIK 802D control system uses feedforward control type Speed feedforward control.

Enabling/disabling the feedforward control in the part program


The feedforward control can be enabled/disabled in the part program using the following highlevel language elements:
FFWON Feedforward control ON
FFWOF Feedforward control OFF (default position when turning on the control system)
MD 32630: FFW_ACTIVATION_MODE defines axis-specifically whether the feedforward control can be enabled by FFWON for this axis and/or whether it can be disabled by FFWOF.
FFWON and FFWOF are used to enable/disable the feedforward control for all axes/spindles
for which MD 32630: FFW_ACTIVATION_MODE = 1 is set.
For interpolating axes, MD 32630: FFW_ACTIVATION_MODE should therefore be set to the
same value.
To avoid jerks, the feedforward control should only be enabled/disabled when the axis/spindle
is at a standstill. This must be observed and guaranteed by the programmer.

Prerequisites
When using the feedforward control, make sure that the following is observed:


rigid machine behavior

exact knowledge of the machine dynamic properties required

no sudden position and speed setpoint changes

Optimizing the control loop


The feedforward control is set axis/spindle-specifically. First, current, speed and position control loop must be set for the corresponding axis/spindle to an optimum value.
References:

Start-Up Guide

Defining the parameters


Then the feedforward control parameters must be entered for the corresponding axis/spindle
and entered in the machine data (refer to the following Section).

16-314

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Compensation (K3)
16.4

16.4.2

Following error compensation (feedforward control)

Speed feedforward control


With the speed feedforward control, a speed setpoint is provided to the input of the speed
controller as an additional setpoint (see Fig. 16-4).
To achieve a speed feedforward control set correctly, the equivalent time constant of the
speed control loop must be determined exactly and entered as a machine data.

NCK

Set value Feedforward


control
(Reference input
variable)

Drive

+
-

Position
controller

Speed
controller

Actual position value

MD 32810: EQUIV_SPEEDCTRL_TIME

Fig. 16-4

Speed feedforward control

Parameters
On start-up, the following axis-specific MD must be defined for the speed feedforward control:
MD 32810: EQUIV_SPEEDCTRL_TIME Equivalent time constant of the
connected speed control loop).

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

16-315

Compensation (K3)
16.5

16.5

Data descriptions (MD, SD)

Data descriptions (MD, SD)

Axis-specific machine data


32450
BACKLASH[n]
MD number
Backlash
Default: 0.0
Min. input limit: ***
Max. input limit: ***
Change valid after NEW_CONF
Protection level: 2/2
Unit: mm and/or degrees
Data type: DOUBLE
Valid from SW release:
Meaning:
Backlash between positive and negative traversing dircetions.
The input of the compensation value is
S positive if the encoder advances the machine part (normal case)
S negative if the encoder follows the machine part.
If 0 is entered, the compenation value is disabled.
The backlash compensation is always active in all operating modes after reference point approach.
Index [n] is coded as follows: [Encoder No.]: 0
Special cases, errors, ......
Related to ....
MD 36500: ENC_CHANGE_TOL
(backlash compensation segment)

32630
MD number
Default: 1
Change valid after RESET
Data type: Byte
Meaning:

Related to ....
Further references

FFW_ACTIVATION_MODE
Feedforward control can be enabled from the program
Min. input limit: 0
Max. input limit: 1
Protection level: 2/2
Unit: Valid from SW release:
This MD can be used to define whether the feedforward control for this axis/spindle can be enabled/disabled from the part program.
0:
The feedforward control cannot be enabled/disabled by FFWON and/or FFWOF.
1:
The feedforward control can be enabled/disabled by FFWON and/or FFWOF from the part
program.
The status last valid remains also active after RESET (and thus also in JOG mode).
Since FFWON and/or FFWOF is used to enable/disable the feedforward control of all axes of the
channel, this MD should be set to the same value for axes that interpolate with each other.
Operation and Programming

32700
ENC_COMP_ENABLE[n]
MD number
Encoder/leadscrew error compensation (LEC)
Default: 0
Min. input limit: 0
Max. input limit: 1
Change valid after NEW_CONF
Protection level: 2/2
Unit: Data type: BOOLEAN
Valid from SW release:
Meaning:
1: The LEC is enabled for the axis/measuring system.
The LEC can be used to compensate leadscrew errors and measuring system errors.
The function will internally only be enabled if the corresponding measuring system is referenced (IS: Referenced/synchronized 1 = 1).
Write-protection function (compensation values) active.
0: The LEC is not active for the axis/measuring system in question.

Related to ....

16-316

Index [n] is coded as follows: [Encoder No.]: 0


IS Referenced/synchronized 1

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Compensation (K3)
16.5

Data descriptions (MD, SD)

32810
EQUIV_SPEEDCTRL_TIME[n]
n = control parameter record No.: 0 ... 5
MD number
Equivalent time constant of speed control loop
Default:
Min. input limit: 0.0
Max. input limit: ***
(0.0005, 0.0005, ... , 0.0005)
Change valid after NEW_CONF
Protection level: 2/2
Unit: s
Data type: DOUBLE
Valid from SW release:
Meaning:
This equivalent time constant is required for the function Speed feedforward control.
The value must correspond to the equivalent time constant of the closed speed control loop.
Setting aid: Orientation value is the time constant of the setpoint smoothing in the drive.
Related to ....
MD 36400: CONTOUR_TOL (tolerance band of contour monitoring)

36500
ENC_CHANGE_TOL
MD number
Backlash compensation segment / tolerance of position actual-value switchover
Default: 0.1
Min. input limit: 0.0
Max. input limit: ***
Change valid after NEW_CONF
Protection level: 2/2
Unit: mm or degrees
Data type: DOUBLE
Valid from SW release:
Meaning:
Segment for backlash compensation input
This MD is used to manage large backlash compensation values. In this case, the backlash will
not be provided to the actual value at a time, but in n steps having a step size of
MD: ENC_CHANGE_TOL. The calculation of the backlash thus lasts n servo cycles. If the time
required to calculate the backlash completely is too large, standstill monitoring alarms can be output.
Related to ....

This MD is only active if MD: ENC_CHANGE_TOL is greater than MD: BACK_LASH.


MD 32450: BACKLASH[0] (backlash compensation)

38000
MM_ENC_COMP_MAX_POINTS[n]
(MD can only be displayed)
MD number
Number of intermediate points for encoder/spindle compensation (LEC)
Default: 125
Min. input limit: Max. input limit: Change valid after Power On
Protection level: 0/7
Unit: Data type: DWORD
Valid from SW release:
Meaning:
With the LEC, the maximum number of intermediate points per axis/measuring system is 125.
The required number k can be calculated as follows using to the specified parameters:
$AA_ENC_COMP_MAX - $AA_ENC_COMP_MIN

k
$AA_ENC_COMP_MIN
$AA_ENC_COMP_MAX
$AA_ENC_COMP_STEP

Related to ....

------------------------------------------- + 1
$AA_ENC_COMP_STEP

starting position
(system variable)
end position
(system variable)
intermediate point distance (system variable)

Index [n] is coded as follows: [encoder No.]: 0


MD 32700: ENC_COMP_ENABLE[n]
LEC active

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

16-317

Compensation (K3)
16.6

Data fields, lists

16.6

Data fields, lists

16.6.1

Interface signals

Number

.Bit

Name

Ref.

Axis/spindle-specific
V390x0000

.4

16.6.2

Referenced/synchronized 1

R1

Machine data

Number

Identifier

Name

Ref.

General
10240

SCALING_SYSTEM_IS_METRIC

Scaling system metric

G2

Axis-specific
32450

BACKLASH[n]

Backlash

32630

FFW_ACTIVATION_MODE

Feedforward control can be enabled from the program

32700

ENC_COMP_ENABLE[n]

Interpolatory compensation active

32810

EQUIV_SPEEDCTRL_TIME[n]

Equivalent time constant of speed control loop

36500

ENC_CHANGE_TOL

Backlash compensation segment

38000

MM_ENC_COMP_MAX_POINTS[n]

Intermediate points for encoder/spindle compensation (LEC) (only for display)

16-318

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Traversing to Fixed Stop (F1)

17

Note
This function is not available with the 802D base line.

With SINUMERIK 802D, this function is an option and available with software release 2.0 and
higher.

17.1

Brief description

Range of application
Using the function Traversing to fixed stop (FXS = Fixed Stop), it is possible to build up defined forces required for the clamping of workpieces, such as they are required for quills and
grippers. Furthermore, this function can also be used to approach mechanical reference
points. With a sufficiently reduced torque, simple measuring processes are also possible without a probe connected.
Traversing to fixed stop can be carried out for several axes at the same time and parallel to
the motion of other axes.
The fixed stop can be approached on a path (straight line, circle).

Availability
The function Traversing to fixed stop is available if the appropriate option is installed, i.e. if
the MD 37000: FIXED_STOP_MODE (mode Traversing to fixed stop) is set to 1. Then, the
function can be started from the NC program using the command FXS[x]=1.

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

17-319

Traversing to Fixed Stop (F1)


17.2

17.2

Functionality

Functionality

Programming
Traversing to fixed stop is selected using the command
FXS[machine axis identifier] = 1, and deselected via
FXS[machine axis identifier] = 0.
The clamping torque is set using the command
FXST[machine axis identifier] = <torque>.
The clamping torque is specified as a percentage of the static torque of the drive or as
a percentage of the motor torque if main spindle drives are used.
To set the width of the fixed stop monitoring window, the command
FXSW[machine axis identifier] = <window width>is used.
Unit: mm, inches or degrees - depending on the basic unit system, linear or rotary axis.
The commands are modal. The distance to be traversed and the activation of the function must be programmed in a separate block.

Note
With FXS..., it is permitted to program the machine axis identifier after MD 10000: AXCONF_NAME_TAB and should be used preferably.
The channel axis identifiers after MD 20070: AXCONF_CHANAX_NAME_TAB are permissible with
FXS... if them is assigned exactly one machine axis and, e.g. no rotation is active in the coordinate
system.

Axis-specific setting / machine data


If no monitoring window is programmed, the value specified in SD 43520:
FIXED_STOP_WINDOW will act. If a value is programmed, it will be effective and be accepted into the SD. In the beginning, the SD with the value specified in MD 37020: FIXED_STOP_WINDOW_DEF is loaded.
If no clamping torque is programmed, the value specified in SD 43510:
FIXED_STOP_TORQUE will act. If a value is programmed, it will be effective and be accepted into the SD. In the beginning, the SD with the value specified in MD 37010: FIXED_STOP_TORQUE_DEF is loaded.
The function is selected/deselected in the program only via FXS[X1]=1 / =0. In this case, the
value will also be written to SD 43500: FIXED_STOP_SWITCH (traversing to fixed stop).

17-320

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Traversing to Fixed Stop (F1)


17.2

Functionality

Programming examples
X250 Y100 F100 FXS[X1]=1

; FXS selected for machine axis X1


Clamping torque and window width as speci-

fied
in the SDs
X250 Y100 F100 FXS[X1]=1 FXST[X1]=12.3 ; FXS selected for machine axis X1
Clamping torque 12.3 %, window width as
specified in the SDs
X250 Y100 F100 FXS[X1]=1 FXST[X1]=2
; FXS selected for machine axis X1
Clamping torque 12.3 %,window width 2 2
X250 Y100 F100 FXS[X1]=1 FXSW[X1]=2
; FXS selected for machine axis X1,
clamping torque as specified in the SD,
window width 2 mm

Note
Once the function Traversing to fixed stop has been activated for one axis/spindle (no analog spindle), no new position may be programmed for this axis.
Before selecting this function, the spindle must be switched to the position-controlled mode.

System variable $AA_FXS[X1] for the status


This system variable delivers the status of Traversing to fixed stop for the specified axis:
Value = 0: Axis is not at the stop
1. The stop was approached successfully
(axis is in fixed-stop monitoring window)
2: Fixed-stop approach was not successful (axis is not at the stop)
3: Traversing to fixed stop activated
4: Stop was recognized
5: Traversing to fixed stop will be deselected. The deselection is not yet completed.
The interrogation of the system variable in the part program triggers a preprocessing stop.
Thanks to the status interrogation in the part program, it is possible, e.g. to react to a faulty
execution of the function Traversing to fixed stop.
Note: With SINUMERIK 802D, only the static states may be acquired.

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

17-321

Traversing to Fixed Stop (F1)


17.2

Functionality

Function example
Actual position after
Traversing to fixed stop

Progr.
end
position
Fig. 17-1

Fixed -stop
monitoring window

Start position

Example for traversing to fixed stop: The quill is pressed onto the workpiece

Selection
When preparing the blocks, the NC detects that the function Traversing to fixed stop has
been selected via the command FXS[x]=1 and signals the PLC using the IS Activate traversing to fixed stop that the function has been selected.
If the MD 37060: FIXED_STOP_ACKN_MASK (observe that traversing to fixed stop must be
acknowledged accordingly by the PLC) is set accordingly, it is waited until the acknowledgment is provided from the PLC via the IS Traversing to fixed stop.
Then, the programmed target position is approached from the start position at the programmed velocity. The fixed stop must be between the start and the target positions of the axis/
spindle. A programmed torque reduction is active from the beginning of the block, i.e. the approach of the stop is also carried out with a reduced torque. This is taken into account in the
NC by automatic acceleration reduction.
If no torque has been programmed in the block or no block has been programmed since the
program has been started, the value entered in the axis-specific MD 37010: FIXED_STOP_TORQUE_DEF (torque default setting) will apply.

Fixed stop is reached


Once the axis pressed onto the mechanical fixed stop (workpiece), the closed-loop control in
the drive will increase the torque to move the axis further. The torque will increase up to the
programmed limit value and will then remain constant.
Depending on the MD 37040:
FIXED_STOP_BY_SENSOR (fixed-stop detection via sensor), the status Fixed stop reached can be determined as follows:


17-322

FIXED_STOP_BY_SENSOR = 0
The status Fixed stop is reached is provided if the axis-specific contour deviation (= difference between the real and the expected following errors) has exceeded the value specified in MD 37030: FIXED_STOP_THRESHOLD (threshold for fixed-stop detection).

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Traversing to Fixed Stop (F1)


17.2

Functionality

FIXED_STOP_BY_SENSOR = 1
External sensor transmits the status Fixed stop reached to the NC via the PLC using the
IS Fixed stop sensor.

FIXED_STOP_BY_SENSOR = 2
The status Fixed stop reached is provided if either the contour monitoring function has
determined this status or when the external sensor this status via signal transition 0 1.

Internal sequences
After the status Fixed stop reached has been detected by the NC, the distance to go is deleted and the position setpoint value will follow; servo enable remains active.
Then the PLC is informed via the IS Fixed stop reached.
If the MD 37060: FIXED_STOP_ACKN_MASK is set accordingly, it is waited until the PLC
has provided the acknowledgment via the IS Acknowledge fixed stop reached.
The NC will then carry out a block change and/or will consider the positioning motion completed, but will leave, however, a setpoint at the drive actuator so that the clamping torque may
act.
After the fixed stop has been reached, the fixed-stop monitoring function is activated.

Monitoring window
If no fixed-stop monitoring window has been programmed in this block or has not been programmed since the program has been started, the value entered in the MD 37020: FIXED_STOP_WINDOW_DEF (default setting for the fixed-stop monitoring window) will apply.
If the axis leaves the position it has had when detecting the stop by more than the window
selected, alarm 20093 Fixed-stop monitoring has tripped is triggered, and the function Traversing to fixed stop is deselected.
It is the users responsibility to make sure that the alarm is only triggered if the stop is broken.

Enabling the fixed-stop alarms


The MD 37050: FIXED_STOP_ALARM_MASK can be used to suppress the output of the following alarms:


20091 Fixed stop not reached

20094 Fixed stop broken

Fixed stop is not reached


If the end position programmed is reached without the status Fixed stop reached detected,
the torque limitation in the drive is canceled and the IS Traversing to fixed stop is reset.
Depending on MD 37060: FIXED_STOP_ACKN_MASK, it is waited until the acknowledgment
is provided from the PLC by resetting the IS Traversing to fixed stop, and then the block
change is carried out.

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

17-323

Traversing to Fixed Stop (F1)


17.2

Functionality

Function is canceled
If the function Traversing to fixed stop is canceled due to the occurrence of a pulse inhibition,
cancellation of the PLC acknowledgments or RESET in the approach block, the display or
suppression of the alarm 20094 can be controlled via MD 37050: FIXED_STOP_ALARM_MASK.

Cancellation without alarm


It is possible to cancel traversing to fixed stop from the PLC in the approach block without triggering an alarm (e.g. when the operator hits a key) if the alarm 20094 is suppressed via the
MD 37050: FIXED_STOP_ALARM_MASK.
Both Fixed stop not reached and Fixed stop canceled will deselect the function Traversing
to fixed stop.

Alarms


If - when traversing to fixed stop - the target position is reached, the alarm 20091 Fixed
stop not reached is output, and a block change is carried out.

If a traversing request (e.g. from the part program or from the operator panel) is provided
for an axis after the fixed stop has been reached, alarm 20092 Traversing to fixed stop still
active is output and the axis is not moved.

If after reaching the fixed stop an axis is pushed out of its position by a value more than
specified in
SD 43520: FIXED_STOP_WINDOW (fixed-stop monitoring window), alarm 20093 Standstill monitoring has tripped at the stop is output, the function Traversing to fixed stop is
deselected for this axis, and the system variable $AA_FXS[x]=2 is set.

