Sinumerik - 828D - Machine Commissioning - 2009 PDF

SINUMERIK 828D
Machine Commissioning
Sinumerik 828D
Edition 2009.8
Training Manual
This document was produced for training purposes.

Siemens assumes no responsibility for its contents.
SINUMERIK 828D
Commissioning Manual
Turning and Milling
Valid for
Controller:- Software:-
Sinumerik 828D 2.06.28
Contents
B060 System overview.

B021 Protection levels.
B002 Toolbox Installation.
B025 Time and Date Settings
B010 PPU Connections and Diagnostics.
B044 Licence and Option Commissioning.
B017 System Restore.
B008 Machine Control Panel .
B026 Creating a PLC Program.
B019 S7-200 PLC Instructions.
B034 PLC Interface.
B031 PLC Alarm and Message Structure.
B032 Remote Diagnosis .
B033 PI Services & PLC Functions.
B058 PLC On board Diagnostic.
B041 Machine and Setting Data.
B068 Commissioning Sequence.
B053 Axis and Drive Diagnostics.
B084 Referencing of Encoders.
B020 Maintenance Planner.
B009 Easy Extend .
B018 Easy Messenger.
B007 Electronic Logbook.
B067 Preparation of series machines.
B100 Servo Optimisation.
B051 Line and Motor Modules .
B006 Electrical Cabinet Design.
B099 Tips & Tricks
B060 System Overview
1 Brief description
Module Objective:-
Upon completion of this module you will know the Sinumerik 828D system and the components which
make up the system.
Module Description:-
The Sinumerik 828D system is made up of a variety of hardware components. This module gives a
graphical overview of those components and shows where each component is connected.
A brief description of the hardware components is also given.
Sinumerik 828D
SINUMERIK 828D Page 1 This document was produced for training purposes.
B060
Contents:- B011
Section 2
System Overview Page 3
Section 3
828D/PPU Page 4
Machine Control Section 4

Panels Page 6
Section 5
Drive Components Page 10
Section 6
NX10 Module Page 14
Section 7
Sensor Modules Page 15
PLC Periphery Section 8

PP72/48 Page 18
Section 9
Hand-held Units Page 20
B060 Page 2 SINUMERIK 828D

System Overview
Section 2
PP72/48PN PLC I/O Notes
MCP310PN
MCP483PN
USB
GSM/GPRS
USB modem
Compact
Flash
PN1 & PN2
Profinet
interfaces.
X140
X1 PN1 PN2 X135 RS232
interface Mini
HHU
X145 X140
Digital I/O
X125 X122, X132 & X142
Sinumerik 828D
X127 & PPU2xx.1 X122
X132
X142
}
X143
X100 X101 X102 X130 X130-Facxtory Ethernet
Hand-wheels
X100, X101 & X103
X127 Service
DriveCliq interfaces.
Ethernet
DMC20
DriveCliq
hub
Sinamics S120
Booksize drive
Modules.
Filter
SMC20/30 SMC20/30
NX10
Reactor
SINUMERIK 828D Page 3 B060

Section 3 Hardware information
Notes PPU2xx.1 with integrated 828D controller
General information.
The controller is available in vertical or horizontal formats. The functionality of the two
variants is identical.
The PPU includes “Qwerty” and numerical keyboard inputs and shortcut keys to spe-
cific machine areas.
The 828D encompasses the HMI, NC, PLC and CU logical components.
PPU interfaces:-
X125 USB interface.
X127 Ethernet service port.
X145 Compact Flash (CF) interface.
RDY Green ready LED
NC Red fault LED
CF Amber CF card activity LED
828D interfaces:-
X1-24V DC supply.
X100 to X103 –Drive Cliq interface.
X130-Ethernet factory network.
X135-USB interface.
X140-RS232 interface
X122 & X132-Digital I/O for Sinamics
X142-Digital I/O for NCK
X143-Hand-wheels x 2
LED Indicators:-
FAULT-Red-fault present, contact Siemens.
SYNCH-Green-synchronisation OK
Rx/Tx-Yellow network activity LED (1 each for PN1, PN2 & X130 interfaces)
Link-Green network connection indicator (1 each for PN1, PN2 & X130 interfaces)
A choice of horizontal or vertical mounting is available:-
Horizontal variant
PPU2x1.1
Vertical variant:
PPU2x0.1

Hardware information Section 3
PPU2xx.1 with integrated 828D controller Notes
Part numbers
General Information.
The PPU type can be identified by the PPU number:-
PPU2xx.1
0 - Vertical
1 - Horizontal
6 - Standard
8 - Performance
PPU Horizontal layout:-
Standard version
6FC5370-5AA00-0AA0 PPU261.1 without system software.
Performance version
PPU Vertical layout:-
Standard version
Performance version
Software (Current system software delivered on CF card):-
Milling (Max 6 axes)

6FC5831-2GY00-0YA0 Standard for PPU260/PPU261
6FC5830-2GY00-0YA0 Performance for PPU280/PPU281
Turning
6FC5831-1GY00-0YA0 Standard for PPU260/PPU261
6FC5830-1GY00-0YA0 Performance for PPU280/PPU281 (Max 8 axes with NX10)
Specifications
Input voltage- 24V DC +20% /-15%

Power Consumption 60W
Protection –Front operator panel IP65
Rear of PPU IP20
Operational temperature 0-45 °C

Operational Relative humidity 5 to 90 % @ 25°C (No condensation)
Horizontal model Vertical model

Width 310mm(12.2 in) 483mm (19 in)
Height 380mm(15in) 220mm (8.66 in)
Depth 105mm(4.13 in) 105mm( 4.13 in)

Notes Machine Control Panels (MCP’s)- Type MCP310C PN
The MCP310 is recommended for use with the vertical style PPU
MCP 310C PN(12.2”)
Part Number:-
6FC5303-0AF23-0AA1
Features:-
 49 mechanical keys with LED
Indicators (16 user assignable)
 Feed override control(16 positions)
 Key switch
 Emergency stop/Spindle override
optional Consumable items:-
 6 x Pre-drilled holes for hard wired 6FC5247-0AF13-1AA0-Feed
user buttons override rotary switch incl. cap, button,
 Connections for 9 user Inputs & 6 pointer & dials.
outputs. 6FC5247-0AF12-1AA0-Spindle
 Connection via Profinet. override rotary switch incl. cap, button,
pointer & dials.
Interfaces:-
X10 24V DC supply
X20 Ethernet port 1
X21 Ethernet port 1
X30 Feed override switch input
X31 Spindle override switch input
X51 User input connections.
X53 User output connections.
H1 LED POWER OK
H2 LED BUSSYNC
H3 LED BUSFAULT
S2 IP address selection switch.