Sequence in case of fault or cancellation


The IS Traversing to fixed stop will be reset.
Depending on MD 37060: FIXED_STOP_ACKN_
MASK, it is waited until the acknowledgment is provided from the PLC by resetting the IS
Traversing to fixed stop, and then the block change is carried out.
Then, the torque limitation is canceled, and a block change is carried out.

Selection
The NC detects that the function has been deselected by programming the command
FXS[x]=0. Then, a preprocessing stop (STOPRE) is initiated internally, since it cannot be determined exactly in advance where the axis will stand after the deselection.
Both the torque limitation and the monitoring of the fixed-stop monitoring window will be canceled; the IS Activate traversing to fixed stop and Fixed stop reached will be reset.
Depending on MD 37060: FIXED_STOP_ACKN_MASK, it is waited until the acknowledgment
is provided from the PLC by resetting the IS Enable traversing to fixed stop and/or Acknowledge fixed stop reached.
The axis will then change to position control. The tracking of the position setpoint will be completed and be synchronized to the new actual position.

17-324

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Traversing to Fixed Stop (F1)


17.2

Functionality

Then, a new programmed traversing motion must be carried out. This must carry away from
the stop; otherwise, either the stop or even the machine could be damaged.
The block change is carried out after the target position has been reached.

Multiple selection
A selection may be carried out only once. If due to faulty programming the function is called
once more after (FXS[axis] = 1) has been activated, the alarm 20092 Traversing to fixed stop
still active is triggered.

Changing the clamping torque and the monitoring window


The commands FXST[x] and FXSW[x] can be used to change the clamping torque and the
fixed-stop monitoring window in the part program. The changes come into effect prior to traversing motions programmed in the same block.
If a new fixed-stop monitoring window is programmed, not only the window width will change,
but also the reference point for the window center if the axis has been moved beforehand. The
actual position of the machine axis when changing the window will be the new window center.

Ramp for the torque limit


MD 37012: FIXED_STOP_TORQUE_RAMP_TIME is used to specify a ramp for the change
of the torque. This ramp determines how long it will take until the new torque limit is reached.

Without ramp
A change in the torque limit will take place without taking into account the ramp in the following cases:


If FXS is activated via (FXS[]=1) to make sure that the reduction comes into effect immediately;

if the drive must be switched dead as fast as possible in case of error.

Behavior in case of pulse inhibition for the drive


MD 37002: FIXED_STOP_CONTROL can be used to control the behavior in case of pulse
inhibition at the stop. Deleting the pulses, e.g. as a result of the IS Pulse inhibition will not
cancel the function. As a result, the drive will press against the stop again when restarting the
pulses if no further operator action is carried out.
The rising time of the torque corresponds to the time required by the current controller of the
drive to reach the limiting again.
If the pulses are deleted during an active deselection (waiting for PLC acknowledgments), the
torque limit will be reduced to zero. In this phase, when restarting the pulses, no torque is
build up any more. Once the deselection has been completed, you can continue to traverse
normally.

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

17-325

Traversing to Fixed Stop (F1)


17.3

17.3

Behavior in case of RESET and cancellation of the function

Behavior in case of RESET and cancellation of the function

Behavior in case of RESET


During the selection (fixed stop is not yet reached), the function FXS can be canceled with
RESET. The cancellation is carried out such that a fixed stop nearly reached (setpoint already
across the fixed stop, but not yet within the threshold required to detect the fixed stop) will not
result in a damage.
This is reached by synchronizing the position setpoint to the new actual position. Once the
fixed stop has been reached, the function will remain active even after RESET.

Cancellation of the function


In the case of EMERGENCY STOP, both the NC and the drive cannot react, i.e. the PLC must
react.

Caution
Make absolutely sure that after cancellation of the function Traversing to fixed stop through
EMERGENCY STOP no hazardous machine situation (MD 37002: FIXED_STOP_CONTROL
e.g. Cancel pulse inhibition) may result.

The fixed-stop monitoring function will trip in the following cases:

17-326

Breakage of the stop

Tool breakage

Pulse inhibition

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Traversing to Fixed Stop (F1)


17.4

17.4

Behavior in the case of block search

Behavior in the case of block search

Block search with calculation


Do not approach the fixed stop before the target block.
Remedy: Use the SKIP function to disable blocks that contain fixed-block approach.

Block search without calculation


The commands FXS, FXST and FXSW will be ignored.

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

17-327

Traversing to Fixed Stop (F1)


17.5

17.5

Miscellaneous

Miscellaneous

Ineffective interface signals


Until deselection, the following interface signals (IS) (PLC ! NCK) are ineffective for axes at
the fixed stop (incl. traversing motion):


IS Axis/spindle disable

IS Servo enable

Actual position at the fixed stop


The system variable $AA_IM[x] can be used to determine the actual position of the machine
axis, e.g. for measuring purposes, after the fixed stop has been approached successfully.

Combination with the measuring function


Measuring with deletion of the distance to go (command MEAS) and Traversing to fixed
stop cannot be programmed in the same block.

Contour monitoring
No axis-specific contour monitoring is carried out during Traversing to fixed stop.

Selection with G64


Bit 0 inMD 37060: FIXED_STOP_ACKN_MASK must be 0 (not waiting for the PLC input signal Traversing to fixed stop enabled), since the selection of FXS may not trigger a motion
stop. If this bit is nevertheless programmed, the alarm 20090 Traversing to fixed stop not possible - check programming and axis data is triggered.

17-328

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Traversing to Fixed Stop (F1)


17.5

Miscellaneous

Diagram
The diagram below shows the characteristics of motor current, following error and interface
signals for Traversing to fixed stop with a digital drive.

FXST[x] or MD: FIXED_STOP_TORQUE_DEF

Motor current
0

MD 37030:
Following error

FIXED_STOP_THRESHOL
D
0

Block with FXS[x]=1


IS Activate FXS
IS FXS reached

Block change

Fig. 17-2

Diagram for FXS with a digital drive

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

17-329

Traversing to Fixed Stop (F1)


17.6

17.6

Data descriptions (MD, SD)

Data descriptions (MD, SD)

Axis-specific machine data


37000
FIXED_STOP_MODE
MD number
Mode Traversing to fixed stop
Default: 0
Min. input limit: 0
Max. input limit: 1
Change valid after Power On
Protection level: 2/2
Unit: Data type: BYTE
Valid from SW release: 2.0
Meaning:
This machine data is used to define how the function Traversing to fixed stop can be started.
Value
=0:
Traversing to fixed stop not available.
=1:
Traversing to fixed stop can be started from the NC program using the command
FXS[x]=1.

37002
FIXED_STOP_CONTROL
MD number
Special functions when traversing to fixed stop
Default: 0
Min. input limit: 0
Max. input limit: 1
Change valid after Power On
Protection level: 2/2
Unit: Data type: BYTE
Valid from SW release: 2.0
Meaning:
Bit 0: Behavior in case of pulse inhibition at the stop
=0:
Traversing to fixed stop will be aborted.
=1:
Traversing to fixed stop will be aborted, i.e. the drive will coats.
Once the pulse inhibition has been canceled, the drive will act again
using the limited torque.
The torque is connected suddenly.

37010
FIXED_STOP_TORQUE_DEF
MD number
Clamping torque default setting
Default: 5.0
Min. input limit: 0
Max. input limit: 100.0
Change valid after Power On
Protection level: 2/2
Unit: %
Data type: DOUBLE
Valid from SW release: 2.0
Meaning:
This machine data is used to enter the clamping torque as a percentage of the maximum motor
torque (with feed drives, corresponds to the percentage of the max. current setpoint).
The clamping torque is effective once the fixed stop has been reached or the IS Acknowledge
fixed stop reached has been set.

Related to ....

The entered value is only a default value and is only effective until
 no clamping torque has been programmed using the command FXST[x];
 the clamping torque has not been changed via the SD 43510: FIXED_STOP_TORQUE (after
reaching the fixed stop).
SD 43510: FIXED_STOP_TORQUE (clamping torque when traversing to fixed stop)

37012
FIXED_STOP_TORQUE_RAMP_TIME
MD number
Time required to reach the new clamping torque when traversing to fixed stop
Default: 0.0
Min. input limit: 0.0
Max. input limit: ***
Change valid after Power On
Protection level: 2/2
Unit: s
Data type: DOUBLE
Valid from SW release: 2.0
Meaning:
Time required to reach the changed torque limit
The division takes place in the position controller cycle and is provided from there suddenly.
The value 0.0 will deactivate the ramp function.

17-330

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Traversing to Fixed Stop (F1)


17.6

Data descriptions (MD, SD)

37020
FIXED_STOP_WINDOW_DEF
MD number
Default setting for the fixed-stop monitoring window
Default: 1.0
Min. input limit: 0
Max. input limit: ***
Change valid after Power On
Protection level: 2/2
Unit: mm, degrees
Data type: DOUBLE
Valid from SW release: 2.0
Meaning:
The default setting for the fixed-stop monitoring window is entered in this machine data.
The fixed-stop monitoring is effective once the fixed stop has been reached,
i.e. once the IS Fixed stop reached has been set.
If the position at which the fixed stop has been detected is left by a value more than the tolerance
specified in the MD: FIXED_STOP_WINDOW_DEF, the alarm 20093 Fixed-stop monitoring has
tripped is output, and the function FXS is deselected.

Related to ....

The entered value is only a default value and is only effective until
 no fixed-stop monitoring window has been programmed using the command FXSW[x];
 the fixed-stop window has not been changed via the SD 43520: FIXED_STOP_WINDOW
(after reaching the fixed stop).
SD 43520: FIXED_STOP_WINDOW (fixed-stop monitoring window)

37030
FIXED_STOP_THRESHOLD
MD number
Threshold for fixed-stop detection
Default: 2.0
Min. input limit: 0
Max. input limit: ***
Change valid after NEW_CONF
Protection level: 2/2
Unit: mm, degrees
Data type: DOUBLE
Valid from SW release: 2.0
Meaning:
The contour monitoring threshold for the fixed-stop detection is entered in this machine data.
This machine data is only effective if MD: FIXED_STOP_BY_SENSOR = 0.

MD not relevant with ......


Related to ....

The interface signal Fixed stop reached is set if the axis-specific contour deviation has exceeded
the value entered in the MD: FIXED_STOP_THRESHOLD.
MD 37040: FIXED_STOP_BY_SENSOR = 1
IS Fixed stop reached

37040
FIXED_STOP_BY_SENSOR
MD number
Fixed-stop detection via sensor
Default: 0
Min. input limit: 0
Max. input limit: 2
Change valid after Power On
Protection level: 2/2
Unit: Data type: BYTE
Valid from SW release: 2.2
Meaning:
This machine data is used to define how the criterion Fixed stop reached
is determined.
Value =0: The criterion Fixed stop reached is determined internally on the basis of the axisspecific
contour deviation (threshold specified by the MD: FIXED_STOP_THRESHOLD).
=1: The criterion Fixed stop reached is determined via an external sensor and
transmitted to the NC via the IS Fixed stop sensor.
=2: The criterion Fixed stop reached is assumed if either the
contour deviation (acc. to value = 0) or
the signal of the external sensor (acc. to value = 1) has tripped.
Related to ....
MD 37030: FIXED_STOP_THRESHOLD (threshold for fixed-stop detection)
IS Fixed stop sensor

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

17-331

Traversing to Fixed Stop (F1)


17.6

Data descriptions (MD, SD)

37050
FIXED_STOP_ALARM_MASK
MD number
Enabling of the fixed-stop alarms
Default: 1
Min. input limit: 0
Max. input limit: 7
Change valid after NEW_CONF
Protection level: 2/2
Unit: Data type: BYTE
Valid from SW release: 2.0
Meaning:
This machine data is used to define whether the alarms
20091 Fixed stop not reached and
20094 Fixed stop broken are signaled.
Value =0:
Suppress alarm 20091 Fixed stop not reached
= 2:
Suppress alarms
20091 Fixed stop not reached and
20094 Fixed stop broken
= 3:
Suppress alarm 20094 Fixed stop broken
Any other permissible values  7 will not suppress the alarms.

37060
FIXED_STOP_ACKN_MASK
MD number
Observing PLC acknowledgments for traversing to fixed stop
Default: 0
Min. input limit: 0
Max. input limit: 3
Change valid after Power On
Protection level: 2/2
Unit: Data type: BYTE
Valid from SW release: 2.0
Meaning:
This machine data defines whether or not it is waited for PLC acknowledgments during the function Traversing to fixed stop.
Bit 0 = 0:

After the NC has transmitted the IS Activate traversing to fixed stop to the PLC,
it will start the traversing motion programmed.

Bit 0 = 1:

After the NC has transmitted the IS Activate traversing to fixed stop to the PLC,
the NC will wait for an acknowledgment by the PLC via the
IS Enable traversing to fixed stop and will then start the traversing motion program-

med.
Bit 1 = 0:

After the NC has transmitted the IS Fixed stop reached to the PLC, the
block change will take place.

Bit 1 = 1:

Related to ....

After the NC has transmitted the IS Activate traversing to fixed stop to the PLC,
the NC will wait for an acknowledgment by the PLC via the
IS Acknowledge fixed stop reached, will then output the torque programmed and will
then carry out the block change.
IS Activate traversing to fixed stop
IS Enable traversing to fixed stop
IS Fixed stop reached
IS Acknowledge fixed stop reached

Axis-specific setting data


43500
SD number
Default: 0
Change valid immediately
Data type: BYTE
Meaning:

FIXED_STOP_SWITCH
Selection Traversing to fixed stop
Min. input limit: 0
Max. input limit: 1
Protection level: 2/2
Unit: Valid from SW release: 2.0
This setting data can be used to check the function Traversing to fixed stop.
Value =0: Deselect Traversing to fixed stop
=1: Select Traversing to fixed stop
The setting data is overwritten by the part program via the command FXS[x]=1/0.

17-332

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Traversing to Fixed Stop (F1)


17.6

43510
SD number
Default: 5.0
Change valid immediately
Data type: DOUBLE
Meaning:

Data descriptions (MD, SD)

FIXED_STOP_TORQUE
Clamping torque when traversing to fixed stop
Min. input limit: 0.0
Max. input limit: 100.0
Protection level: 2/2
Unit: %
Valid from SW release: 2.0
This setting data is used to enter the clamping torque as a percentage of the maximum motor torque
(with feed drives, corresponds to the percentage of the max. current setpoint).
Make sure that a clamping torque greater than 100% may exist only for a short time; otherwise, the
motor will be damaged!
When selecting the function Traversing to fixed stop by programming FXS[.],
the default setting of the MD 37010: FIXED_STOP_TORQUE_DEF is effective up to the programming with FXST[.] .
The command FXST[x] results in a block-synchronous change of this setting data.
Furthermore, this setting data can be changed by the operator.
The SD is already active when the stop is approached.

Related to ....

The fixed stop is deemed to be reached if


the IS Fixed stop reached is set by the NC in the MD 37060: FIXED_STOP_ACKN_MASK,
Bit 1 = 0: (no acknowledgment required);
Bit 1 = 1: (acknowledgment required) the IS Fixed stop reached is set by the NC
and an acknowledgment is provided via the IS Acknowledge fixed stop reached.
MD 37010: FIXED_STOP_TORQUE_DEF (torque default setting)

43520
SD number
Default: 1.0
Change valid immediately
Data type: DOUBLE
Meaning:

FIXED_STOP_WINDOW
Fixed-stopmonitoring window
Min. input limit: 0.0
Max. input limit: ***
Protection level: 7/7
Unit: mm, degrees
Valid from SW release: 2.0
The fixed-stop monitoring window is entered in this machine data.
This setting data is only effective if the fixed stop has been reached.
The fixed stop is deemed to be reached if
the IS Fixed stop reached is set by the NC in the MD 37060: FIXED_STOP_ACKN_MASK,
Bit 1 = 0: (no acknowledgment required);
Bit 1 = 1: (acknowledgment required) the IS Fixed stop reached is set by the NC
and an acknowledgment is provided via the IS Acknowledge fixed stop reached.
If the position at which the fixed stop has been detected is left by a value more than the tolerance
specified in the SD43520: FIXED_STOP_WINDOWDEF, the alarm
20093 Fixed-stop monitoring has tripped is output, and the function FXS is deselected.
The command FXSW[x] results in a block-synchronous change of this setting data.
Furthermore, this setting data can be changed by the operator.

Related to ....

Otherwise, if Traversing to fixed stop is active, the value specified in the MD: FIXED_STOP_WINDOW_DEF is accepted into the setting data.
MD 37020: FIXED_STOP_WINDOW_DEF (default setting for the fixed-stop monitoring window)

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

17-333

Traversing to Fixed Stop (F1)


17.7

17.7

Signal descriptions

Signal descriptions

Signals to axis/spindle
V380x 0001.1
Interface signal
Edge evaluation: no
Signal status 1 or signal
transition 0 - - -> 1

Signal status 0

Acknowledge fixed stop reached


Signal(s) to axis/spindle (PLC ! NCK)
Signal(s) updated: cyclically
Signal(s) valid from SW release: 2.0
Meaning after reaching the fixed stop:
IS Fixed stop reached = 1
! The axis presses with the clamping torque against the fixed stop
! the fixed-stop window is activated
! a block change is carried out
Meaning after reaching the fixed stop:
IS Fixed stop reached = 1
! The axis presses with its clamping torque against the fixed stop
! the fixed-stop window is activated
! No block change is carried out and the channel message
Wait: AuxFunct acknowledgment missing is displayed.

Signal transition 1 - - -> 0

IS not relevant with ....


Related to ....

Meaning after reaching the fixed stop:


IS Fixed stop reached = 1
The function is canceled; the alarm 20094 axis %1 function was canceled is displayed.
Meaning when deselecting the function FXS = 0 via the part program:
Both the torque limitation and the monitoring of the fixed-stop monitoring window will be canceled;
MD 37060: FIXED_STOP_ACKN_MASK (observe PLC acknowledgments for traversing to fixed
stop) = 0 or 1 (but with values >1)
MD 37060: FIXED_STOP_ACKN_MASK (observe PLC acknowledgments for traversing to fixed
stop)
IS Fixed stop reached

V380x 0001.2
Interface signal
Edge evaluation: no
Signal status 1 or signal
transition 0 - - -> 1
Signal status 0 or signal
transition 1 - - -> 0
Related to ....

Fixed stop sensor


Signal(s) to axis/spindle (PLC ! NCK)
Signal(s) updated: cyclically
Fixed stop is reached.

V380x 0003.1
Interface signal
Edge evaluation: no
Signal status 1 or signal
transition 0 - - -> 1

Enable traversing to fixed stop


Signal(s) to axis/spindle (PLC ! NCK)
Signal(s) updated: cyclically
Signal(s) valid from SW release: 2.0
Meaning when selecting the function FXS via the part program
(IS Activate traversing to fixed stop = 1):

Signal(s) valid from SW release: 2.0

Fixed stop is not reached.


The signal is only effective if MD 37040: FIXED_STOP_BY_SENSOR = 1.

Traversing to fixed stop will be enabled and the axis will traverse from the starting position to the
programmed target position at the velocity programmed.

17-334

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Traversing to Fixed Stop (F1)


17.7

Signal descriptions

V380x 0003.1
Interface signal
Signal status 0

Enable traversing to fixed stop


Signal(s) to axis/spindle (PLC ! NCK)
Meaning when selecting the function FXS via the part program
(IS Activate traversing to fixed stop = 1):
! Traversing to fixed stop is disabled.
! The axis stands with the reduced torque at the starting position.
! The channel message Wait: AuxFunct acknowledgment missing is displayed.

Signal transition 1 - - -> 0

Meaning before reaching the fixed stop


IS Fixed stop reached = 0.
! Traversing to fixed stop is canceled
! The alarm 20094: Axis%1 function was canceled is displayed.

IS not relevant with ....


Related to ....

Meaning after reaching the fixed stop


IS Fixed stop reached = 1.
Both the torque limitation and the monitoring of the fixed-stop monitoring window will be canceled;
MD 37060: FIXED_STOP_ACKN_MASK (observe PLC acknowledgments for traversing to fixed
stop) = 0 or 2.
MD 37060: FIXED_STOP_ACKN_MASK (observe PLC acknowledgments for traversing to fixed
stop)
IS Activate traversing to fixed stop

Signals from axis/spindle


V390x 0002.4
Interface signal
Edge evaluation: no
Signal status 1 or signal
transition 0 - - -> 1

Activate traversing to fixed stop


Signal(s) from axis/spindle (NCK ! PLC)
Signal(s) updated: cyclically
The function Traversing to fixed stop is active.

Signal status 0 or signal


transition 1 - - -> 0

The function Traversing to fixed stop is not active.

V390x 0002.5
Interface signal
Edge evaluation: no
Signal status 1 or signal
transition 0 - - -> 1

Fixed stop reached


Signal(s) from axis/spindle (NCK ! PLC)
Signal(s) updated: cyclically
Signal(s) valid from SW release: 2.0
The fixed stop was reached after the function FXS has been selected.

Signal status 0 or signal


transition 1 - - -> 0

The fixed stop was even not yet reached after the function FXS has been selected.

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Signal(s) valid from SW release: 2.0

17-335

Traversing to Fixed Stop (F1)


17.8

Data fields, lists

17.8

Data fields, lists

17.8.1

Interface signals

Number

.Bit

Name

Ref.

axis/spindle-specific
V380x 0001

.1

Acknowledge fixed stop reached

V380x 0001

.2

Fixed stop sensor

V380x 0001

.3

Axis/spindle disable

Chpt.18

V380x 0002

.1

Servo enable

Chpt. 18

V380x 0003

.1

Enable traversing to fixed stop

V390x 0002

.4

Activate traversing to fixed stop

V390x 0002

.5

Fixed stop reached

17.8.2

Machine data/setting data

Machine data
Number

Identifier

Name

Ref.

axis-specific
37000

FIXED_STOP_MODE

Mode Traversing to fixed stop

37002

FIXED_STOP_CONTROL

Special functions when traversing to fixed stop

37010

FIXED_STOP_TORQUE_DEF

Clamping torque default setting

37012

FIXED_STOP_TORQUE_RAMP_TIME

Time required to reach the new clamping torque


when traversing to fixed stop

37020

FIXED_STOP_WINDOW_DEF

Default setting for the fixed-stop monitoring window

37030

FIXED_STOP_THRESHOLD

Threshold for fixed-stop detection

37040

FIXED_STOP_BY_SENSOR

Fixed-stop detection via sensor

37050

FIXED_STOP_ALARM_MASK

Enabling of the fixed-stop alarms

37060

FIXED_STOP_ACKN_MASK

Observing PLC acknowledgments for traversing to


fixed stop

Setting data
Number

Identifier

Name

Ref.

axis-specific
43500

FIXED_STOP_SWITCH

Selection Traversing to fixed stop

43510

FIXED_STOP_WINDOW

Fixed-stopmonitoring window

43520

FIXED_STOP_TORQUE

Clamping torque when traversing to fixed stop

17-336

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Kinematic Transformations (M1)

18

Note
This function is not available with the 802D base line.

With SINUMERIK 802D, these functions are options and are available with software release
2.0 and higher.

18.1

Brief description

Range of application
The control system transforms programmed traversing instructions from a Cartesian coordinate system into a real coordinate system.
The TRANSMIT transformation is used for the end-face milling machining of turned parts on
turning machines (without Y machine axis).
The TRACYL transformation is used for the machining of peripheral surfaces of cylindrical
bodies. The main application is the milling of grooves. One TRACYL variant is intended for
turning machines. A second variant is intended for turning machines with an additional Y machine axis or for milling machines with a suitable rotary table.

Machine requirements
The turning machine must possess a main spindle which is able to be operated as a C axis. A
2nd spindle must be able to drive the milling tool.
When working with TRACYL, the milling machine must possess a rotary table which is able to
interpolate with the other axes.

Availability
The functions TRANSMIT and TRACYL are available if the relevant option is installed. They
are configured via separated machine data blocks and activated/deactivated via special statements in the program.
With SINUMERIK 802D, a maximum of two kinematic transformations (TRANSMIT, TRACYL)
can be configured; one of them can be activated via the program.

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

18-337

Kinematic Transformations (M1)


18.2

TRANSMIT

18.2

TRANSMIT

18.2.1

Overview

CM

Fig. 18-1

XM
ASM
ZM

Face-end milling machining of turned parts using TRANSMIT

Legend for the diagram above:


X, Y, Z Cartesian coordinate system for programming the face-end machining
ASM 2. Spindle (work spindle for milling tool, drill)
ZM
Z machine axis (linear)
XM
X machine axis (linear)
CM
C axis (main spindle as a rotary axis)

Required machine kinematics


The two linear axes (XM, ZM) must stand vertically to one another. The rotary axis (CM) must
run parallel to the linear axis ZM (rotate around ZM). The linear axis XM intersects the rotary
axis CM (turning center).

Activating / deactivating TRANSMIT


The TRANSMIT function is activated in the program via
TRANSMIT
in a separate block and deactivated via
TRAFOOF
also programmed in a separate block.
TRAFOOF will deactivate any active transformation function.

18-338

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Kinematic Transformations (M1)


18.2

TRANSMIT

Programming principle
N10 G0 X... Z... SPOS=...
; Park positions; spindle in position control
N20 G17 G94 T...
; Plane, feedrate type, select milling tool
N30 SETMS(2)
; Switching over: master spindle is now milling spindle
N40 TRANSMIT
; Activate TRANSMIT
N50 G1 G41 F200 X... Y... Z... M3 S... ; Milling of the end face with cutter radius compensation
...
N90 G40 ...
N100 TRAFOOF
; Deactivate TRANSMIT
N110 G18 G95 T...
; Switching back to turning
N120 SETMS
; Master spindle is main spindle
Explanation:
Depending on the programmed X-Y path (straight line or path), the machine axes XM and CM
move such that the contour at the end face of the turned part is created by the milling tool.
The programmed Z axis (infeed) is continued to be traversed as a Z axis.

18.2.2

Configuring TRANSMIT

General
The transformation function TRANSMIT is configured via appropriate settings in the machine
data.
Note:
The Toolbox for SINUMERIK 802D offers a file with default machine data. By specifying appropriate values and loading this file into the control system, a quick start-up of TRANSMIT is
possible.

General machine data


The names of the machine axes, channel axes and geometry axes used for the general machine data ($MN_AXCONF... and $MC_AXCONF... ) are also used for the transformation.
The geometry axis assignments made in $MC_AXCONF_GEOAX_ASSIGN_TAB only apply
with the transformation disabled. For the transformation enabled, special assignments are
made.

Note
The machine axis names, channel axis names and geometry axis names specified for transformations must be different:
MD 10000: AXCONF_MACHAX_NAME_TAB,
MD 20080: AXCONF_CHANAX_NAME_TAB,
MD 20060: AXCONF_GEOAX_NAME_TAB.
Exception with TRANSMIT:
The axis names of MD 20060 and MD 20080 (geometry and channel axes) can be the same for the
transformation TRANSMIT, e.g.: X, Y, Z. There is no Y axis if the transformation is not enabled.

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

18-339

Kinematic Transformations (M1)


18.2

TRANSMIT

Machine data required for transformations


$MC_TRAFO_TYPE_n
; = 256 for the TRANSMIT transformation
$MC_TRAFO_GEOAX_ASSIGN_TAB_n : Geometry axes, in particular, for transformation n
$MC_TRAFO_AXES_IN_n
; Assignment of the channel axes for transformation n
n = 1 of 2 (number of the transformation)
Required assignment of the channel axes for the TRANSMIT transformation:
$MC_TRAFO_AXES_IN_1[0]= Channel axis number of the axis vertically to the rotary axis
$MC_TRAFO_AXES_IN_1[1]= Channel axis number of the rotary axis
$MC_TRAFO_AXES_IN_1[2]= Channel axis number of the axis parallel to the rotary axis

Special machine data required particularly for TRANSMIT


$MC_TRANSMIT_ROT_AX_OFFSET_1
; Position of rotation of the x-y plane of the
Cartesian coordinate system with regard to the defined zero position of the
rotary axis in degrees (0...<360)
$MC_TRANSMIT_ROT_SIGN_IS_PLUS_1 ; If the direction of rotation of the rotary axis in
the x-y plane is CCW when viewing in the opposite direction of the positive
axis, then set the machine data to 1; otherwise, to 0.
Y
+
X

Fig. 18-2

Direction of rotation for MD value =1

$MC_TRANSMIT_BASE_TOOL_1
; The control system is communicated the position of
the tool zero with reference to the origin of the coordinate system agreed for
TRANSMIT. The machine data possesses three components for the three
axes of the Cartesian coordinate system.
Assignment of the axis components:
$MC_TRANSMIT_BASE_TOOL_1[0]=Tx
$MC_TRANSMIT_BASE_TOOL_1[1]=Ty
$MC_TRANSMIT_BASE_TOOL_1[2]=Tz

(see diagram below )

Y
Tx

Tz
Ty

Tool zero

Tx, Ty, Tz - axis components of the position

Fig. 18-3

18-340

Position of the tool zero with reference to the origin of the Cartesian coordinate
system (turning center)

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Kinematic Transformations (M1)


18.2

$MC_TRANSMIT_POLE_SIDE_FIX_1 = 0

TRANSMIT

; Pole passed continuously

Passing the pole


The turning center in the point X=0, Y=0 of the TRANSMIT plane is called the pole (X machine axis intersects the turning center).
In the vicinity of the pole, even small changes in the position of the geometry axes X, Y
usually result in large changes in the position of the machine rotary axis (except: the path results only in a motion of the XM axis).
It is therefore not recommended to machine a workpiece in the vicinity of the pole, since in
some cases substantial feedrate reductions are required to avoid that the rotary axis is not
overloaded. Avoid to select TRANSMIT if the tool stands exactly in the pole. Avoid an intersection of the pole X0/Y0 with the path of the tool center point.

Example: Machine data settings required for TRANSMIT


; general settings (here axis names: XM->X1, ZM->Z1, CM->SP1):
N10000 $MN_AXCONF_MACHAX_NAME_TAB[0]=X1
N10000 $MN_AXCONF_MACHAX_NAME_TAB[1]=Z1
N10000 $MN_AXCONF_MACHAX_NAME_TAB[2]=SP1
N10000 $MN_AXCONF_MACHAX_NAME_TAB[3]=SP2
N10000 $MN_AXCONF_MACHAX_NAME_TAB[4]=
N20050 $MC_AXCONF_GEOAX_ASSIGN_TAB[0]=1
N20050 $MC_AXCONF_GEOAX_ASSIGN_TAB[1]=0
N20050 $MC_AXCONF_GEOAX_ASSIGN_TAB[2]=2
N20060 $MC_AXCONF_GEOAX_NAME_TAB[0]=X
N20060 $MC_AXCONF_GEOAX_NAME_TAB[1]=Y
N20060 $MC_AXCONF_GEOAX_NAME_TAB[2]=Z
N20070 $MC_AXCONF_MACHAX_USED[0]=1
N20070 $MC_AXCONF_MACHAX_USED[1]=2
N20070 $MC_AXCONF_MACHAX_USED[2]=3
N20070 $MC_AXCONF_MACHAX_USED[3]=4
N20070 $MC_AXCONF_MACHAX_USED[4]=0
N20080 $MC_AXCONF_CHANAX_NAME_TAB[0]=X
N20080 $MC_AXCONF_CHANAX_NAME_TAB[1]=Z
N20080 $MC_AXCONF_CHANAX_NAME_TAB[2]=C
N20080 $MC_AXCONF_CHANAX_NAME_TAB[3]=SP2
N20080 $MC_AXCONF_CHANAX_NAME_TAB[4]=
N20090 $MC_SPIND_DEF_MASTER_SPIND=1
; Transformation type TRANSMIT:
N24100 $MC_TRAFO_TYPE_1=256
N24110 $MC_TRAFO_AXES_IN_1[0]=1
N24110 $MC_TRAFO_AXES_IN_1[1]=3
N24110 $MC_TRAFO_AXES_IN_1[2]=2
N24110 $MC_TRAFO_AXES_IN_1[3]=0
N24110 $MC_TRAFO_AXES_IN_1[4]=0
N24120 $MC_TRAFO_GEOAX_ASSIGN_TAB_1[0]=1
N24120 $MC_TRAFO_GEOAX_ASSIGN_TAB_1[1]=3
N24120 $MC_TRAFO_GEOAX_ASSIGN_TAB_1[2]=2

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

18-341

Kinematic Transformations (M1)


18.2

TRANSMIT

; Special TRANSMIT settings:


N24900 $MC_TRANSMIT_ROT_AX_OFFSET_1=0
N24910 $MC_TRANSMIT_ROT_SIGN_IS_PLUS_1=1
N24920 $MC_TRANSMIT_BASE_TOOL_1[0]=0
N24920 $MC_TRANSMIT_BASE_TOOL_1[1]=0
N24920 $MC_TRANSMIT_BASE_TOOL_1[2]=0
; Setting data for the special cases of tool compensation:
; (only if necessary)
N42940 $SC_TOOL_LENGTH_CONST=18
N42950 $SC_TOOL_LENGTH_TYPE=2
; Settings for the 2nd spindle (milling spindle of the turning machine):
N30300 $MA_IS_ROT_AX[AX4]=1
N30310 $MA_ROT_IS_MODULO[AX4]=1
N30320 $MA_DISPLAY_IS_MODULO[AX4]=1
N35000 $MA_SPIND_ASSIGN_TO_MACHAX[AX4]=2
N43300 $SA_ASSIGN_FEED_PER_REV_SOURCE[AX4]=0
Note: Special handling of milling tools on turning machines is only possible with regard to the
length compensation. Reference: Chapter Tool: Compensation and Monitoring

18-342

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Kinematic Transformations (M1)


18.3

18.3
18.3.1

TRACYL

TRACYL
Overview

Standard turning machine (without Y machine axis)

CM

ASM

XM

ZM

Legend:
XM
ZM
CM
ASM
Fig. 18-4

Infeed axis, vertically to the rotary axis


Axis parallel to the rotary axis
Rotary axis
Workspindle
Machining a groove on a cylinder peripheral surface using X-C-Z kinematics

Required machine kinematics


The two linear axes (XM, ZM) must stand vertically to one another. The rotary axis (CM) must
run parallel to the linear axis ZM (rotate around ZM). The linear axis XM intersects the rotary
axis CM (turning center).