Machine Control Panels (MCP’s)- Type MCP310 PN Notes
The MCP310 is recommended for use with the vertical style PPU
MCP 310 PN(12.2”)
Part Number:-
6FC5303-0AF23-1AA1
Features:-
 49 membrane keys with LED
Indicators (16 user assignable)
 Feed override control(16 positions)
 Key switch
 Emergency stop/Spindle override
optional Consumable items:-
 6 x Pre-drilled holes for hard wired 6FC5247-0AF13-1AA0-Feed
user buttons override rotary switch incl. cap, button,
 Connections for 9 user Inputs & 6 pointer & dials.
outputs. 6FC5247-0AF12-1AA0-Spindle
 Connection via Profinet. override rotary switch incl. cap, button,
pointer & dials.
Interfaces:-
X10 24V DC supply
X20 Ethernet port 1
X21 Ethernet port 1
H1 LED POWER OK
H2 LED BUSSYNC
H3 LED BUSFAULT
S2 IP address selection switch.

Hardware information
Section 4
Notes Machine Control Panels (MCP’s)- Type MCP483C PN.
The MCP483 is recommended for use with the horizontal style PPU.
MCP 483C PN (19”)
Part Number:-
6FC5303-0AF22-0AA1
Features:-
 50 mechanical keys with LED
indicators (17 user assign-
able)
 Spindle & feed override con-
trol.
 Key switch
 Emergency stop button Consumable items:-
 2 x Pre-drilled holes for hard 6FC5247-0AF13-1AA0-Feed override
wired user buttons rotary switch incl. cap, button, pointer & di-
 Connection via Ethernet als.
 2 x Hand-wheel connections 6FC5247-0AF12-1AA0-Spindle override ro-
tary switch incl. cap, button, pointer & dials.
 Connections for 9 user
Inputs & 6 outputs.
 Connection via Profinet
Interfaces:-
X10 24V DC supply
X20 Ethernet port 1
X21 Ethernet port 2
LED Indicators:-
H1 LED POWER OK LED
H2 LED BUSSYNC (Bus ok & synchronised)
H3 LED BUSFAULT (Bus fault)
S1 Hand-wheel type selection switch
S2 IP address selection switch

Section 4
Machine Control Panels (MCP’s)- Type MCP483 PN. Notes
The MCP483 is recommended for use with the horizontal style PPU.
MCP 483C PN (19”)
Part Number:-
6FC5303-0AF22-1AA1
Features:-
 50 membrane keys with LED
indicators (17 user assign-
able)
 Spindle & feed override con-
trol.
 Key switch
 Emergency stop button Consumable items:-
 2 x Pre-drilled holes for hard 6FC5247-0AF13-1AA0-Feed override
wired user buttons rotary switch incl. cap, button, pointer & di-
 Connection via Ethernet als.
 2 x Hand-wheel connections 6FC5247-0AF12-1AA0-Spindle override ro-
tary switch incl. cap, button, pointer & dials.
 Connections for 9 user
Inputs & 6 outputs.
 Connection via Profinet
Interfaces:-
X10 24V DC supply
X20 Ethernet port 1
X21 Ethernet port 2
LED Indicators:-
H1 LED POWER OK LED
H2 LED BUSSYNC (Bus ok & synchronised)
H3 LED BUSFAULT (Bus fault)
S1 Hand-wheel type selection switch
S2 IP address selection switch

Notes Line Modules.
Smart Line Module Active Line Module
General.
Line modules are responsible for generating the DC link supply for the drive system.
They require 3-phase AC for the DC link and +24V DC for the electronic supply.
The DC link and 24V DC voltages are distributed to other drive modules in the
system via a bus bar system.
The modules are available in several variants of size and functionality.
Smart Line Modules (SLM)

These modules are capable of mains regeneration but the DC link is not
stabilised.
SLM modules of 5 & 10 Kw do not connect to the DriveCliq network.
Modules of 16 Kw and above do connect to the DriveCliq.
Active Line Modules (ALM)

These modules are capable of mains regeneration and the DC link is stabilised.
All ALM modules are connected to the DriveCliq network.
Interfaces:-
SLM (5 & 10Kw variant)
X21-Enable, ready and fault signals
X22-Regeneration inhibit and fault reset signals.
X24-24V DC electronics supply.
U1, V1, W1-3-Phase supply.
X200, X201, X202-DriveCliq connections.
SLM (16Kw and above) & ALM (All variants)
X21-Enable & temperature sensor input.
X24-24V DC electronics supply.
U1, V1, W1-3-Phase supply.
X200, X201, X202-DriveCliq connections