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

18-343

Kinematic Transformations (M1)


18.3

TRACYL

Machine with a Y axis

CM
YM

XM

ASM

ZM

Legend:
XM
YM
ZM
CM
ASM
Fig. 18-5

Infeed axis, vertically to the rotary axis


Additional axis
Axis parallel to the rotary axis
Rotary axis
Workspindle
Machining a groove on a cylinder peripheral surface using X-Y-Z-C kinematics

Extended machine kinematics


In addition to the required machine kinematics (see above), the linear axis YM is additionally
existing here. This is arranged vertically to XM and ZM and, together with them, constitutes a
right-handed Cartesian coordinate system.
These kinematics are typical for milling machines; they can be used to manufacture grooves
with which the groove wall and the groove bottom stand vertically to one another - if the milling diameter is less than the groove diameter (groove wall compensation). Otherwise, these
grooves can only be manufactured if the milling diameter matches exactly.

18-344

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Kinematic Transformations (M1)


18.3

Grooves in cross section



Longitudinal groove

Cross groove

Without groove wall compensation


(without YM axis)

Fig. 18-6

TRACYL

Longitudinal groove
limited in parallel
via groove wall
compensation
(use of the YM axis)

Grooves with and without groove compensation

Activating / deactivating TRACYL


The TRACYL function is activated in the program via
TRACYL(d)
in a separate block and deactivated via
TRAFOOF
also programmed in a separate block.
d - machining diameter of the cylinder in mm
TRAFOOF will deactivate any active transformation function.

Programming principle
; without YM axis The geometry axes X, Y, Z are programmed
N10 G0 X... Z... SPOS=...
; Park positions; spindle in position control
N20 G19 G94 T...
; Plane, feedrate type, select milling tool
N30 SETMS(2)
; Switching over: Master spindle is now milling spindle
N40 TRACYL(24.876)
; Activation of TRACYL; diameter: 24.876 mm
N50 G1 F200 X... M3 S...
; Infeed, turning on the milling spindle
N600 G41 F200 Y... Z...
; Milling of the cylinder peripheral surface with
cutter radius compensation
...
N90 G40 ...
N100 TRAFOOF
; Deactivate TRACYL
N110 G18 G95 T...
; Switching back to turning
N120 SETMS
; Master spindle is main spindle
Explanation:
Depending on the programmed Y-Z path (straight line or path), the machine axes ZM and CM
move such that this contour is created by the milling tool on the peripheral surface of the cylindrical workpiece. The programmed X axis (infeed) is continued to be traversed as an X axis.

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

18-345

Kinematic Transformations (M1)


18.3

TRACYL

The cylinder rolled off at the outside diameter d results in the


peripheral surface with the programming plane Y -Z (G19).
Thus, e.g. the direction of rotation is also defined when
working with G2, G3.
0

d*

Groove

Fig. 18-7

Peripheral surface of the cylinder, G19 (Y-Z plane)

Address OFFN
Distance of the groove side wall to the reference contour (see also Programming example
TRACYL)
Programming: OFFN=...
; Distance in mm
Usually, the groove center line is programmed. OFFN defines the groove width when working
with cutter radius compensation (G41, G42). Set OFFN=0 after manufacturing the groove.

18.3.2

Configuring TRACYL

General
The transformation function TRACYL is configured via appropriate settings in the machine
data.
Note:
The Toolbox for SINUMERIK 802D offers a file with default machine data. By specifying appropriate values and loading this file into the control system, a quick start-up of TRACYL is
possible.

General machine data


The names of the machine axes, channel axes and geometry axes used for the general machine data ($MN_AXCONF... and $MC_AXCONF... ) are also used for the transformation.

18-346

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Kinematic Transformations (M1)


18.3

TRACYL

The geometry axis assignments made in $MC_AXCONF_GEOAX_ASSIGN_TAB only apply


with the transformation disabled. For the transformation enabled, special assignments are
made.

Note
The machine axis names, channel axis names and geometry axis names specified for transformations must be different:
MD 10000: AXCONF_MACHAX_NAME_TAB,
MD 20080: AXCONF_CHANAX_NAME_TAB,
MD 20060: AXCONF_GEOAX_NAME_TAB.
Exception with TRACYL:
The axis names of MD 20060 and MD 20080 (geometry and channel axes) can be the same
for the transformation TRACYL (e.g.: X, Y, Z) if there is no Y axis if the transformation is not
enabled. This is generally the case with turning machines.

Machine data required for transformations


$MC_TRAFO_TYPE_n

; = 512 for the TRACYL transformation (without YM axis)


; = 513 for the TRACYL transformation with YM axis
$MC_TRAFO_GEOAX_ASSIGN_TAB_n : Geometry axes, in particular, for transformation n
$MC_TRAFO_AXES_IN_n
; Assignment of the channel axes for transformation n
n = 1 of 2 (number of the transformation)
Required assignment of the channel axes for the TRACYL transformation:
$MC_TRAFO_AXES_IN_1[0]= Channel axis number of the axis radially to the rotary axis
$MC_TRAFO_AXES_IN_1[1]= Channel axis number of the rotary axis
$MC_TRAFO_AXES_IN_1[2]= Channel axis number of the axis parallel to the rotary axis

if configured with the existing YM axis:$MC_TRAFO_AXES_IN_1[3]=


Channel axis number of the axis parallel to the cylinder peripheral surface
and vertically to the rotary axis (-> YM axis)

Special machine data required particularly for TRACYL


$MC_TRACYL_ROT_AX_OFFSET_1; Position of rotation: Rotary axis position at which Y=0
in degrees (0...<360)

Y
b
a

Angle a-b in degrees

a
b
Fig. 18-8

Position of the rotation of the


rotary axis with C= 0
Position of Y= 0

Position of the rotation of the axis in the cylinder peripheral surface

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

18-347

Kinematic Transformations (M1)


18.3

TRACYL

$MC_TRACYL_ROT_SIGN_IS_PLUS_1 ; If the direction of rotation of the rotary axis in the


x-y plane is CCW when viewing in the opposite direction of the positive axis,
then set the machine data to 1; otherwise, to 0.
y
+
x

Fig. 18-9

Direction of rotation for MD value =1

$MC_TRACYL_BASE_TOOL_1

Assignment of the axis components:


$MC_TRACYL_BASE_TOOL_1[0]=Tx
$MC_TRACYL_BASE_TOOL_1[1]=Ty
$MC_TRACYL_BASE_TOOL_1[2]=Tz

; The control system is communicated the position


of the tool zero with reference to the origin of the
coordinate system agreed for TRACYL. The
machine data possesses three components for the
three axes of the Cartesian coordinate system.

(see diagram below )

Ty
Tx

Y
X

Tz

Tool zero

YC

Fig. 18-10 Position of the tool zero with regard to the machine zero

Example: Machine data settings required for TRACYL on a standard turning machine
; general settings (here axis names: XM->X1, ZM->Z1, CM->SP1):
N10000 $MN_AXCONF_MACHAX_NAME_TAB[0]=X1
N10000 $MN_AXCONF_MACHAX_NAME_TAB[1]=Z1
N10000 $MN_AXCONF_MACHAX_NAME_TAB[2]=SP1
N10000 $MN_AXCONF_MACHAX_NAME_TAB[3]=SP2
N10000 $MN_AXCONF_MACHAX_NAME_TAB[4]=
N20050 $MC_AXCONF_GEOAX_ASSIGN_TAB[0]=1
N20050 $MC_AXCONF_GEOAX_ASSIGN_TAB[1]=0
N20050 $MC_AXCONF_GEOAX_ASSIGN_TAB[2]=2
N20060 $MC_AXCONF_GEOAX_NAME_TAB[0]=X

18-348

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Kinematic Transformations (M1)


18.3

TRACYL

N20060 $MC_AXCONF_GEOAX_NAME_TAB[1]=Y
N20060 $MC_AXCONF_GEOAX_NAME_TAB[2]=Z
N20070 $MC_AXCONF_MACHAX_USED[0]=1
N20070 $MC_AXCONF_MACHAX_USED[1]=2
N20070 $MC_AXCONF_MACHAX_USED[2]=3
N20070 $MC_AXCONF_MACHAX_USED[3]=4
N20070 $MC_AXCONF_MACHAX_USED[4]=0
N20080 $MC_AXCONF_CHANAX_NAME_TAB[0]=X
N20080 $MC_AXCONF_CHANAX_NAME_TAB[1]=Z
N20080 $MC_AXCONF_CHANAX_NAME_TAB[2]=C
N20080 $MC_AXCONF_CHANAX_NAME_TAB[3]=SP2
N20080 $MC_AXCONF_CHANAX_NAME_TAB[4]=
N20090 $MC_SPIND_DEF_MASTER_SPIND=1
; Transformation type TRACYL for the 2nd transformation:
N24200 $MC_TRAFO_TYPE_2=512
; = without groove wall compensation (no YM axis)
N24210 $MC_TRAFO_AXES_IN_2[0]=1
N24210 $MC_TRAFO_AXES_IN_2[1]=3
N24210 $MC_TRAFO_AXES_IN_2[2]=2
N24210 $MC_TRAFO_AXES_IN_2[3]=0
N24210 $MC_TRAFO_AXES_IN_2[4]=0
N24220 $MC_TRAFO_GEOAX_ASSIGN_TAB_2[0]=1
N24220 $MC_TRAFO_GEOAX_ASSIGN_TAB_2[1]=3
N24220 $MC_TRAFO_GEOAX_ASSIGN_TAB_2[2]=2
; Special TRACYL settings:
N24900 $MC_TRACYL_ROT_AX_OFFSET_1=0
N24910 $MC_TRACYL_ROT_SIGN_IS_PLUS_1=1
N24920 $MC_TRACYL_BASE_TOOL_1[0]=0
N24920 $MC_TRACYL_BASE_TOOL_1[1]=0
N24920 $MC_TRACYL_BASE_TOOL_1[2]=0
; Setting data for the special cases of tool compensation:
; (only if necessary)
N42940 $SC_TOOL_LENGTH_CONST=18
N42950 $SC_TOOL_LENGTH_TYPE=2
; Settings for the 2nd spindle (milling spindle of the turning machine):
N30300 $MA_IS_ROT_AX[AX4]=1
N30310 $MA_ROT_IS_MODULO[AX4]=1
N30320 $MA_DISPLAY_IS_MODULO[AX4]=1
N35000 $MA_SPIND_ASSIGN_TO_MACHAX[AX4]=2
N43300 $SA_ASSIGN_FEED_PER_REV_SOURCE[AX4]=0
Note: Special handling of milling tools on turning machines is only possible with regard to the
length compensation. Reference: Chapter Tool: Compensation and Monitoring

18.3.3

Programming example for TRACYL

Manufacturing a groove with groove wall compensation

($MC_TRAFO_TYPE_1 = 513)

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

18-349

Kinematic Transformations (M1)


18.3

TRACYL

Contour
A groove which is wider than the tool is created by programming the direction of the compensation (G41, G42) and the distance of the groove side wall to the reference contour relatively
to the programmed reference contour via the address OFFN=... .

Tool radius
The tool radius is taken into account automatically with reference to the groove side wall using
G41, G42. The full functionality of the tool radius compensation in the plane is provided (continuous transition at external and internal corners, as well as detection of bottle neck problems).

50

100

115

Z
N100

10
N80

Path I
OFFN

N70

Milling tool

N60

N105
OFFN
70

N110

Path II

N120

D x Pi =
40 x 3.1415
= 125.664
Y

Programmed path
Peripheral surface

Fig. 18-11 Groove with groove wall compensation - diagram above as an example

Example program for X-Y -Z-C machine kinematics


TRACYL is used for the milling of grooves on a cylinder peripheral surface whereby the sections Path I and Path II are machined using different OFFN values.
CC is the channel axis name of the rotary axis, cutter radius of T1, D1: 8.345 mm

18-350

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Kinematic Transformations (M1)


18.3

TRACYL

N1 SPOS=0

; Acceptance of the spindle into position control


(only for turning machines)
N5 T1 D1
; Tool selection
N10 G500 G0 G64 X50 Y0 Z115 CC=200 DIAMOF
; Positioning of the machine, Y at turning center
N20 TRACYL(40)
; Selection of transformation, reference diameter for peripheral
surface: 40mm
N30 G19 G90 G94 G1 F500
; Machining surface is cylinder peripheral surface Y/Z
N40 OFFN=12.35 Y70 Z115
; Define groove spacing, initial position, now Y transformation axis
N50 X20 M2=3 S2=300 ; Infeed tool to groove bottom, turn on milling spindle
; Approach groove wall:
N60 G1 G42 Y70 Z100
; Select TRC to approach groove wall
; Manufacturing of groove section path I :
N70 Z50
; Groove part parallel to cylinder plane
N80 Y10
; Groove part parallel to circumference
N90 OFFN=11.5
; Change groove spacing
; Manufacturing of groove section path II :
N100 G1 G42 Y10 Z50
; Select TRC to approach groove wall for path II
N105 Y70
; Groove part parallel to circumference
N110 Z100
; Back to the starting value
; Retract from groove wall:
N120 G1 G40 Y70 Z115 ; Select TRC, retract from groove wall
N130 G0 X25 M2=5
; Retract, stop of milling spindle
N140 TRAFOOF
; Disable TRACYL
N150 G0 X50 Y0 Z115 CC=200 OFFN=0
; Back to the starting point
N160 M30

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

18-351

Kinematic Transformations (M1)


18.4

18.4

Special features with TRANSMIT and TRACYL

Special features with TRANSMIT and TRACYL

Power On / RESET / end of program


The behavior after Power On or RESET (end of program) depends on the settings defined in
the machine data MD 20110: RESET_MODE_MASK (access to this machine data only with
protection level 1/1) and
(active transformation after RESET).
MD 20140:TRAFO_RESET_VALUE

When selecting, observe the following:




Make sure that the tool radius compensation (G40) is deselected.

The frame active prior to TRANSMIT / TRACYL will be deselected by the control system
(G500).

Any active work area limitations will be deselected by the control system for the axes to
which the transformation applies (WALIMOF).

Continuous-path mode and corner rounding will be interrupted.

DRF offsets in transformed axes must be deleted by the operator.

Any motion intermediate blocks, which contain a chamfer or radius, possibly instructed will
not be inserted.

When deselecting, observe the following




Make sure that the tool radius compensation (G40) is deselected.

Continuous-path mode and corner rounding will be interrupted.

Any motion intermediate blocks, which contain a chamfer or radius, possibly instructed will
not be inserted.

After deselecting TRANSMIT / TRACYL, any zero offsets (frames) and settings made for
turning must be set anew.

Modes, mode change

18-352

When working with TRANSMIT / TRACYL, the program is executed in the AUTOMATIC
mode.

An interruption of the AUTOMATIC mode and switching to JOG is possible. When returning to AUTOMATIC, the operator must make sure that the tool is repositioned without undue problems.

Referencing of the axes with a transformation active is not possible.

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Kinematic Transformations (M1)


18.5

18.5

Data descriptions (MD, SD)

Data descriptions (MD, SD)

Transformation -specific machine data


20140
MD number
Default: 0
Change valid after RESET
Data type: BYTE
Meaning:

TRAFO_RESET_VALUE
Transformation active after RESET
Min. input limit: 0
Max. input limit: 2
Protection level: 2/2
Unit: Valid from SW release: 2.0
Definition of the transformation data record selected during power-up and at
Reset or at the end of the part program
(depending on the machine data $MC_RESET_MODE_MASK and when starting the part program
depending on the machine data $MC_START_MODE_MASK).

22534
TRAFO_CHANGE_M_CODE
MD number
M code when switching the transformation for the geometry axes
Default: 0
Min. input limit: 0
Max. input limit: 99999999
Change valid after Power On
Protection level: 2/2
Unit: Data type: DWORD
Valid from SW release: 2.0
Meaning:
Number of the M code output at the VDI interface when switching the transformation for the geometry axes.
If this MD has one of the values 0 to 6, 17, 30, no M code is output.
No monitoring is carried out whether an M code created in this way results in conflicts with other
functions.

24100
TRAFO_TYPE_1
MD number
Type of the 1st transformation
Default: 0
Min. input limit: 0
Max. input limit: 2048
Change valid after NEW_CONF
Protection level: 2/2
Unit:
Data type: DWORD
Valid from SW release: 2.0
Meaning:
Transformation type of the 1st transformation:

0
256
512
513

No transformation
TRANSMIT transformation
TRACYL transformation
TRACYL transformation with X -Y -Z -C kinematics

No further transformations are available with SINUMERIK 802D.


MD not relevant with ......
Related to ....

No transformations
TRAFO_TYPE_2

24110
TRAFO_AXES_IN_1[i]
MD number
Axis assignment for transformation 1 [axis index]: 0 ... 4
Default: 1,2,3,4,5
Min. input limit: 1
Max. input limit: 5
Change valid after NEW_CONF
Protection level: 2/2
Unit:
Data type: BYTE
Valid from SW release: 2.0

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

18-353

Kinematic Transformations (M1)


18.5

Data descriptions (MD, SD)

24110
MD number
Meaning:

MD not relevant with ......


Related to ....