Section 5
Line Modules-continued Notes
Part Numbers-SLM
6SL3130-6AE15-0AB0 5Kw Internal cooling.
6SL3130-6AE21-0AB0 10Kw “ “
6SL3130-6TE21-6AA3 16Kw “ “
6SL3130-6TE23-6AA3 36Kw “ “
6SL3131-6AE15-0AA0 5Kw External cooling
6SL3131-6AE21-0AA0 10Kw “ “
Part Numbers-ALM
6SL3130-7TE21-6AA3 16Kw Internal cooling.
6SL3130-7TE23-6AA3 36Kw “ “
6SL3130-7TE25-5AA3 55Kw “ “
6SL3130-7TE28-0AA3 80Kw “ “
6SL3130-7TE31-2AA3 120Kw “ “
6SL3131-7TE21-6AA3 16Kw External cooling
6SL3131-7TE23-6AA3 36Kw “ “
6SL3131-7TE25-5AA3 55Kw “ “
6SL3131-7TE28-0AA3 80Kw “ “
6SL3131-7TE31-2AA3 120Kw “ “
Motor Modules (MM)
The motor modules convert the DC link

voltage into a variable AC voltage which
is then output to the servo
Motors.
They are also supplied with 24V DC via
the ALM/SLM
All motor modules are connected to the
DriveCliq network.
They are available in one or two axis
variants and can be internally or
externally cooled.
Interfaces:-
MM –Single
X1-Output to Motor.
X21-Enable & temperature sensor input
X200, X201, X202-DriveCliq
connections.
MM –Double
X1 & X2-Output to Motors.
X21-Enable & temperature sensor input
(Motor 1)
X22-Enable & temperature sensor
input (Motor 2)
X200, X201, X202, X203-DriveCliq
Single MM Double MM
connections.

Notes Motor Modules (MM)-continued
Part Numbers-single modules

6SL3120-1TE13-0AA3 1.6Kw Internal cooling.
6SL3120-1TE15-0AA3 2.7Kw “ “
6SL3120-1TE21-0AA3 4.8Kw “ “
6SL3120-1TE21-8AA3 9.7Kw “ “
6SL3120-1TE23-0AA3 16Kw “ “
6SL3120-1TE24-5AA3 24Kw “ “
6SL3120-1TE26-0AA3 32Kw “ “
6SL3120-1TE28-5AA3 46Kw “ “
6SL3120-1TE31-3AA3 71Kw “ “
6SL3120-1TE32-0AA3 107Kw “ “
6SL3121-1TE13-0AA3 1.6Kw External cooling.
6SL3121-1TE15-0AA3 2.7Kw “ “
6SL3121-1TE21-0AA3 4.8Kw “ “
6SL3121-1TE21-8AA3 9.7Kw “ “
6SL3121-1TE23-0AA3 16Kw “ “
6SL3121-1TE24-5AA3 24Kw “ “
6SL3121-1TE26-0AA3 32Kw “ “
6SL3121-1TE28-5AA3 46Kw “ “
6SL3121-1TE31-3AA3 71Kw “ “
6SL3121-1TE32-0AA3 107Kw “ “
Part Numbers-double modules

6SL3120-2TE13-0AA3 2 x 1.6Kw Internal cooling.
6SL3120-2TE15-0AA3 2 x 2.7Kw “ “
6SL3120-2TE21-0AA3 2 x 4.8Kw “ “
6SL3120-2TE21-8AA3 2 x 9.7Kw “ “
6SL3121-2TE13-0AA3 2 x 1.6Kw External cooling.
6SL3121-2TE15-0AA3 2 x 2.7Kw “ “
6SL3121-2TE21-0AA3 2 x 4.8Kw “ “
6SL3121-2TE21-8AA3 2 x 9.7Kw “ “
Braking Modules & Resistors.

If the regenerative capability of the line
module is inadequate it can be
supplemented by the inclusion of a braking
module.
These modules fit neatly into the drive
system.
Further braking capacity can be added in
the form of braking resistors which connect
to the braking module. Braking resistors
require good ventilation and ideally need to
be mounted externally.
Braking modules and resistors can also
facilitate the controlled shut down of the
drives in the event of a power failure.
Another feature is the fast discharge of the
DC link. This feature is used to quickly
discharge the capacitors so that
maintenance tasks can be carried without Braking resistor
having to await natural discharge times.
Fast discharging should only be carried out
1 to 2 times per week to avoid damaging
the capacitors.
The braking module is connected to the DC
link and 24V DC bus systems.
Connector X21 on the braking module is
used for enable/fault/ready signals.
Connector X1 is for connecting the
external resistor. Braking Module

Hardware information Section 5
Braking Modules & Resistors-continued Notes
Part Numbers-
6SL3100-1AE31-0AB0 Braking Module 1.5Kw rated power
6SN1113-1AA00-0DA0 Braking Resistor 0.3Kw rated power
6SL3100-1BE31-0AA0 Braking Resistor 1.5Kw rated power
Control Supply Modules.
The Control Supply Module is a 24V/20A DC

Power Supply Unit.
It is used to maintain the 24V DC in the event of a
power failure.
The initial power to the module is taken from the

line supply, when a power failure occurs power is
taken from the residual voltage of the DC link.
Part number:-6SL3100-1DE22-0AA0
Control Supply
Module

Notes NX10 Module (Numerical Control Extension) Only for the T version
General.
Since the integrated control unit (CU) can control

only 6 axes, an NX10 module is required to
achieve the maximum number of 8 axes allowed
by the system.
The modules are of the same design as the
Sinamics S120 drives and fit neatly into the drive
rack.
All modules have to be connected to the

DriveCliq network.
Digital input & output functionality is available.

Drive enable signals OFF1 and OFF3 are
required to be connected here.
The functionality of the inputs and outputs can be
assigned by the user.
To maintain consitency with the CU the
recommended drive enable connections are:-
X122.1 = OFF1
X122.2 = OFF3
A separate 24V DC supply is required in order for

the inputs and putputs to function.
NX10
Part Number:-
6SL3040-0NC00-0AA0

Section 7
Sensor Modules (SMC & SME) Notes
General.
Sensor modules are required to convert non-DriveCliq encoder signals into

DriveCliq signals.
They are available for cabinet mounting (SMC) and external mounting (SME)
Several variants of each are available:-
SMC10/SMC20
SMC10
For the evaluation of 2-pole resolvers & Multi-pole resolvers, including motor
temperature evaluation (KTY84-130)
Interfaces:-
 X500 DriveCliq.
 X520 Measuring system input (25 pin D-type connector)
 X524 24V DC supply
 Status LED’s
Part Number:-
6SL3055-0AA00-5AA0
SMC20
For the evaluation of the following measuring systems:-
Incremental sin/cos 1v pp
Absolute EnDat encoders
SSI with incremental signals Sin/Cos 1V pp
(Temperature evaluation-KTY84-130 can also be used)
Interfaces:-
 X500 DriveCliq.
 X520 Measuring system input (25 pin D-type connector)
 Status LED’s
Part Number:-
6SL3055-0AA00-5BA1

Notes Sensor Modules (SMC & SME)-continued
SMC30
SMC30

Incremental with TTL/HTL signals
SSI with incremental TTL/HTL signals
SSI without incremental signals
Interfaces:-
 X500 DriveCliq.
 X520 TTL measuring system input (25 pin D-type connector)
 X521 HTL/TTL measuring system input (Screw type connector)
 X531 “ measuring system input (Screw type connector)
 Status LED’s
Note-The extra measuring system interfaces offer more flexibility for
connecting the encoder, The device however can only handle a single
encoder.
Part Number:-
6SL3055-0AA00-5CA1

Section 7
Sensor Modules (SMC & SME)-continued Notes
SME20 SME25
Incremental sin/cos 1v pp with C and D tracks 5V supply-SME20
Absolute EnDat encoders 5V supply-SME25
Absolute SSI with incremental signals 5V supply Sin/Cos 1V pp-SME25
Interfaces:-
 DriveCliq-Also supplies 24V DC.
 Measuring system input
Part Number:-
6SL3055-0AA00-5EA0-SME20
6SL3055-0AA00-5HA0-SME25
SME20SME25
SME120SME125
Incremental sin/cos 1v pp with C and D tracks 5V supply-SME120
Absolute EnDat encoders 5V supply-SME125
Interfaces:-
 DriveCliq-Also supplies 24V DC.
 Measuring system input
 Hall effect sensor input
 Temperature sensor input
Part Number:-
6SL3055-0AA00-5JA0-SME120
6SL3055-0AA00-5KA0-SME25
SME120SME125

Notes PP72/48D PN Modules (Combined I/O module)
PP72/48D PN modules are a compact component which connect to the Profinet
network (Ports PN1 or PN2 of the PPU)
There are two variants, one of which is all digital while the other offers both digital and
analogue functionality.
A 24V DC supply is required.
In total 72 digital inputs and 48 digital outputs are available on each of the two
variants.
The analogue module has an additional two analogue inputs and two analogue out-
puts.
Part number:- 6FC5311-0AA00-0AA0 Digital only (PP72/48D PN)

6FC5311-0AA00-1AA0 Digital/analogue (PP72/48 2/2A PN)
A maximum of 4 PP72/48 modules with the PPU260 and PPU261 variants.

A maximum of 5 PP72/48 modules with the PPU280 and PPU281 variants.
Interface Location:-
S1
X111
X222
X2 X2
Port 2 Port 1
X333
X1

Section 8
PP72/48D PN Modules (Combined I/O module) Notes
The PP72/48 is part of the Profinet network and as such needs to be addressed so
that the system associates the various I/O with the correct function.
To introduce some compatibility the default start address for the inputs and outputs
should be defined as 0.
This is determined by the setting of switch S1 on the PP72/48 module. Each profinet
device has an IP address of 192.168.214.xxx . The S2 setting determines the last part
of the IP address (xxx)
For Profinet applications switch positions 9 and 10 always need to be set to on.
Switch S1 Binary
Position Value
1 1
2 2
3 4
4 8
5 16
6 32
7 64
8 128
Machine Data Index IP address Switch S1

Input Address Range Output Address Range
12986[x] 192.168.214.xxx Setting
0 9 0 to 8 0 to 5 1 & 4 on
1 8 9 to 17 6 to 11 4 on
2 7 18 to 26 12 to 17 1, 2 & 3 on
3 6 27 to 35 18 to 23 2 & 3 on
4 5 36 to 44 24 to 29 1 & 3 on
5 20 96 to 111 96 to 111 3 & 5 on
6 64 112 to 129 112 to 119 7 on
7
To assign the default start address of 0, switch S1 should be set to 9 (S1.1 and 1.4
set to on). To release the I/O for use by the PP72/48 the relevant machine data
should be set to a value of –1
In this case this is machine data 12986[0]. By default this will have the value of 0.
Further PP72/48 modules will need to be addressed in a similar fashion.
PP72/48 No.1 Input range 0 to 8, output range 0 to 5 Switch 1 & 4 on

PP72/48 No.2 Input range 9 to 17, output range 6 to 11 Switch 4 on
PP72/48 No.3 Input range 18 to 26, output range 12 to 17 Switch 1, 2 & 3 on
Below:-Example of machine data 12986 set to enable the PP72/48 modules

addressed as 8 & 9.
The machine data is activated with an NCK power off.

Notes Ribbon cable connections. Below is an example of the pins and associated
I/O addresses. This is assuming the PP72/48 is addressed with input bytes 0, 1, & 2
and output bytes 0 & 1.
Consult the manufacturers documentation for actual addressing.
X111
Pin Signal Pin Signal Pin Signal
1 0V DC 19 I2.0 37 Q0.6
2 +24V DC Output 20 I2.1 38 Q0.7
3 I0.0 21 I2.2 39 Q1.0
4 I0.1 22 I2.3 40 Q1.1
5 I0.2 23 I2.4 41 Q1.2
6 I0.3 24 I2.5 42 Q1.3
7 I0.4 25 I2.6 43 Q1.4
8 I0.5 26 I2.7 44 Q1.5
9 I0.6 27 Not used 45 Q1.6
10 I0.7 28 Not used 46 Q1.7
11 I1.0 29 Not used 47 +24V DC Input
13 I1.2 31 Q0.0 49 +24V DC Input
14 I1.3 32 Q0.1 50 +24V DC Input
15 I1.4 33 Q0.2
16 I1.5 34 Q0.3
17 I1.6 35 Q0.4
18 I1.7 36 Q0.5