TRAFO_AXES_IN_1[i]
Axis assignment for transformation 1 [axis index]: 0 ... 4
Axis assignment at the input of the 1st transformation
Example - Transmit:
With TRANSMIT, the index i will receive the values 0,1, 2.
$MC_TRAFO_AXES_IN_1[0]=

Channel axis number of the axis vertically to the rotary axis

$MC_TRAFO_AXES_IN_1[1]=

Channel axis of the rotary axis

$MC_TRAFO_AXES_IN_1[2]=
Channel axis of the axis parallel to the rotary axis
Example for TRACYL: see Chapter TRACYL
No transformation
TRAFO_AXES_IN_2

24120
MD number

TRAFO_GEOAX_ASSIGN_TAB_1[i]
Assignment of the geometry axes to the channel axes with transformation 1
[geometry axis number]: 0 ... 2
Default: 0,0,0
Min. input limit: 0
Max. input limit: 5
Change valid after NEW_CONF
Protection level: 2/4
Unit:
Data type: BYTE
Valid from SW release: 2.0
Meaning:
If a transformation 1 is active, this MD specifies to which channel axes the axes of the Cartesian
coordinate system are imaged.
With TRANSMIT, the index i will receive the values 0, 1, 2. It refers to the first, second and third
geometry axes.
MD not relevant with ......
No transformation
Application example(s)
$MC_TRAFO_GEOAX_ASSIGN_TAB_1[0]= 2 ; 2nd channel axis
Related to ....
$MC_AXCONF_GEOAX_ASSIGN_TAB if no transformation is active

24200
TRAFO_TYPE_2
MD number
Type of transformation
Default: 0
Min. input limit: 0
Max. input limit: 2048
Change valid after NEW_CONF
Protection level: 2/2
Unit:
Data type: DWORD
Valid from SW release: 2.0
Meaning:
as with TRAFO_TYPE_1, but for transformation 2

24210
TRAFO_AXES_IN_2[i]
MD number
Axis assignment for transformations 2/3/4/5/6/7/8 [axis index]: 0 ... 4
Default: 1,2,3,4,5
Min. input limit: 1
Max. input limit: 5
Change valid after NEW_CONF
Protection level: 2/2
Unit: Data type: BYTE
Valid from SW release: 2.0
Meaning:
Axis assignment at the input of the 2ndtransformation
Meaning as TRAFO_AXES_IN_1

24220
MD number

TRAFO_GEOAX_ASSIGN_TAB_2[i]
Assignment of the geometry axes to the channel axes with transformation 2
[geometry axis number]: 0 ... 2
Default: 0,0,0
Min. input limit: 0
Max. input limit: 5
Change valid after NEW_CONF
Protection level: 2/2
Unit: Data type: BYTE
Valid from SW release: 2.0
Meaning:
If a transformation 2 is active, this MD specifies to which channel axes the axes of the Cartesian
coordinate system are imaged.
In all the other respects, the meaning of this machine data is as with TRAFO_GEOAX_ASSIGN_TAB_1.

18-354

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Kinematic Transformations (M1)


18.5

Data descriptions (MD, SD)

Function -specific machine data TRANSMIT


24900
TRANSMIT_ROT_AX_OFFSET_1
MD number
Position offset of the rotary axis
Default: 0
Min. input limit: 0
Max. input limit: 360
Change valid after NEW_CONF
Protection level: 2/2
Unit: degrees
Data type: DOUBLE
Valid from SW release: 2.0
Meaning:
specifies the offset of the rotary axis in degrees with reference to the zero position for the TRANSMIT transformation when TRANSMIT is active
MD not relevant with ......
No TRANSMIT active
Application example(s)
$MC_TRANSMIT_ROT_AX_OFFSET_1=15.0

24910
TRANSMIT_ROT_SIGN_IS_PLUS_1
MD number
Sign of the rotary axis
Default: 1
Min. input limit: 0
Max. input limit: 1
Change valid after NEW_CONF
Protection level: 2/2
Unit: Data type: BOOLEAN
Valid from SW release: 2.0
Meaning:
specifies for the TRANSMIT transformation with which sign the rotary axis is taken into account
with the TRANSMIT transformation
MD not relevant with ......
No TRANSMIT transformation
Application example(s)
$MC_TRANSMIT_ROT_SIGN_IS_PLUS_1= 1

24911
TRANSMIT_POLE_SIDE_FIX_1
MD number
Limitation of the working area before/after the pole
Default: 0
Min. input limit: 0
Max. input limit: 2
Change valid after NEW_CONF
Protection level: 2/2
Unit:
Data type: BYTE
Valid from SW release: 2.0
Meaning:
Limitation of the working area before/after the pole or no limitation, i.e. passing the pole
The values assigned have the following meaning:
0:
No limitation of the working area; passing the pole
1:
2:

Working area of the linear axis for positions >=0,


(if the tool length compensation parallel to the linear axis equal to 0)
Working area of the linear axis for positions <=0,
(if the tool length compensation parallel to the linear axis equal to 0)

24920
TRANSMIT_BASE_TOOL_1[i]
MD number
Vector of the basic tool when activating the transformation [geo axis index]]: 0 ... 2
Default: 0
Min. input limit: 0
Max. input limit:
Change valid after NEW_CONF
Protection level: 2/2
Unit: mm
Data type: DOUBLE
Valid from SW release: 2.0
Meaning:
specifies the distance of the tool zero with reference to the geometry axes active in TRANSMIT if
TRANSMIT is active, without a length compensation selected
Programmed tool length compensations act additively to the basic tool.
The index i receives the values 0, 1, 2 for the 1st to 3rd geometry axes.
MD not relevant with ......
No TRANSMIT transformation
Application example(s)
$MC_TRANSMIT_BASE_TOOL_1[0]=20.0

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

18-355

Kinematic Transformations (M1)


18.5

Data descriptions (MD, SD)

Function -specific machine data TRACYL


24800
TRACYL_ROT_AX_OFFSET_1
MD number
Offset of the rotary axis for the TRACYL transformation
Default: 0
Min. input limit: ***
Max. input limit: ***
Change valid after NEW_CONF
Protection level: 2/2
Unit: degrees
Data type: DOUBLE
Valid from SW release: 2.0
Meaning:
specifies the offset of the rotary axis in degrees with reference to the zero position the first agreed
TRACYL transformation for each channel if TRACYL is active
MD not relevant with ......
No TRACYL active
Application example(s)
$MC_TRACYL_ROT_AX_OFFSET_1=15.0

24810
TRACYL_ROT_SIGN_IS_PLUS_1
MD number
Sign of the rotary axis for the TRACYL transformation
Default: 1
Min. input limit: 0
Max. input limit: 1
Change valid after NEW_CONF
Protection level: 2/2
Unit: Data type: BOOLEAN
Valid from SW release: 2.0
Meaning:
specifies for the TRACYL transformation with which sign the rotary axis is taken into account with
the TRACYL transformation
MD not relevant with ......
No TRACYL transformation
Application example(s)
$MC_TRACYL_ROT_SIGN_IS_PLUS_1 = 1

24820
TRACYL_BASE_TOOL_1[i]
MD number
Vector of the basic tool when activating the TRACYL transformation [geo axis index]: 0 ... 2
Default: 0
Min. input limit: 0
Max. input limit:
Change valid after NEW_CONF
Protection level: 2/2
Unit: mm
Data type: DOUBLE
Valid from SW release: 2.0
Meaning:
specifies the distance of the tool zero with reference to the geometry axes active in TRACYL if
TRACYL is active, without a length compensation selected
Programmed tool length compensations act additively to the basic tool.
The index i receives the values 0, 1, 2 for the 1st to 3rd geometry axes.
MD not relevant with ......
No TRACYL transformation
Application example(s)
$MC_TRACYL_BASE_TOOL_1[0]=tx

18-356

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Kinematic Transformations (M1)


18.6

18.6

Signal descriptions

Signal descriptions

Signals from the channel


V3300 0001.6
Interface signal
Edge evaluation: no
Signal status 1 or signal
transition 0 - - -> 1

Transformation active
Signal(s) from the NCK channel (NCK->PLC)
Signal(s) updated: cyclically
Signal(s) valid from SW release: 2.0
Either the NC command TRANSMIT or the command TRACYL is programmed in the part program. The appropriate block has been executed by the NC, and now a transformation is enabled.

Signal status 0

No transformation is active.

Signal transition 1 - - -> 0

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

18-357

Kinematic Transformations (M1)


18.7

Data fields, lists

18.7
18.7.1

Data fields, lists


Interface signals

Number

.Bit

Name

Ref.

channel-specific
V3800 0001

18.7.2

.6

Transformation active

Machine data/setting data

Machine data
Number

Identifier

Name

Ref.

channel-specific
20110

RESET_MODE_MASK

Definition of the control initial position after power up and RESET/end of part program (access only in
protection level 1/1)

20140

TRAFO_RESET_VALUE

Initial position : Transformation active after RESET

22534

TRAFO_CHANGE_M_CODE

M code when switching the transformation for the


geometry axes

24100

TRAFO_TYPE_1

Type of the 1st transformation, possibly with axis


sequence

24110

TRAFO_AXES_IN_1

Axis assignment at the input of the 1st transformation

24120

TRAFO_GOEAX_ASSIGN_TAB_1

Assignment of the geometry axes with the 1st


transformation

24200

TRAFO_TYPE_2

Type of the 2ndtransformation, possibly with axis


sequence

24210

TRAFO_AXES_IN_2

Axis assignment at the input of the 2ndtransformation

24220

TRAFO_GOEAX_ASSIGN_TAB_2

Assignment of the geometry axes with the


2ndtransformation

24800

TRACYL_ROT_AX_OFFSET_1

Deviation of the rotary axis from the zero position in


degrees (1st TRACYL )

24810

TRACYL_ROT_SIGN_IS_PLUS_1

Sign of the rotary axis with TRACYL (1st TRACYL)

24820

TRACYL_BASE_TOOL_1

Distance of the tool zero from the origin of the geometry axes (1st TRACYL)

24900

TRANSMIT_ROT_AX_OFFSET_1

Deviation of the rotary axis from the zero position in


degrees (1stTRANSMIT)

24910

TRANSMIT_ROT_SIGN_IS_PLUS_1

Sign of the rotary axis with TRANSMIT (1st


TRANSMIT)

24911

TRANSMIT_POL_SIDE_FIX_1

Limitation of the working area before/after the pole,


1st transformation

24920

TRANSMIT_BASE_TOOL_1

Distance of the tool zero from the origin of the geometry axes (1st TRANSMIT)

18-358

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

19

Various Interface Signals (A2)

19.1

Brief description

Brief description
This Description of Functions describes the functionalities of various interface signals that are
of general importance and are not described in other Descriptions of Functions.

Interfaces
The exchange of signals and data between the PLC user program and


NCK (Numerical Control Kernel)

HMI (display unit)

is carried out via various data areas. The PLC user program need not take care of the exchange. From the users view, this is carried out automatically.
NCK
General

General

PLC

Signals to NC
Signals from NC
User
program
Operating Modes

Operating
Modes

Signals to NCK
Signals from NCK

Channel

Axis,
spindle

Channel
Signals to NCK
Signals to NCK
Signals from NCK
Signals from NCK

Spindle (n+1)
Axis n
Axis 2
Axis 1
Signals to NCK
Signals from NCK

Fig. 19-1

PLC/NCK interface

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

19-359

Various Interface Signals (A2)


19.2

Signals from PLC to NCK

Cyclic signal exchange


The control and status signals of the PLC/NCK interface are updated cyclically.
They can be divided into the following groups (see Fig. 17-1):

19.2

General signals

Mode signals

Channel signals

Axis/spindle signals

Signals from PLC to NCK

Access rights
The access to programs, data and functions is protected user-oriented by 8 hierarchical
protection levels. These protection levels are divided into:


4 password protection levels for Siemens, machine manufacturer (2x) and end user

4 protection levels for end users (interface signals V26000000.4 to .7)

This provides a safety concept to manage the access rights, which contains several levels.
See also Start-Up Guide, Section Access rights
Table 19-1

Access protection

Protection level: Type

User

Access to (examples)

Password

SIEMENS, reserved

Password

Expert mode

defined functions, programs and data;

Password

Machine manufacturer

defined functions, programs and data;


for standard start-up

Password

End user

assigned functions, programs and data;

IS
V2600
0000.7

End user:
Programmer
Setter

less than protection levels 0 to 3;


defined either by machine manufacturer or
end user

IS
V2600
0000.6

End user:
Qualified operator,
who will not program

less than protection levels 0 to 3;


defined by end user

IS
V2600
0000.5

End user:
Trained operator
who will not program

Example:
only program selection, input of tool wear
and zero offsets

IS
V2600
0000.4

End user:
Semi-skilled operator

Example:
No inputs, no program selection
only possible if the machine control
panel can be operated

19-360

fewer
access
rights

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Various Interface Signals (A2)


19.2

Signals from PLC to NCK

Deleting the distance to go - channel-specific (V3200 0006.2)


The IS Delete distance to go (channel-specific) is only active for path axes.
The distance to go is deleted for all axes of the geometry group with the rising edge of the
interface signal, and it is immediately stopped by ramp stop. Then, the next program block is
started.

Axis/spindle lock (V380x 0001.3)


The IS Axis/spindle lock can be used for testing purposes.
Axis lock (for axis):
If the IS Axis lock is provided, no more partial position setpoints are output to the position
controller of this axis; the traversing movement of this axis is thus disabled. The position
control loop remains closed and the remaining following error will be compensated. If an axis
is traversed with axis lock, the actual value position display will show the set position, and the
velocity actual value display will show the setpoint velocity, whereby the machine axis does
not actually travel. The IS RESET (V3000 0000.7) is used to set the position actual value
display to the real actual value of the machine. The traversing commands for this axis are still
output to the PLC. If the interface signal is canceled, the corresponding axis can be traversed
normally again. If the interface signal Axis lock is provided for a traversing axis, the axis will
be stopped with ramp stop.
Spindle interlocking (for spindle):
If the IS Spindle lock is provided, no more speed setpoint values are output to the speed
controller for this spindle in control mode and no more position partial setpoint values are
output to the position controller in positioning mode. The spindle motion is thus locked. The
speed actual value display will display the speed setpoint. The spindle locking is canceled by
Reset or program end (M2) and restarting the program. If the interface signal Spindle lock
is provided for a rotating spindle, the spindle is stopped according to its acceleration
characteristic.
The cancellation of Axis/spindle lock (edge change 1 0) will only come into effect if the
axis/spindle is at a standstill (i.e. if the interpolation setpoint is no longer present). The new
movement starts with new setpoints. (e.g.: new program block with movement settings in AUTOMATIC mode).
Note: Different actual values between simulated and real axes!

Follow -up mode (V380x 0001.4)


If an axis/spindle is in follow-up mode, its setpoint position will follow the current actual
position. In follow-up mode, the position setpoint value is not provided from the interpolator,
but is derived from the current actual position. Since the position actual value of the axis is
continued to be acquired, re-referencing of the axis is not necessary after canceling the
follow-up mode.
Zero speed, clamping and positioning monitoring are not active in follow-up mode.
Effect:
The IS Follow-up mode is only applicable if the servo enable of the drive has been canceled
(e.g. by the IS Servo enable = 0 signal or inside the control system due to a fault), and/or
servo enable is provided again.

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

19-361

Various Interface Signals (A2)


19.2

Signals from PLC to NCK

IS Follow-up mode = 1:
If the IS Servo enable is canceled, the position setpoint value of the relevant axis is followed
up the actual value continuously. This state is signaled to the PLC using the IS Follow-up
active (V390x 0001.3). If the IS Servo enable is then set again, a repositioning to the last
programmed position is carried out internally in the control system if a part program is active
(REPOSA: Approach on a straight path with all axes).
Otherwise:
the axis motion will start at the new actual position possibly changed.
IS Follow-up mode = 0:
If the IS Servo enable is canceled, the old position setpoint value is maintained. If the axis is
pushed off its position, a following error between the position setpoint value and the position
actual value occurs, which is compensated by the control system when the IS Servo enable
is set. The axis motion starts at the setpoint position which existed before Servo enable was
canceled.
In Stop state, the IS Follow-up active (V390x 0001.3) is at 0.
Clamping or zero speed monitoring are active.

Position measuring system 1 (V380x 0001.5)


A position encoder can be connected to the spindle. In this case, the signal for the spindle
must be set.
This signal is in any case required for the axes. A position encoder must be provided.

Servo enable (V380x 0002.1)


If Servo Enable is provided for the drive, the position control loop of the axis/spindle will be
closed. The axis/spindle is thus in position control.
If Servo Enable is disabled, the position control loop will be opened, and the speed control
loop of the axis/spindle will be opened with delay.
IS Position controller active (V390x 0001.5) will be set to 0-signal (checkback signal).
Enabling:
Servo Enable for the drive can be set and disabled from the following points:
1. from the PLC user program using the interface signal Servo enable (normal case)
Application: Disabling of Servo Enable prior to clamping an axis/spindle.
2. Internally in the control system, servo enable is disabled in case of various faults on the
machine, the drive, the position encoder or the control system (fault).
Application: In case of a fault, all axes moving must be stopped by rapid stop.
3. internally in the control system in case of the following events: IS EMERGENCY STOP
(V2600 0000.1) is present
Disabling servo enable for a moving axis/spindle:

19-362

The spindle is decelerated to standstill using rapid stop, taking into account
MD 36610: AX_EMERGENCY_STOP_TIME (duration of brake ramp in case of errors).
Then alarm 21612 Servo enable reset during the movement is output.

The position control loop of the axis/spindle will be opened. Checkback message to the
PLC using IS Position controller active (V390x0001.5) = 0 signal. In addition, the timer for
the time delay of servo enable (MD 36620: SERVO_DISABLE_DELAY_TIME (servo disable delay time) is started.

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Various Interface Signals (A2)


19.2

Signals from PLC to NCK

Once the actual velocity reaches the standstill range, Servo Enable will be canceled.
Checkback message to PLC with IS Speed controller active (V390x0001.6) = 0 signal.
The servo enable of the drive is canceled at the latest after expiration of the time defined in
MD 36620: SERVO_DISABLE_DELAY_TIME.
Caution: If you have set the servo enable shutdown delay too small, servo enable will be
disabled even if the axis/spindle is still traversing/rotating. It will then suddenly be stopped
with setpoint 0.

The actual position value of the axis/spindle will still be acquired by the control system.

This state of the axis/spindle can only be changed after RESET.


Interpolation axis group:
All axes involved in the interpolation will be stopped if Servo Enable is disabled for one of the
axes involved.
The axes are stopped as described above. All axes of the geometry group will be stopped
with rapid stop. In addition, alarm 21612 Servo enable reset during the movement is output.
An execution of the NC program is then no longer possible.

Signals for digital drives, to axis/spindle


Ramp function generator rapid stop (V380x 4000.1)
Rapid stop is requested by the PLC user program for the drive. The drive is then stopped
without a ramp function (with speed setpoint 0). Servo enable remains stored.

Speed setpoint smoothing (V380x 4000.3)


The PLC user program requests a filter for smoothing the speed setpoint for the axis/spindle.
The smoothing is enabled in the drive module only under certain conditions.

Drive parameter record selection A, B, C (V380x 4001.0 to .2)


With SIMODRIVE 611UE, the bit combination A, B, C can be used to select up to 8 different
drive parameter records from the PLC user program.

Integrator disabled for speed controller (V380x 4001.6)


The PLC user program disables the integrator of the speed controller for the drive. The speed
controller is thus switched over from a PI to a P controller.

Pulse enable (V380x 4001.7)


The PLC user program provides pulse enable for the axis/spindle. Pulse enable for the drive
module is only carried out if all enable signals are present.

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

19-363

Various Interface Signals (A2)


19.3

19.3

Signals from NCK to PLC

Signals from NCK to PLC

Drives in cyclic mode (V2700 0002.5)


The NCK signals to the PLC that all existing drives are in cyclic mode.

Drive ready (V2700 0002.6)


A signal is provided from the NCK to the PLC that all existing drives are ready for operation.
The IS Drive Ready is provided from all axes/spindles (group signal).

NCK alarm is present (V2700 0003.0)


A signal is provided from the control system to the PLC that at least one NCK alarm is present. The channel-specific interface (V3300 0004.7) can be interrogated whether a standstill
of machining has been initiated.

Air temperature alarm (V2700 0003.6)


The ambient temperature or fan monitoring function has responded.

Channel -specific NCK alarm is present (V3300 0004.6)


A signal is provided from the control system to the PLC that at least one NCK alarm is present
for the channel. The IS NCK alarm with program standstill present (V33000004.7) can be
used to make a conclusion on the extent the current program execution has been interrupted
and/or aborted.

External language mode active (V3300 4001.0)


The control system signals to the PLC that the active program language for the part program
is not a SIEMENS language. A language switch-over has been carried out using G291.

NCK alarm with program stop present (V3300 0004.7)


The control system signals to the PLC that at least one NCK alarm is present for the channel
which has interrupted and/or aborted the current program execution (program standstill).

Follow -up active (V390x 0001.3)


Follow-up mode is active for this axis.
(Follow-up in detail: refer to the IS Follow-up mode (V380x0001.4))

Axis/spindle stopped (V390x 0001.4)


The current actual velocity of the axis and/or the actual speed of the spindle is within the
range defined as the standstill. This range is defined by MD 36060: STANDSTILL_VELO_TOL
(max. velocity/speed for the signal Axis/spindle stopped).

19-364

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Various Interface Signals (A2)


19.3

Signals from NCK to PLC

Position controller active (V390x 0001.5)


The position controller for the axis/spindle is closed; the position control is active.

Speed controller active (V390x 0001.6)


The speed controller for the axis/spindle is closed; the speed control is active.

Current controller active (V390x 0001.7)


The current controller for the axis/spindle is closed; the current control is active.

Lubrication pulse (V390x 1002.0)


The IS Lubrication pulse is sent by NCK and changes its state, as soon as the axis/spindle
has traveled a distance longer than defined by MD 33050: LUBRICATION_DIST (distance to
be traversed for lubrication from PLC).

Signals for digital drives, from axis/spindle


Ramp function generator disabling active (V390x 4000.1)
The drive feeds back to the PLC that ramp function generator quick stop is active. This will
stop the drive without a ramp function (with speed setpoint 0).

Speed setpoint smoothing active (V390x 4000.3)


The PLC user program requests a filter for smoothing the speed setpoint for the axis/spindle.
The smoothing is activated in the drive module only under certain conditions.

Active drive parameter records A, B, C (V390x 4001.0 to .2)


The drive module feeds back to the PLC which drive parameter block is currently active. With
SIMODRIVE 611UE, the bit combinations A, B, C can be used to select 8 different drive
parameter records from the PLC.

DRIVE ready (V390x 4001.5)


Response that the drive is ready for operation. Thus, the preconditions of the drive for
traversing the axis/spindle are given.
This message is dependent on the SIMODRIVE 611UE parameter 1012.2:
Value=1 (default): is reported if
terminals 48 and 63 of the power supply module, as well as terminal 663 of the controller
module are enabled and no drive alarm is pending.
Value =0: is reported if no drive alarm is pending.

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

19-365

Various Interface Signals (A2)


19.3

Signals from NCK to PLC

Integrator of speed controller disabled (V390x 4001.6)


The intergrator of the speed controller is interlocked. The speed controller has thus been
switched over from a PI to a P controller.

Pulses enabled (V390x 4001.7)


Pulse enable for the drive module is provided. The axis/spindle can thus be traversed.

Motor temperature prewarning (V390x 4002.0)


The drive module signals to the PLC that the motor temperature has exceeded the warning
threshold. If the motor temperature remains too high, the drive is stopped after expiration of a
defined time (drive MD) and pulse enable is disabled.

Heat sink temperature prewarning (V390x 4002.1)


The drive module signals to the PLC that the heat sink temperature has exceeded the warning
threshold. After 20 seconds, pulse enable is canceled for the drive module concerned.

Acceleration process completed (V390x 4002.2)


The signal signals that the speed actual value has reached the new setpoint value taking into
account the tolerance band set on the drive. Thus, the acceleration process is completed.
Following speed variations due to load changes have no effect on the interface signal.

|Md| < Mdx (V390x 4002.3)


The signal signals that the current torque |Md| is less than the threshold torque set in the drive
Mdx.

|nact| < nmin (V390x 4002.4)


The signal signals that the speed actual value |nist| is less than the set minimum speed nmin.

nact| < nx (V390x 4002.5)


The signal signals that the speed actual value |nact| is less than the set threshold speed nx.

nact = nset (V390x 4002.6)


It is signaled to the PLC that the speed actual value nact has reached the new setpoint value,
taking into account the tolerance band set on the drive, and that this value continues to be
within the tolerance band.

Variable signaling function (V390x 4002.7)


Using the variable signaling function, the SIMODRIVE 611UE can monitor any parameter for
exceeding a defined threshold and feed it back to the PLC as an interface signal.
The quantity to be monitored is defined using 611UE machine data.

19-366

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Various Interface Signals (A2)


19.3

Signals from NCK to PLC

DC link < warning threshold (V390x 4003.0)


The drive signals to the PLC that the DC link voltage (UZK) is less than the DC link low voltage threshold.

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

19-367

Various Interface Signals (A2)


19.4

19.4

Signals from PLC to HMI

Signals from PLC to HMI

OP key lock (V1900 5000.2)


The IS OP key lock can be used to disable (1 signal) or enable (0 signal) the operator panel
keyboard for the operator.

Program number (VB1700 1000) (not available for 802D base line)
A defined program number is transferred from PLC to HMI if an NC program is to be selected from
the PLC. The currently selected NC program can be saved and also reselected via the command
interface (see VB 1700 1001).
With SINUMERIK 802D, programs are managed via their names (STRING). To assign a program
number to a program name, the file PLCPROG.LST has been implemented in the control. In this
assignment list, program numbers for a maximum of 255 programs can be defined and assigned.
The use of the numbers is divided according to the protective areas of the programs:
1 to 100:
User area (protection level of the end user)
101 to 200:
Machine manufacturer (protection level of the machine manufacturer)
201 to 255:
SIEMENS (SIEMENS protection level).
The file PLCPROG.LST can be edited under the lower end user protection level using the following
operation: System -> PLC -> Program list, or using the normal program editor
(Program Manager -> User cycles). For the editor, however, it is recommended to set at least the
machine manufacturer protection level. This file can also be created externally and be loaded into
the control system via PCIN Tool / V.24 interface. This must be done observing the following
structure rule, with the header entry first:
%_N_PLCPROG_LST
;$PATH=/_N_CUS_DIR
Each line contains two colums. These are separated either via TAB, by spaces or via the
| character. The first column contains the program number, and the second column the
program name.
Example:
%_N_PLCPROG_LST
;$PATH=/_N_CUS_DIR
1|BOHR2.MPF
2|PUMPT14.MPF
54|BOHR3.MPF
Program number (VB 1700 1000) is related to the IS Program has been selected (V1700 2000.0)
and to the IS Error selecting the program (V1700 2000.1).
The program selection is started from the PLC by writing a program number >0. As soon as the HMI
detects a program number >0, it starts the internal processing of this task and sets the program
number (VB 1700 1000) to 0. The PLC waits until the acknowledgement signal has arrived from
HMI: V1700 2000.0 or V1700 2000.1 and evaluates them immediately. The program number and
acknowledgement signals provide a PLC cycle after they have received an acknowledgement cycle
and are then deleted by the PLC system automatically.

19-368

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Various Interface Signals (A2)


19.4

Signals from PLC to HMI

Command (VB 1700 1001) (not available for 802D base line)
A command task is here passed from the PLC to the HMI.

Table 19-2

Command

Action

none

Save name of the selected program

Select program with the saved program name

Command (VB 1700 1001) is related to the IS Command performed (V1700 2001.0) and to the
IS Error performing command (V1700 2001.1). The PLC task is started with the writing of
Command >0. As soon as the HMI detects a Command >0, it starts the internal processing of this
task and sets the command (VB 1700 101) to 0.
The PLC waits until it receives the acknowledge signal from the HMI: V1700 2001.0 or
V1700 2001.1 and evaluates this signal immediately. The acknowledge signals are available for one
PLC cycle after receiving of the acknowledge signal and are then deleted automatically by the PLC
operating system.

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

19-369

Various Interface Signals (A2)


19.5

19.5

Signals from HMI to PLC

Signals from HMI to PLC

Program has been selected (V1700 2000.0) (not available for 802D base line)
HMI signals to the PLC that the requested NC program has been selected successfully. This signal
provides a PLC cycle. It is related to VB1700 1000.

Error selecting the program (V1700 2000.1) (not available for 802D base line)
HMI signals to the PLC that the selection of the requested NC program has failed. This signal
provides a PLC cycle. It is related to VB1700 1000.

Command performed (V1700 2001.0) (not available for 802D base line)
HMI signals to the PLC that the command has been performed successfully. This signal provides a
PLC cycle. It is related to the VB1700 1001.

Error performing command (V1700 2001.1) (not available for 802D base line)
HMI signals to the PLC that the performing of the requested command has failed. This signal
provides a PLC cycle. It is related to the VB1700 1001.

19-370

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

20

PLC User Interface

20.1

Address ranges
Operand identifier

Description

Range

Data

V0.0 to V79999999.7 (see below)

Timers

T0 to T31

Counters

C0 to C31

Image of digital inputs

I0.0 to I17.7

Image of digital outputs

Q0.0 to Q11.7

Flags

M0.0 to M255.7

SM

Special flags

SM0.0 to SM 0.6 (see below)

ACCU (logics)

AC0, AC1 (UDword)

ACCU (arithmetics)

AC2, AC3 (Dword)

Generating the V range address:


Type ID

Range No.

(DB No.)

(Channel, axis No.)

Subrange

Offset

Addressing
symbolic
(8 digits)

10

00

000

(10-79)

(00-99)

(0-9)

(000-999)

Special flags SM bit definition (read-only):


SM bits

Description

SM 0.0

Flag with defined ONE signal

SM 0.1

Default setting: first PLC cycle 1, following cylces 0

SM 0.2

Buffered data lost - valid only in the first PLC cycle (0 - data o.k., 1 - data lost)

SM 0.3

Power On: first PLC cycle 1, following 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 a cycle 0, then a cycle 1)

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

20-371

PLC User Interface


20.1

Address ranges

Note
All empty fields in the user interface are Reserved for Siemens and may not be filled out or
evaluated!
Fields marked with 0 must always be loaded with the value logic 0.
Anny references on the description of the interface signals always refer to the appropriate
Chapters/Sections of the Description of Functions and are specified with [F Chapter/Section
No.].

Access rights to variables:


[r]
marks a read-only area
[r/w]
marks a random access area
plus specification of data format
1:
BIT
8:
BYTE
16:
INT / WORD
32:
DINT / DWORD / REAL
no data format specified: all data formats specified can be read or written

Note
Some interface signals are not available for 802D base line. These signals
are marked ***) .

20-372

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

PLC User Interface


20.2

20.2
20.2.1

User data

User data
User data 1

1000

Data 1 [r/w]

Data block
Byte

Bit 7

Bit 6

Bit 5

Bit 4

Bit 3

Bit 2

Bit 1

Bit 0

Bit 3

Bit 2

Bit 1

Bit 0

Bit 3

Bit 2

Bit 1

Bit 0

User data
1000 0000
to
User data
1000 0011

20.2.2

User Data 2
Data 2 [r/w]

1100
Data block
Byte

Bit 7

Bit 6

Bit 5

Bit 4
User data

1100 0000
to
User data
1100 0007

20.2.3

Retentive data area

1400

Retentive data [r/w]

Data block
Byte

Bit 7

Bit 6

Bit 5

Bit 4
User data

1400 0000
to
User data
1400 0127

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

20-373

PLC User Interface


20.3

User alarm

20.3

User alarm
Note: For information on PLC alarms including the configuration of user alarms, please refer
to:
References:
Start-up Gude, Section PLC alarms

20.3.1

User alarm: Enabling

1600

Enable alarm [r/w]

Data block
Byte

Interface PLC - - - - -> HMI


Bit 7

Bit 6

Bit 5

Bit 4

Bit 3

Bit 2

Bit 1

Bit 0

700002

700001

700000

700010

700009

700008

700018

700017

700016

700026

700025

700024

700034

700033

700032

700042

700041

700040

700050

700049

700048

700058

700057

700056

Enable alarm No.


1600 0000

700007

700006

700005

700004

700003

Enable alarm No.


1600 0001

700015

700014

700013

700012

700011

Enable alarm No.


1600 0002

700023

700022

700021

700020

700019

Enable alarm No.


1600 0003

700031

700030

700029

700028

700027

Enable alarm No.


1600 0004

700039

700038

700037

700036

700035

Enable alarm No.


1600 0005

700047

700046

700045

700044

700043

Enable alarm No.


1600 0006

700055

700054

700053

700052

700051

Enable alarm No.


1600 0007

20.3.2

700063

700062

700061

700060

700059

Variable for alarm

1600

Variable for alarm [r32/w32]

Data block

Interface PLC - - - - -> HMI

Byte
1600 1000

Variable for alarm 700000 (4-byte)

1600 1004

Variable for alarm 700001 (4-byte)

1600 1008

Variable for alarm 700002 (4-byte)

...

...