X222 Notes

1 0V DC 19 I5.0 37 Q2.6
2 +24V DC Output 20 I5.1 38 Q2.7
3 I3.0 21 I5.2 39 Q3.0
4 I3.1 22 I5.3 40 Q3.1
5 I3.2 23 I5.4 41 Q3.2
6 I3.3 24 I5.5 42 Q3.3
7 I3.4 25 I5.6 43 Q3.4
8 I3.5 26 I5.7 44 Q3.5
9 I3.6 27 Not used 45 Q3.6
10 I3.7 28 Not used 46 Q3.7
13 I4.2 31 Q2.0 49 +24V DC Input
14 I4.3 32 Q2.1 50 +24V DC Input
15 I4.4 33 Q2.2
16 I4.5 34 Q2.3
17 I4.6 35 Q2.4
18 I4.7 36 Q2.5
X333
1 0V DC 19 I8.0 37 Q4.6
2 +24V DC Output 20 I8.1 38 Q4.7
3 I6.0 21 I8.2 39 Q5.0
4 I6.1 22 I8.3 40 Q5.1
5 I6.2 23 I8.4 41 Q5.2
6 I6.3 24 I8.5 42 Q5.3
7 I6.4 25 I8.6 43 Q5.4
8 I6.5 26 I8.7 44 Q5.5
9 I6.6 27 Not used 45 Q5.6
10 I6.7 28 Not used 46 Q5.7
13 I7.2 31 Q4.0 49 +24V DC Input
14 I7.3 32 Q4.1 50 +24V DC Input
15 I7.4 33 Q4.2
16 I7.5 34 Q4.3
17 I7.6 35 Q4.4
18 I7.7 36 Q4.5

Notes Hand Held Unit (HHU)
Hand held units allow the operator to manually control the machine remotely from the
main operator panel.
Below:-HHU with coiled cable, connector and mounting device.
The HHU offers manual axis movement via hand wheel or jog buttons.
A rotary switch is used to select the required axis, it is only possible to select one axis
at a time from the maximum of five axes.
Safety is provided via a 2 channel emergency stop button and a 3 position “Dead
mans” enable button.
The casing has magnets which are useful to attach the unit to any suitable metallic
surface, alternatively a holder can purchased for this purpose.
A terminating connector is available to facilitate the (Cold) removal of the HHU
without affecting the machine operation.
In addition to the +/- & Rapid jog buttons there are three user assignable buttons.
The signals from the HHU are split into three categories.
1. The emergency and enabling buttons should be used in the safety/enabling
circuit of the machine.
2. The jog and axis selection should be done via the user PLC program
3. The hand-wheel signals need to be taken to X143 of the PPU
Part numbers:-
6FX2007-1AD03 Mini HHU with coiled cable, 1.5m (4.92 ft) stretches to 3.5m (11.5 ft)
6FX2007-1AD13 Mini HHU with straight cable, 5m (16.4 ft)
6FX2006-1BG03 Non assembled connection kit with terminator.
6FX2006-1BG13 Non assembled connection kit without terminator.
6FX2006-1BG20 Pre assembled connection kit with terminator.
6FX2006-1BG25 Pre assembled connection kit without terminator.
6FX2006-1BG70 Holding cradle

B021 Protection levels
1 Brief Description.
Module Objective:
Upon completion of this module you will be able to set the different protection levels via a password
or key switch.
You will also be able to change the protection levels of individual programmes.
Module Description:
The data of 828D controller is protected by seven protection levels. Four of which are set via inputs
and three by password.
This module explains the different protection levels, how to set these levels and how to protect
individual files.
Sinumerik 828D
B021
Contents: B021
Password and Section 2

key-switch information. Page 3
Setting and Deleting Section 3

the Password Page 4
Protection of files Section 4

Page 6

Password and key-switch information.
Section 2
Notes
The following table shows the password/key-switch positions and associated
protection levels/users.
Protection
Intended user:- Protected via:-
level
1 Manufacturer Password: SUNRISE
2 Service Password: EVENING
3 User Password: CUSTOMER
4 End user: Programmer, Setter Key-switch position 3
5 End user: Qualified operator Key-switch position 2
6 End user: Trained operator Key-switch position 1
7 End user: Untrained operator Key-switch position 0
The key switch is located to the bottom right of the MCP and has four positions.
Three colour coded keys are available, each of which allow a different access level.
This is from a standard Siemens machine control panel. It is possible that a
manufacturer may use a different method to set the interface signal.
Key switch Colour coded keys
Access levels of the three keys:-
Key colour Switch position Protection level
No key required 0 7
Black 0&1 6-7
Green 0, 1 & 2 5-7
Orange 0, 1, 2 & 3 4-7
The signals from the key switch are automatically set via the MCP interface.
The higher the authorisation level the more data is available to the user.
Example:- The machine data area is not available unless protection level 4 (Key
position 3) or higher is released.

Section 3 Setting, deleting & changing the password.
Notes Setting the password:-
The screen for entering the password is reached via the following key presses
A dialogue box is opened, this box shows the current access level and allows a
password to be entered using the keyboard.
After typing the password it is confirmed by pressing the “OK” soft key.
The dialogue box disappears and the current access level is displayed above the left
hand horizontal soft-keys.