1600 1244

Variable for alarm 700061 (4-byte)

1600 1248

Variable for alarm 700062 (4-byte)

1600 1253

Variable for alarm 700063 (4-byte)

20-374

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

PLC User Interface


20.4

20.3.3

Active alarm reaction

1600

Active alarm reaction [r]

Data block

Interface PLC - - - - -> HMI

Byte

Signals from/to HMI

Bit 7

Bit 6

Bit 5

1600 2000

Bit 4
PLC STOP

Bit 3
EMERGENCY
STOP

Bit 2

Bit 1

Bit 0

Feed lock
of all
axes

Read-in
disable

NC start inhibited

Bit 1

Bit 0

1600 2001
1600 2002
1600 2003

20.4
20.4.1

Signals from/to HMI


Program control signals from HMI (retentive area)

1700

HMI signals [r]

Data block

Interface HMI - - - - -> PLC

DBB

Bit 7

1700 0000

Bit 6

Bit 5

Bit 4

Bit 3

Dry run
feed selected

M01 selected

DRF selected

[F10.8.2]

[F10.8.2]

Bit 2

[F10.8.2]
1700 0001

Program
test selected

Feed override for rapid traverse


selected

[F10.8.2]

[F10.8.2]
[F11.5.1]
1700 0002

Block skip
selected
[F10.8.2]

1700 0003

Measuring
in JOG
active ***)
[F15.8]

***) These signals are not available for 802D base line.

1700

HMI signals [r/w]

Data block

Interface PLC- - - - -> HMI

Byte

Bit 7

Bit 6

Bit 5

Bit 4

Bit 3

Bit 2

1700 1000

Program selection from PLC: Program number ***) [F19.4]

1700 1001

command task from PLC: command ***) [F19.4]

Bit 1

Bit 0

1700 1002
bis
1700 1003

***) These signals are not available for 802D base line.

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

20-375

PLC User Interface


20.4

Signals from/to HMI

1700

HMI signals [r]

Data block

Interface HMI - - - - -> PLC

Byte

Bit 7

Bit 6

Bit 5

Bit 4

Bit 3

Bit 2

Bit 1

Bit 0

1700 2000

Error selecting the program ***)


[F19.5]

Program
has been
selected
***)
[F19.5]

1700 2001

Error
performing
command
***)
[F19.5]

Command
performed
***)
[F19.5]

Bit 2

Bit 1

Bit 0

JOG mode

MDA mode

[F15.8]

[F15.8]

AUTO
mode

1700 2002
to
1700 2003

***) These signals are not available for 802D base line.

1800

HMI signals [r]

Data block

Signals HMI - - - - -> PLC

Byte

Bit 7

1800 0000

Bit 6

Bit 5

Bit 4

Start measuring in
JOG ***)

Mode
change disable

[F15.8]

[F15.8]

Bit 3

[F15.8]

1800 0001

Machine
function
REF
[F15.8]

***) These signals are not available for 802D base line.

1900

HMI signals [r/w]

Data block

Interface HMI - - - - -> PLC

Byte
1900 0000

Bit 7

Bit 6

Bit 5

Bit 4

Bit 3

Bit 2

Bit 1

Bit 0

Simulation
active
[F10.8.2]

1900 0001
1900 0002
1900 0003

20-376

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

PLC User Interface


20.4

20.4.2

General selection/status signals from MMC (retentive area)

1900

HMI signals [r]

Data block

Interface HMI - - - - -> PLC

Byte

Signals from/to HMI

Bit 7

Bit 6

Bit 5

Bit 4

Bit 3

Bit 2

Bit 1

Bit 0

1900 1000
1900 1001
1900 1002
Axis number for handwheel 1
1900 1003

Machine
axis
[F9.6.1]

[F9.6.1]

[F9.6.1]

[F9.6.1]

Axis number for handwheel 2


1900 1004

Machine
axis
[F9.6.1]

[F9.6.1]

[F9.6.1]

[F9.6.1]

Axis number for handwheel 3


1900 1005

Machine
axis
[F9.6.1]

[F9.6.1]

[F9.6.1]

[F9.6.1]

1900 1006
1900 1007

20.4.3

General selection/status signals to MMC (retentive area)

1900

Signals to operator panel [r/w]

Data block
Byte

Interface PLC - - - - -> HMI


Bit 7

Bit 6

1900 5000

Bit 5

Bit 4

Bit 3

Bit 2

Bit 1

Bit 0

OP key
lock
[F19.4]

1900 5001

Update tool
list
[F14.7]

1900 5002

Enable tool
gauging in
JOG
[F15.8]

1900 5003
1900 5004
...
1900 5007

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

T number for tool gauging in JOG (DINT)


[F15.8]

20-377

PLC User Interface


20.5

Auxiliary function transfer from NC channel

20.5

Auxiliary function transfer from NC channel

2500

Auxiliary functions from NCK channel[r]

Data block
Byte

PLC interface
Bit 7

Bit 6

Bit 5

Bit 4

Bit 3

Bit 2

Bit 1

Bit 0

M funct. 5

M funct. 4

M funct. 3

M funct. 2

M funct. 1

change

change

change

change

change

[F13.8]

[F13.8]

[F13.8]

[F13.8]

[F13.8]

2500 0000
to
2500 0003
2500 0004

2500 0005
2500 0006

S func. 1
change
[F13.8]

2500 0007
2500 0008

T func. 1
change
[F13.8]

2500 0009
2500 0010

D func. 1
change
[F13.8]

2500 0011
2500 0012

H func. 3
change
[F13.8]

H func. 2
change
[F13.8]

H func. 1
change
[F13.8]

Bit 2

Bit 1

Bit 0

M2

M1

M0

M10

M9

M8

M18

M17

M16

2500 0013
to
2500 0019

20.5.1

Decoded M signals (M0 - M99)

2500

M functions from NCK channel [r]

Data block

NCK interface

Byte

Bit 7

Bit 6

Bit 5

Bit 4

Bit 3

Dynamic M functions [F13.8]


2500 1000

M7

M6

M5

M4

M3

Dynamic M functions [F13.8]


2500 1001

M15

M14

M13

2500 1002

M23

M22

M21

M12

M11

Dynamic M functions [F13.8]


M20

M19
...

20-378

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

PLC User Interface


20.5

Auxiliary function transfer from NC channel

Dynamic M functions [F13.8]


2500 1012

M99

M98

M97

M96

Bit 2

Bit 1

Bit 0

Bit 2

Bit 1

Bit 0

2500 1013
to
2500 1015
Note: The signals are output for the duration of one PLC cycle.

20.5.2

T functions transferred

2500

T functions from NCK channel [r]

Data block

PLC interface

Start byte

Bit 7

Bit 6

Bit 5

2500 2000

Bit 4

Bit 3

T function 1 (DINT) [F13.8]

2500 2004
to
25002007

20.5.3

M functions transferred

2500

M functions from NCK channel [r]

Data block

PLC Interface

Start byte

Bit 7

Bit 6

Bit 5

Bit 4

Bit 3

2500 3000

M function 1 (DINT) [F13.8]

2500 3004

Extended address of M function 1 (bytes)

2500 3008

M function 2 (DINT) [F13.8]

2500 3012

Extended address of M function 2 (bytes)

2500 3016

M function 3 (DINT) [F13.8]

2500 3020

Extended address of M function 3 (bytes)

2500 3024

M function 4 (DINT) [F13.8]

2500 3028

Extended address of M function 4 (bytes)

2500 3032

M function 5 (DINT) [F13.8]

2500 3036

Extended address of M function 5 (bytes)

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

20-379

PLC User Interface


20.5

Auxiliary function transfer from NC channel

20.5.4

S functions transferred

2500

S functions from NCK channel [r]

Data block

PLC interface

Start byte

Bit 7

Bit 6

Bit 5

Bit 4

Bit 3

Bit 2

Bit 1

Bit 0

Bit 2

Bit 1

Bit 0

Bit 2

Bit 1

Bit 0

2500 4000

S function 1 (REAL) [F13.8]

2500 4004

Extended address of S function 1 (bytes)

2500 4008

S function 2 (REAL) [F13.8]

2500 4012

Extended address of S function 2 (bytes)

20.5.5

D functions transferred

2500

D functions from NCK channel [r]

Data block

PLC interface

Start byte

Bit 7

Bit 6

Bit 5

2500 5000

Bit 4

Bit 3

D function 1 (DINT) [F13.8]

2500 5004

20.5.6

H functions transferred

2500

H functions from NCK channel [r]

Data block

PLC interface

Start byte

Bit 7

Bit 6

Bit 5

Bit 4

Bit 3

2500 6000

H function 1 (REAL) [F13.8]

2500 6004

Extended address of H function 1 (INT) [F13.8]

2500 6008

H function 2 (REAL)

2500 6012

Extended address of H function 2 (byte) (INT) [F13.8]

2500 6016

H function 3 (REAL) [F13.8]

2500 6020

Extended address of H function 3 (byte) (INT) [F13.8]

20-380

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

PLC User Interface


20.6

20.6

NCK signals

2600

General signals to NCK [r/w]

Data block

Interface PLC - - - - -> NCK

Byte

NCK signals

Bit 7

Bit 6

2600 0000

Bit 5

Bit 4

Bit 3

Protection level [F19.2]

Bit 2

Bit 1

Acknowledge
EMERGENCY
STOP

EMERGENCY
STOP

Bit 0

[F1.5]

[F1.5]
2600 0001

Request distances to
go along
the axes
[F20.12]

Requerst
axis actual
values
[F20.12]

INC inputs
in mode
group area
active 1)
[F9.6.2]

2600 0002
2600 0003
Notes: 1) see operating mode signals

2700

General signals from NCK [r]

Data block

Interface NCK - - - - -> PLC

Byte

Bit 7

Bit 6

Bit 5

2700 0000

2700 0001

Bit 4

Bit 3

Bit 2

Bit 1

Bit 0

EMERGENCY
STOP active
[F1.5]
INCH dimension
system

Sensor 1 is
actuated.
[F15.8]

[F3.6]
2700 0002

Drive
ready
[F19.3]

2700 0003

Air temperature alarm


[F19.3]

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Drives in
cyclic
mode
[F19.3]
NCK alarm
is present
[F19.3]

20-381

PLC User Interface


20.6

NCK signals

3000

Operating mode signals to NCK [r/w]

Data block

Interface PLC - - - - -> NCK

Byte

3000 0000

Bit 7

Bit 6

Bit 5

Bit 4

Reset

Mode

[F10 8 1]
[F10.8.1]

change didi
sable

Bit 3

Bit 2

Bit 1

Bit 0

Operating mode

[F10.8.1]

JOG

MDA

AUTOM.

[F10.8.1]

[F10.8.1]

[F10.8.1]

Machine function
3000 0001

REF

Teach In

[F10.8.1]

Machine function 1)
3000 0002

Continuous
traversing

NCvar.

INC10 000

[F9.6.2]

INC 1000

INC 100

INC 10

INC 1

3000 0003

Note:
1) To be be able use the machine function signals in VB3000 0002, set the signal INC inputs in mode group area active
(V2600 0001.0) to 1.
The machine function INC10 000 is not supported by all machine control panels.

3100

Operating mode signals from NCK [r]

Data block

Interface NCK - - - - -> PLC

Byte

Bit 7

Bit 6

Bit 5

Bit 4

Bit 3

Bit 2

Bit 1

Bit 0

Active mode
3100 0000

802READY
[F10.8.1]

JOG

MDA

AUTOM.

[F10.8.1]

[F10.8.1]

[F10.8.1]

Active machine function


3100 0001

REF

Teach In

[F10.8.1]
3100 0002
3100 0003

20-382

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

PLC User Interface


20.7

20.7
20.7.1

Channel signals

Channel signals
Signals to NC channel

Control signals to NC channel

3200

Signals to NCK channel [r/w]

Data block
Byte

Interface PLC - - - - -> NCK


Bit 7

3200 0000

Bit 6

Bit 5

Bit 4

Enable dry
run feed

Enable M01

Enable single block 4)

[F10.8.2]

[F11.5.1]
3200 0001

Bit 3

Bit 2

Bit 1

Bit 0

[F10.8.2]

Enable program test

Enable referencing

[F10.8.2]

[F8.6]

3200 0002

Enable
block skip
[F10.8.2]

3200 0003
Feed override2) [F11.5.1]

3200 0004
H

3200 0006

Feed override1) active

Feed override active

Program level abortion

[F11.5.1]

[F11.5.1]

[F10.8.2]

3200 0007

3200 0013

Delete distance to
go
[17.2]

Read-in disable

Feed disable

[F10.8.2]

[F11.5.1]

Rapid traverse override3) [F11.5.1]

3200 0005

Do not diable tool ***)


[F14.4]

NC Stop fpr
axes plus
spindle

NC Stop

NC Stop at
block border

NC Start

NC Start inhibited

[F10.8.2]

[F10.8.2]

[F10.8.2]

[F10.8.2]

[F10.8.2]

Disable
workpiece
counter ***)
[F14.7]

Note:
1)+ Feed override active

Even if feed override is not active (=100%), the position 0% is nevertheless


active.
2)+ Feed override
31 positions (Gray code)
3)+ Rapid traverse override
31 positions (Gray code)
4)+ Single block
Use softkey for Single block type selection (SBL1/SBL2) (see Users Guide)

***) These signals are not available for 802D base line.

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

20-383

PLC User Interface


20.7

Channel signals

Control signals to geometry axes (axes in WCS)

3200

Signals to NCK channel [r/w]

Data block

Interface PLC - - - - -> NCK

Byte

Bit 7

Bit 6

Bit 5

Bit 4

Bit 3

Bit 2

Bit 1

Bit 0

Geometry axis 1 (axis 1 in WCS)


3200 1000

Traversing keys
+

Rapid traverse override

[F9.6.3]

[F9.6.3]

[F9.6.3]

Traversing
key lock

Feed stop

[F9.6.3]

[F11.5.1]

Enable handwheel
3

[F9.6.3]

[F9.6.3]

[F9.6.3]

INC100

INC10

INC1

Geometry axis 1 (axis 1 in WCS)


Machine function 1) [9.6.3]

3200 1001
Continuous
traversing

INCvar.

INC10 000

INC1000

32001002
32001003
Geometry axis 2 (axis 2 in WCS)
3200 1004

Traversing keys
+

[F9.6.3]

[F9.6.3]

Rapid traverse override

Traversing
key lock

Feed stop[
[F11 5 1]
[F11.5.1]

[F9.6.3]

[F9.6.3]

Activate handwheel
3

[F9.6.3]

[F9.6.3]

[F9.6.3]

INC100

INC10

INC1

Axis 2 in WCS
Machine functions 1) [9.6.3]

3200 1005
Continuous
traversing

INCvar.

INC10 000

INC1000

3200 1006
3200 1007
Geometry axis 3 (axis in WCS)
3200 1008

Traversing keys
+

[F9.6.3]

[F9.6.3]

Rapid traverse override


[F9.6.3]

Traversing
key lock
[F9.6.3]

Feed stop

[F11.5.1]

Activate handwheel
3

[F9.6.3]

[F9.6.3]

[F9.6.3]

INC100

INC10

INC1

Geometry axis 1 (axis 3 in WCS)


Machine functions 1) [9.6.3]

3200 1009
Continuous
traversing

INCvar.

INC10 000

INC1000

3200 1010
3200 1011

Notes:
1) Machine function settings for the machine function in VB3200 1001, VB3200 1005, VB3200 1009 only if signal
INC inputs in mode group area active (V2600 0001.0) is not set.
The machine function INC10 000 is not supported by all machine control panels.

20-384

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

PLC User Interface


20.7

20.7.2

Channel signals

Signals from NC channel

Status signals from NC channel

3300

Signals from NCK channel [r]

Data block

Interface NCK - - - - -> PLC


Bit 7

3300 0000

3300 0001

Program
test active
[F10.8.2]

Bit 6

Bit 5

Bit 4

Bit 3

Last action
block active

M0/M1 active

Approach
block active

Action
block active

Bit 2

Bit 1

Bit 0

[F10.8.2]

[F10.8.2]

[F10.8.2]

[F10.8.2]

Transformation active ***)


[F18.6]

M2/M30 active

Block
search active

Revolutional feed active

Referencing
active

[F10.8.2]

[F10.8.2]

[F11.5.1]

[F8.6]

3300 0002
Channel status
3300 0003
3300 0004

Program status

Reset

Interrupted

Active

Aborted

Interrupted

Stopped

Running

[F10.8.2]

[F10.8.2]

[F10.8.2]

[F10.8.2]

[F10.8.2]

[F10.8.2]

[F10.8.2]

NCK alarm
with porcessing
stop is present

Channelspecific
NCK alarm
is present

All axes
stopped

All axes referenced

[F12.7]

[F8.6]

[F19.3]

[F19.3]

3300 0005
3300 0006
3300 0007

***) These signals are not available for 802D base line.

Status signals of geometry axes (axes in WCS)

3300

Signals from NCK channel [r]

Data block
Byte

Interface NCK - - - - -> PLC


Bit 7

Bit 6

Bit 5

Bit 4

Bit 3

Bit 2

Bit 1

Bit 0

Geometry axis 1 (axis 1 in WCS)


3300 1000

Travel command

Handwheel active

plus

minus

[F9.6.3]

[F9.6.3]

[F9.6.3]

[F9.6.3]

[F9.6.3]

INC100

INC10

INC1

Active machine function [9.6.3]


3300 1001

Continuous
traversing

INCvar.

INC10 000

INC1000

3300 1002
3300 1003
Geometry axis 2 (axis 2 in WCS)
3300 1004

Travel command

Handwheel active

plus

minus

[F9.6.3]

[F9.6.3]

[F9.6.3]

[F9.6.3]

[F9.6.3]

INC100

INC10

INC1

3300 1005

Active machine function [9.6.3]


Continuous
traversing

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

INCvar.

INC10 000

INC1000

20-385

PLC User Interface


20.7

Channel signals

3300 1006
3300 1007
Geomery axis 3 (axis 3 in WCS)
3300 1008

Travel command

Handwheel active

plus

minus

[F9.6.3]

[F9.6.3]

[F9.6.3]

[F9.6.3]

[F9.6.3]

INC100

INC10

INC1

Bit 1

Bit 0

3300 1009

Active machine function [9.6.3]


Continuous
traversing

INCvar.

INC10 000

INC1000

3300 1010
3300 1011

3300

Signals from NCK channel [r]

Data block

Interface NCK - - - - -> PLC

Byte

Bit 7

Bit 6

Bit 5

Bit 4

Bit 3

Bit 2

3300 4000

G00 active

3300 4001

Workpiece
setpoint reached

External
language
mode active

[F10.8.2]

[F19.3]

Bit 1

Bit 0

3300 4002
3300 4003

G functions from the NC channel

3500

Signals from NCK channel [r]

Data block

Interface NCK - - - - -> PLC

Byte

Bit 7

3500 0000

Bit 6

Bit 5

Bit 4

Bit 3

Bit 2

Active G function of group 1

3500 0001

Active G function of group 2

3500 00..

Active G function of group ...