Setting, deleting & changing the password.
Section 3
Deleting the password:- Notes
Before deleting a password the next highest password level or higher should be set..
Navigate to the screen where the password is entered, and select the “Delete
password” soft key
A dialogue box is opened, this box shows the current access level and asks if you
really want to delete the current password, if yes select the “OK” softkey to delete the
password
The dialogue box will then disappear. The access level will be now be determined by
the key switch position.
The password remains active after power on. If working on a machine the password
should always be set back to the level found on arrival.
Changing the password:-

It may be necessary to change the password from the defaults found on page 3.
To change a password the same level of access or higher should be set. E.G To
change the “Service” password, levels 2, 1 or 0 must be active.
It should be noted that the highest level password (Level 0) is not available for
general use. This means that if the “Manufacturer” password is changed and then
forgotten, the only way to gain access to level 1 is to re-commission the controller
and return the passwords to default.
Locate and select the “Change password” soft key.
The following dialogue box will be displayed. This allows a new password to be
entered and confirmed.
In this example the “Manufacturer” password is active, this allows the Manufacturer,
Service & User passwords to be changed.
Navigation of the dialogue box is achieved via the cursor and select keys,
confirmation is via the “OK” soft key.
In this example the “Manufacturer” password is active, this allows the Manufacturer,
Service & User passwords to be changed.

Section 4
Protection of files
Notes Certain files such as important cycles, programmes etc can be individually protected
against accidental editing, deletion or execution. They can also be hidden from view.
The desired file has to be located before the properties can be edited. In this
example, the part programme “828.MPF” is to have it’s properties changed.
The “Part program” directory is located by selecting the
“Program manager” key.
By highlighting the correct directory and opening it with the “Input” key we can see
the program “828D.MPF”. Ensure this is highlighted.
The properties of the file are found by paging right and selecting the properties
Soft-key.
A dialogue box allows four properties to be changed. In the following example, the
program:-
Can only be executed if the “Service” password or higher is active
Can only be written to (Edited) if the “Manufacturer” password or higher is active
Will only be listed if the key switch position 0 or higher is active
Can only be read if the key switch position 1 or higher is active

Protection of files
Section 4
Notes
When the correct settings have been entered the “OK” soft key has to be selected.

B002
Installation of Commissioning Tools
1 Brief description
Module Objective:
Upon completion of this module you will be able to install the commissioning tools required to
commission and service a machine with the 828D controller.
Module description:
The machine with the 828D controller is commissioned using software obtained from the Toolbox
DVD which is supplied with each controller. The software needs to be installed on to a PG/PC before
the commissioning procedure commences.
Sinumerik 828D
B002
Contents:- B002
Section 2
Toolbox Installation
Page 3
RCS Commander Section 3

Installation Page 13

Section 2
Toolbox Installation.
This module deals with the installation of three items:- Notes
Configuration Data:- A folder will be created which contains reloadable language
files.
PLC Programming Tool:- For Creating/Loading/Editing the PLC user programme.
Start-up Tool:- For the commissioning of the drives.
Uninstalling Existing Software.
Existing software may be present from a previous toolbox, this is usually

automatically uninstalled by the toolbox installation process. It may sometimes be
necessary to manually uninstall incompatible software.
To uninstall existing software first locate the “Control Panel” area of the PG/PC by
selecting “Start\settings\Control Panel”
Please bear in mind that the actual views may differ from PG/PC to PG/PC.
Locate and double click the “Add or Remove Programs” icon.
Select the “Change or Remove Programs” button.

Section 2 Toolbox Installation.
Notes The list can be checked for installed programs, these can be removed with the
“Change/Remove” button if required.
Installation Process.
Each controller is delivered with a Toolbox DVD. This Toolbox DVD contains a
number of files and folders.
One of these Files is an executable file named “Setup.exe”. The installation is started
by double clicking this file.
The contents of the toolbox DVD:-
Double click the “Setup.exe” file to start

the toolbox installation.
The installation process will now begin with a series of dialogue boxes which need to
be acknowledged.
It is possible that the installation process will display different messages, this could be
due to the detection of existing software installed on the PG/PC.
To reiterate the point made earlier, it is suggested that the software be installed on
dedicated hard disk, dual boot system or a VM ware partition.

Section 2
Notes
Software licence agreement:-
After reading the agreement!
After reading All available programs need to be selected and installed.

Section 2
Notes Confirmation that the Configuration Data is being installed.
Configuration Data Install

Recommendation to close all other applications.:-
Software licence agreement:-
After reading the agreement!
Step 1 - Configuration Data Installation.

The default installation path is “C:\Program Files\Toolbox 828D.
It is good practice to avoid installing to the C drive of the PG/PC. This drive typically
contains the operating system installation folders.
Use the “Browse” button to select another more suitable drive.

Section 2
The default installation path is “C:\Program Files\Toolbox 828D. Notes
It is good practice to avoid installing to the C drive of the PG/PC. This drive typically
contains the operating system installation folders.
Use the “Browse” button to select another more suitable drive.
Opportunity to choose the installation folder:-
Type in the path directly or locate the path via the “Directories” and “Drives” options.

Notes If a new non-existent directory is typed the system will create it for you.
The configuration files will

now be installed.
To finalise the setup,

Select the “Finish” button
to continue.
PLC828 Programming Tool.

The next item of the Toolbox to be installed is the PLC828 Programming Tool. This
follows on when the previous “Finish” button is pressed.

Section 2
Notes
The set-up language can be

changed if required.
Close all Windows

programs before
continuing!
Enter the user name and

company information.
As with the configuration

files it is recommended
that the destination folder
is not on the Windows
installation drive.
This is changed with the
“Browse” button.

Notes When the destination folder has been selected and acknowledged, the installation is
continued by pressing the “Next” button.
Select the languages which should be installed.
The program will now be installed. When installation is complete the following
dialogue box will be displayed. Acknowledge this with the “Finish” button.
Start-up Tool installation.
The language can be selected

(German or English)

Section 2
Notes
Close all Windows

programs before
continuing!
Licence agreement.
The 828D controller operates with the Sinamics drive system, therefore the

Section 2
Notes Information and recommendations.
When the PC has rebooted, run the “setup.exe” file again.
Double click the “Setup.exe” file to start

the toolbox installation.
The program will display the following dialogue box, select finish to complete the
installation.