3500 0063

Active G function of group 64

Note:
With SINUMERIK 802D, G group 2 is transferred in VB3500 0001 as an active G command with the
values
0: - no G command of group 2 active,
1: G4,
2: G63,
3: G74,
4: G75,
11: G147,
12: G247,
13: G347,
14: G148,
15: G248,
16: G348
(remaining values: not available with SINUMERIK 802D; default setting).
Other settings are possible with MD 22510: see Section 21.3.
At the end of the NC program or when aborting the NC program, the last status of the groups is
kept. The meaning of the G commands is explained in
Reference: Programming and Operation, Chapter Overview of Statements
Please note: It is not guaranteed that an PLC user program provides a block -synchronous interrelation between active NC block and existing G code. The interrelation is not provided, e.g. when
working with short blocks (as the time regards) in the continuous -path mode (G64).

20-386

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

PLC User Interface


20.8

20.8
20.8.1

Axis/spindle signals
Transferred M/S functions, axis- specific

3700...3704

M/S functions [r]

Data block

Interface PLC - - - - -> NCK

Start byte

Bit 7

Bit 6

Bit 5

Bit 4

Bit 3

370x 0000

M function for spindle (DINT) [F5.10]

370x 0004

S function for spindle (REAL) [F5.10]

20.8.2

Axis/spindle signals

Bit 2

Bit 1

Bit 0

Bit 2

Bit 1

Bit 0
A

Signals to axis/spindle

Common signals to axis/spindle

3800...3804

Signals to axis/spindle [r/w]

Data block

Interface PLC - - - - -> NCK

Byte

Bit 7

Bit 6

Bit 5

Bit 4

Bit 3

Feed override [F11.5.2]


380x 0000

380x 0001

Override
active

Position encoder 1

Follow-up
mode

Axis/spindle
lock
[F19.2]

Sensor fixed stop


***) [F17.7]

[F11.5.2]

[F19.2]

[F19.2]

Acknowledge fixed
stop reached ***)
[F17.7]

Clamping
process
running

Distance to
go/spindle
reset

Servo
enable

[F2.7]

[F5.10]

380x 0002

380x 0003

Velocity/
spindle
speed limitation

[F19.2]
Fahren auf
Festanschlag ***)
[F17.7]

[F2.7]
Traversing keys
380x 0004

plus

minus

Rapid traverse override

[F9.6.4]

[F9.6.4]

[F9.6.4]

Traversing
key lock
[F9.6.4]

Feed stop

Enable handwheel

Spindle Stop

[F11.5.2]

[F9.6.4]

[F9.6.4]

[F9.6.4]

Machine functions 1)
380x 0005

Continuous
traversing

INCvar

INC10 000

INC1000

INC100

INC10

INC1

380x 0006
to
380x 0011

Notes: 1) Machine function settings for the machine function in VB38x 0005 only if signal INC inputs in mode group range
active (V2600 0001.0) is not set.
The machine function INC10 000 is not supported by all machine control panels.

***) These signals are not available for 802D base line.

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

20-387

PLC User Interface


20.8

Axis/spindle signals

Signals to axis

3800...3804

Signals to axis [r/w]

Data block

Interface PLC - - - - -> NCK

Byte

Bit 7

380x 1000
(axis)

Delayed reference
point approach

Bit 6

Bit 5

Bit 4

Bit 3

Bit 2

2nd software limit switch

Bit 1

Bit 0

Hardware limit switch

plus

minus

plus

minus

[F2.7]

[F2.7]

[F2.7]

[F2.7]

Bit 1

Bit 0

[F8.6]
380x 1001
to
380x 1003

Signals to spindle

3800...3804

Signals to spindle [r/w]

Data block

Interface PLC - - - - -> NCK

Byte

Bit 7

Bit 6

Bit 5

Bit 4

380x 2000
(spindle)
Invert
M3/M4
380x 2001
(spindle)

Bit 3

Bit 2

Gear is
switched
over

Actual gear stage


C

[F5.10]

[F5.10]

[F5.10]

[F5.10]

Resynchronization
when positioning 1

[F5.10]

Feed override valid for


spindle
[F11.5.2]

[F5.10]
Set direction of rotation
380x 2002

CCW

CW

Oscillation
speed
d

(spindle)

[F5.10]

[F5.10]

[F5.10]

380x 2003

Oscillation
f
from
PLC
[F5.10]
Spindle override [F11.5.2]

(spindle)

Bit 2

Bit 1

Bit 0

Signals to drive

3800...3804

Signals to axis/spindle [r/w]

Data block

Interface PLC - - - - -> NCK

Byte

Bit 7

Bit 6

380x 4000

Bit 5

Bit 4

Bit 3
Speed setpoint smoothing

HLGSS
[F19.2]

[F19.2]
380x 4001

Pulse
enable
[F19.2]

Integrator
lock n controller

Parameter set selection [F19.2]


C

[F19.2]
380x 4002
380x 4003

20-388

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

PLC User Interface


20.8

20.8.3

Axis/spindle signals

Signals from axis/spindle

General signals from axis/spindle

3900...3904

Signals from axis/spindle [r]

Data block
Byte

Interface NCK - - - - -> PLC


Bit 7

Bit 6

Bit 5

Position reached
390x 0000

390x 0001

Bit 4

with exact
stop fine

with exact
stop coarse

Referenced/synd/
chronized 1

[F12.7]

[F12.7]

[F8.6]

Current
controller
acitve

Speed controller active


[F19.3]

[F19.3]

Position
controller
active

Axis/spindle
stopped (n
< nmin)

Bit 3

Bit 2
Encoder frequency exceeded 1
[F2.7]

Bit 1

Bit 0
Spindle/no
p
axis
i
[F5.10]

Follow-up
active
[F19.3]

[F19.3]
[F17.3]

390x 0002

Fixed stop
reached
***) [F17.7]

Activate traversing to
fixed stop
***) [F17.7]

Measuring
active
[F17.7]

390x 0003
Traversing command
390x 0004

Handwheel active

plus
p

minus

[F9.6.4]

[F9.6.4]

[F9.6.4]

[F9.6.4]

[F9.6.4]

INC100

INC10

INC1

Bit 2

Bit 1

Bit 0

Active machine function [9.6.4]


390x 0005

continuous

NCvar.

INC10 000

INC1000

390x 0006
to
390x 0011

***) These signals are not available for 802D base line.

Signals from axis

3900...3904

Signals from axis [r]

Data block

Interface NCK - - - - -> PLC

Byte

Bit 7

Bit 6

Bit 5

Bit 4

Bit 3

390x 1000
390x 1001
390x 1002

Lubrication
pulse
[F19.3]

390x 1003

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

20-389

PLC User Interface


20.8

Axis/spindle signals

Signals from spindle

3900...3904

Signals from spindle [r]

Data block

Interface NCK - - - - -> PLC

Byte

Bit 7

Bit 6

Bit 5

Bit 4

Bit 3

Bit 2

Bit 1

Bit 0

390x 2000

Switch over
gear

(spindle)

[F5.10]

[F5.10]

[F5.10]

[F5.10]
Speed limit
exceeded

390x 2001
(spindle)

Spindle

Actual direction of
rotation CW

in setpoint
range

Setpoint
speed increased

Setpoint
speed limited

[F5.10]

[F5.10]

[F5.10]

[F5.10]

Active spindle mode


390x 2002
(spindle)

Set gear stage

Control
mode

Oscillation
mode

Positioning
mode

[F5.10]

[F5.10]

[F5.10]

Rigid
g tapp
ping
i

[F5.10]
Constant
cutting
tti rate
t
active

[F5.10]

[F5.10]

390x 2003

Signals from drive

3900...3904

Signals from axis/spindle [r]

Data block
Byte

Interface NCK PLC - - - - -> PLC


Bit 7

Bit 6

Bit 5

Bit 4

390x 4000

390x 4001

Pulses
enabled
[F19.3]

390x 4002

Bit 3

Bit 2

Speed setpoint smoothing active


[F19.3]

Variable
signaling
g
g
f
function
1
[F19.3]

Integrator of
n controller
disabled
[F19.3]

Bit 1

Bit 0

Ramp function generator encoder


lock
active
[F19.3]

Drive
ready
y

Active parameter record [F19.3]

[F19.3]

nact = nset

nact<nx

nact < nmin

Md < Mdx

[F19.3]

[F19.3]

[F19.3]

[F19.3]

Acceleration prop
cess completed

Temperature prewarning
Heat sink

Motor

[F19.3]

[F19.3]

[F19.3]
390x 4003

UZK<warning threshold
[F19.3]

20-390

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

PLC User Interface


20.9

20.9
20.9.1

PLC machine data

PLC machine data


INT values (MD 14510 USER_DATA_INT)

4500

Signals from NCK [r16]

Data block

Interface NCK - - - - -> PLC

Byte
4500 0000

Int value (WORD/ 2 byte)

4500 0002

Int value (WORD/ 2 byte)

4500 0004

Int value (WORD/ 2 byte)

to
4500 0062

20.9.2

Int value (WORD/ 2 byte)

HEX values (MD 14512 USER_DATA_HEX)

4500

Signals from NCK [r8]

Data block

Interface NCK - - - - -> PLC

Byte
4500 1000

Hex value (BYTE)

4500 1001

Hex value (BYTE)

to
45001031

20.9.3

Hex value (BYTE)

FLOAT values (MD 14514 USER_DATA_FLOAT)

4500

Signals from NCK [r32]

Data block

Interface NCK - - - - -> PLC

Start byte
4500 2000

Float value (REAL/ 4-byte)

4500 2004

Float value (REAL/ 4-byte)

to
4500 2028

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Float value (REAL/ 4-byte)

20-391

PLC User Interface


20.10

Reading and writing of PLC variables

20.9.4

User alarm: Configuration (MD 14516 USER_DATA_PLC_ALARM)

4500

Signals from NCK [r8]

Data block

Interface NCK - - - - -> PLC

Byte
4500 3000

Alarm reaction/reset criterion for alarm 700000

4500 3001

Alarm reaction/reset criterion for alarm 700001

to
4500 3031

Alarm reaction/reset criterion for alarm 700031

Note: For information on PLC alarms including the configuration of user alarms, please refer
to:
References:
Start-up Guide, Section PLC alarms

20.10 Reading and writing of PLC variables


4900

PLC variables [r/w]

Data block

PLC interface

Byte
4900 0000

Offset[0]

4900 0001

Offset[1]

to
4900 0511

Offset[511]

Note: the organization if this data area is the sole and only responsibility of the application
programmers of NCK and PLC. Data type, position offset and meaning of the variables must
be agreed. The memory area limits per variable must be observed according to the variable
type concerned (1, 2 or 4-byte types).
For further information, please refer to:
References:
Programming and Operation, Section Reading and writing of PLC variables

20-392

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

PLC User Interface


20.11

20.11

Tool management functions provided by the NC channel

Tool management functions provided by the NC channel

Change signals provided by tool management functions

5300

Tool management functions [r]

Data block
Byte

Interface NCK PLC - - - - -> PLC


Bit 7

Bit 6

Bit 5

Bit 4

Bit 3

Bit 2

5300 0000

Bit 1

Bit 0

Tool limit
value reached ***)

Tool prewarning limit reached ***)

[F14.7]
[F14.7]

***) These signals are not available for 802D base line.

Tool management functions transferred

5300

tool management functions [r32]

Data block

Interface NCK - - - - -> PLC

Byte
5300 1000

T number for tool prewarning limit (DINT) ***) [F14.7]

5300 1004

T number for tool limit value (DINT) ***)

[F14.7]

***) These signals are not available for 802D base line.

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

20-393

PLC User Interface


20.12

Axis actual values and distances to go

20.12 Axis actual values and distances to go


5700 ... 5704

Signals from axis / spindle [r32]

Data block

Interface NCK - - - - -> PLC

Byte
570x 0000

Axis actual value (REAL)

570x 0004

Distance to go along the axis (REAL)

Note:

The axis actual values and dustances to go can be requested separately:


- V2600 0001.1 Request axis actual values
- V2600 0001.2 Request distances to go along the axes
If the appropriate request is set, the required values are delivered from NCK for all axes.

20-394

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

21

Various Machine Data

This Chapter describes machine data that are of general importance, but for which no topicrelated chapters/sections are included in this Description of Functions.

21.1

Display machine data

202
MD number

FIRST_LANGUAGE
First language

Default: 1

Min. input limit: 1

Change valid: immediately

Max. input limit: 2

Protection level: 2/3

Date type: BYTE

Unit: -

Valid from SW release:

Meaning:

This machine data can be used to set the language (1 or 2) automatically displayed after each
system power up.
With the SINUMERIK 802D, 2 languages can be used at a time. Other languages implemented
in the control system in the delivery status can be loaded during start-up.
It is also possible to switch over the language temporarily using the appropriate softkey in the
System operating area. After Power On, the language set using this MD will be active again.

Further references

Operation and Programming

203
MD-Nummer

DISPLAY_RESOLUTION
Display resolution

Default: 3

Min. input limit: 0

Change valid: immediately

Max. input limit: 5

Protection level: 2/3

Date type: BYTE

Unit: -

Valid from SW release:

Meaning:

This machine data is used to define the number of decimal places for the position display of
linear axes if a metric system is used and, generally, for rotary axes.
Spindle positions are treated as rotary axes positions.
The position is displayed with a maximum of 10 characters including sign and decimal point.
A positive sign is not displayed.
By default, 3 places after the decimal point are displayed
MD value=3: Display unit = 10 - 3 [mm] or [degrees]

Related to ....

MD 10200: INT_INCR_PER_MM bzw. MD 10210: INT_INCR_PER_DEG

204
MD number

DISPLAY_RESOLUTION_INCH
Display unit for inch scaling system

Default: 4

Min. input limit: 0

Change valid: immediately

Max. input limit: 5

Protection level: 2/3

Date type: BYTE

Unit: -

Valid from SW release:

Meaning:

This machine data is used to define the number of decimal places for linear axes if an inch scaling system is used.
The position is displayed with a maximum of 10 characters including sign and decimal point. A
positive sign is not displayed.
By default, 4 places after the decimal point are displayed
MD value=4: Display unit = 10 - 4 [inch]
For rotary axes and spindle positions, the display remains as defined acc. to MD 203.

Related to ....

MD 10200: INT_INCR_PER_MM, MD 203: DISPLAY_RESOLUTION

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

21-395

Various Machine Data


21.2

General machine data

205
MD number:

DISPLAY_RESOLUTION_SPINDLE
Display unit for spindle values

Default: 1

Min. input limit: 0

Change valid: immediately

Protection level: 2/3

Date type: BYTE


Meaning:

21.2

Max. input limit: 5


Unit: -

Valid from SW release:


This machine data defines the number of decimal places for the display of the spindle speed.
The display is carried out with a max. of 10 characters including sign and decimal point. A positive sign is not displayed.
By default 1 place after the decimal point is displayed
MD value=1: display resolution = 10 - 1

General machine data

10000
MD number

AXCONF_MACHAX_NAME_TAB[0]...[4]
Machine axis name

Default:
Turning: (X1, Z1, SP, A1, B1)
Milling: (X1, Y1, Z1, SP, A1)
Change valid after Power On

Min. input limit: a letter

Protection level: 2/2

Date type: STRING


Meaning:

Max. input limit: 15 characters


starting with a letter,
16th character reserved (end of string)
Unit: -

Valid from SW release:


The name of the machine axis is entered in this machine data.
 An axis identifier consists of a valid address letter (A, B, C, Q, U, V, W, X, Y, Z) followed by
an optional numerical extension; (1-99) should be used preferably.
 The selected machine axis identifier must differ from the designation of geometry axes (X, Y,
Z) and further channel axes (MD 20080: AXCONF_CHANAX_NAME_TAB - if a transformation
is intended (e.g.: TRANSMITT).
Note: Transformations are not implemented in SW release P1 of the SINUMERIK 802D.
 A free machine axis identifier that has been entered (axis name) may not be a name,
address, vocabulary word or predefined identifier already used by the control system or
which is reserved for a different functionality (e.g.: SPOS, DIAMON, ...).
Note: Not the entire functionality of the SINUMERIK 802D control system is documented; a free
axis name may therefore only be used conditionally.

Special cases, errors, ......

For machine axes, the following is recommended:


X1, Y1, Z1, U1, V1, W1, Q1
for linear axes,
A1, B1, C1
for rotary axes

Related to ....

MD 20060: AXCONF_GEOAX_NAME_TAB (geometry axis name)


MD 20080 :AXCONF_CHANAX_NAME_TAB (channel axis name)

10074
MD number

PLC_IPO_TIME_RATIO
Factor of PLC task for power up (IPO)

Default: 2
Change valid after: Power On
Date type: DWORD
Meaning:

Min. input limit: 1

Max. input limit: 50

Protection level: 2/2

Unit: -

Valid from SW release:


Division ratio between IPO and PLC task.
For example, a value of 2 means that the PLC task is only processed in every second IPO cycle. The PLC cycle time thus amounts to 2 IPO times. Thus, more runtime is provided for the
other tasks.
The PLC runtime may not exceed this PLC cycle time; otherwise, an alarm is generated with
PLC STOP.

Application example(s)

21-396

SINUMERIK 802D, 802D base line


6FC5 697-2AA10-0BP2 (11.03) (DF)

Various Machine Data


21.2

10136
MD number

DISPLAY_MODE_POSITION
Display mode for actual position in the WCS

Default: 0

Min. input limit: 0

Change valid after RESET

Max. input limit: 1

Protection level: 2/2

Data type: DWORD


Meaning:

General machine data

Unit: -

Valid from SW release:


specifies how to display both the position and the distance-t