RCS Commander Installation.
Section 3
RCS Commander Installation Notes
RCS Commander is not part of the Toolbox but is required for certain commissioning
procedures.
RCS Commander allows connection between the 828D controller and remote PG/PC’s.
The software incorporates VNC viewer which the user can view and change the
controller settings (Depending upon access rights set up on the controller).
A backup function is also available which is used to create an image of the system CF
card. This image can then be used to restore the system, in the event of a CF card
failure.
The software is delivered on a separate CD/DVD
To install the RCS Commander software, locate the “Setup.exe” in the root of the DVD.
Start the installation by double clicking the file.
Double click the

“Setup.exe” file to
start the toolbox
installation.
It is possible to choose between two languages, English or German.
Allow a few moments for the following dialogue box to appear then select the “Next”
key:-

Section 3 RCS Commander Installation.
Notes The Licence Agreement must be read and the terms accepted.
The destination folder can be changed if required.
From the drop down menu choose the preferred destination. A new folder can be
Created via the “New Folder” button. Confirm the destination folder with the ok button
“New Folder” button.

RCS Commander Installation.
Section 3
Continue by selecting the “next” button. Notes
Select the “Install” button to start the installation.
The installation process begins.
A successful installation is confirmed by the following dialogue box.

B025 Time and Date Settings
1 Brief description
Module objective:
Upon completion of this module you will be able to set the time and date for the system.
Module description:-
It is important that the system date and time are correct.

This is necessary for checking when an alarm occurred or when a file (Part program, archive etc)
was created or edited.
Before the date and time displays can be edited, the password for the “User” or higher must be
entered.
Sinumerik 828D
B025
Contents:- B025
Setting the Date and Section2

Time Page 3

Time and Date Settings
Section 2
Before the date and time displays can be edited, the password for the “User” or Notes
higher must be entered. See Module B025 for more information about passwords.
The Date/Time screen is reached with the following soft key sequence:-
The time and date can now be checked and corrected if necessary.
Use the cursor keys to move between the data fields.
The format can be changed by highlighting the required box and using the “Select”
key
If the date or time is changed, each element has to be confirmed using the “Input” key.
Once the time & date are correct press the “OK” soft key.

B010 PPU Connections and Diagnostics
Module objective:
Upon completion of this module you will be able to locate the status LED's and determine the status
of the CNC controller.
You will also be able to locate the general connections and understand their functionality.
Module description:
The 828D PPU can be diagnosed using status LED’s. The status can be quickly assessed prior to
using more detailed diagnostic tools.
For the controller to function correctly the interfaces should be correctly connected, the location and
functionality of these interfaces is described in this module.
Sinumerik 828D
B010
Contents:- B010
PPU Status LED’s and Section 2

Interfaces (Front) Page 3
PPU Status LED’s Section 3

and Interfaces (Rear) Page 4
Digital Input/Output Section 4

Terminal Description Page 5

PPU Status LED's & Interfaces (Front) Section 2
The interfaces are found on the front and the rear of the PPU. The front interfaces are Notes
found beneath a hinged cover to the left of the screen.
Ethernet DHCP server port. Default ad-

X127 dress-192.168.215.1
Issues addresse up to 192.168.215.9
RDY
NC LED status indicators, see table below.
CF
USB port for keyboard and memory
X125 devices.
Compact Flash port for customer data

X145 storage and service/commissioning work.
LED Green Orange Red Red/Orange
Booting in
System
RDY PLC/Periphery fault Progress
healthy
(Alternating)
System healthy
NC Internal NCK error
(Flashes at 1Hz)
Internal/External CF
CF card access
(Flashes randomly)
The CF card should not be removed while the CF LED is flashing.

Section 3 PPU Status LED's & Interfaces (Rear)
Notes Interface locations:-
Rear view of PPU2xx showing interfaces.
Interface connectors:
X1 24V DC supply
X100 DriveCliq interface for line/motor modules
X101 DriveCliq interface for DMC modules
X102 DriveCliq interface for NX modules
X120 Profinet interface
X121 Profinet interface
X130 Ethernet-Factory network
X135 USB interface
X140 RS232 interface for modem only.
X122 Digital I/O for Sinamics
X132 Digital I/O for Sinamics
X142 Digital I/O for NC
X143 Interface for two Hand-wheels
T0 Analogue output measuring socket
M Electronic ground for analogue measuring sockets
LED Indicators:
FAULT Red fault LED

SYNCH Red synchronisation OK LED
Rx/Tx Yellow network activity (1 each for X120, X121, & X130 interfaces)
Green network link OK indicator (1 each for X120, X121, & X130 interfaces)

Section 4
Digital Input/Output Terminal Description
X122, X132, X142 & X143 Terminal Description Notes
The following signals are automatically assigned

at start up.
X122 Signal Function/Default Setting

Pin 1 Sinamics DI0 Off1(ALM, SLM >16Kw) Pulses enabled (SLM <16Kw)
Pin 2 Sinamics DI1 Off3 drive enable-Fast Stop
Pin 3 Sinamics DI2 Safety Integrated SH/SBC 1 Group 1 input
Pin 4 Sinamics DI3 Safety Integrated SH/SBC 1 Group 2 input
Pin 5 24V ground (M) Ground for pins 1 to 4
Pin 6 +24V DC (P) +24V DC common
Pin 7 Sinamics DI/O8 Safety Integrated SH/SBC 1 Group 1 output
Pin 8 Sinamics DI/O9 Safety Integrated SH/SBC 1 Group 2 output
Pin 9 24V Ground (M) Ground for pins 7 & 8
Pin 10 Sinamics DI/O10 Bero 1 reference mark input
Pin 11 Sinamics DI/O11 Probe 1 centralised/de-centralised input

Pin 1 Sinamics DI4 DI 4 Free to assign
Pin 4 Sinamics DI7 Line contactor check back signal input
Pin 7 Sinamics DI/O12 Infeed is ready output
Pin 8 Sinamics DI/O13 Ready to power up output
Pin 10 Sinamics DI/O14 Line module contactor control output
Pin 11 Sinamics DI/O15 Probe 2 centralised/de-centralised input

Pin 1 NCK DI 0 DI $A_IN[1]
Pin 7 NCK DI/O 4 DO $A_OUT[4]

Section 4
Digital Input/Output Terminal Description
Notes
Pin 1 5V DC (P5) Hand-wheel 1 +5V DC common
Pin 2 0V DC (M) Hand-wheel 1 0V DC common
Pin 3 1A Hand-wheel 1 signal A
Pin 4 –1A Hand-wheel 1 signal –A
Pin 5 1B Hand-wheel 1 signal B
Pin 6 –1B Hand-wheel 1 signal –B
Pin 7 5V DC (P5) Hand-wheel 2 +5V DC common
Pin 8 0V DC (M) Hand-wheel 2 0V DC common
Pin 9 2A Hand-wheel 2 signal A
Pin 10 –2A Hand-wheel 2 signal –A
Pin 11 2B Hand-wheel 2 signal B
Pin 12 –2B Hand-wheel 2 signal –B

B044 Licensing of Options.
Module Objective:
Upon completion of this module you will be able to check the control for the correct licence and
activate options.
Module Description:
When a controller and options are purchased a licence key is issued. The licence key is unique to the
internal flashcard of the controller.
This module explains here the licence number can be checked and how to switch on a licensed
option.
Sinumerik 828D
B044
Contents:- B044
Entering and Checking Licenses Section 2

Page 3

To check the licence number, use the following key combination:- Notes
Information regarding the license and the CF card serial number is displayed.
The licence number is specific to the internal compact flash card serial number.
For this reason a copied CF card cannot be used without generating an error
message.
The licence key can be entered on this page. This is activated by an NCK reset using
the “Reset (po)” soft-key.
The control should arrive with documentation regarding the licence key and options.
This needs to be kept in a secure place.
The licence key should be saved at first commissioning and prior to attempting any
work where the NC data might be lost/reloaded.

Section 2 Entering and Checking Licenses
Notes It is possible to save the licence number to a file so that in the event of a hardware
failure it can easily be restored.
Saving the licence number:-
Choose the destination for the licence key
Create a new directory if required.
The new folder appears in the chosen place. Select “OK” to save the licence key file
to this folder.
A message is displayed momentarily above horizontal soft-keys
To check that the licence save was successful select the “Exp. Licence requirement”
soft-key again.
The file is automatically given a name by the system.

Restoring the licence number:- Notes
To prove that the restoring of the licence works, first delete the existing licence using
the “DEL” key .
Select the “Read in licence key” soft-key.
Highlight the licence key file and press the “OK” soft-key
The licence key should now appear in the licence key box.

Section 3 Entering and Checking Licenses
Notes The “All options” soft-key can be selected to view all set and licensed options
To select an option use the cursor keys to highlight the desired option and the press
the “Select” key to activate or enter a number depending on the type of option being
activated.
A “Reset (po)” is required to complete the procedure.
If an non-licensed option is activated, the controller will issue an alarm.

The NC/Cycle Start will also be inhibited.
To see all non-licensed options, select the “Missing licenses” soft-key

B003 System Restore
1 Brief Description
Module Objective:
Upon completion of this module you will know to create archives using the Data Class system of the
828D controller and how to create and restore a system image.
Module Description:
The 828D controller operates using data which is separated into Data Classes. Data Classes allow
archives to be created which contain only the data from a specific area of the controller. This enables
upgrades etc to be carried out while leaving other non-related data in the controller untouched.
Sinumerik 828D
B003
Contents:- B003
Section 2
Data Classes Page 3
Section 3
Creating Archives Page 5
Section 4
Restoring Archives Page 9
Section 5
Save Data Function Page 12
Section 6
Restore Data Function Page 13
Section 7
Creating a System
Page 16
Image
Section 8
Restoring a System Page 18
Image

Data Classes
Section 2
Types Of Data Classes:- Notes
The Data Classes are spilt into three categories:-
Manufacturer - This data is used throughout a particular machine series. Once a

prototype of a machine is complete, an archive of the Manufacturer type would
loaded into subsequent machines.
Individual - This data is machine specific (Compensations, reference points etc). An

archive of the Individual type would typically be made prior to a software update.
User - This data is user specific (Part programs, tool data, zero points etc). An
archive of the User type could be used to transfer data to an identical machine
cutting the same component (Offsets etc will need adjusting) or in the case of a soft-
ware update.
Example:- An archive containing only Manufacturer data can be used as a master

copy for a series of identical machines. In the future, if changes have to be made to
this archive, a new one can be created and sent to the customers. Loading the
archive will not have any effect on the Individual or User Data Classes.
Data Classes for Machine Data.
When looking at the machine data area of the controller it is possible to see which
machine data belong to which Data Class.
Use the following soft-keys to locate the axis machine data area of the controller.
The right hand column indicates the type of data class that the machine data belongs
to. This class will determine whether or not the machine data is included in a
particular archive.
Data Class Identifier

Section 2 Data Classes
Notes Data Classes for PLC Data Blocks.
It is also possible to select the Data Class of Data Blocks in the User PLC program.
When a Data Block is first created, the properties box is displayed.
The Data Class can be changed via the drop down menu. If the Data Block already
exists, the properties can be viewed by right clicking on the Data Block and selecting
properties.
Selection of the required

Data Class.

Creating Archives Section 3
To create a Series Start-up Archive locate the correct area by using the following key Notes
sequence.
Ensure that the option “Create series start-up” is selected and select “OK”
A number of choices are available regarding what to include in the archive you are
about to create.

Section 3
Creating Archives
Notes To navigate the screen use the “Cursor” & “Select” keys
By activating the “Execute” option it is possible to choose from three items.
Manufacturer:-This will create an archive containing all manufacturer

relevant data of the machine. This will not contain any individual machine specific
data. This file can be used as a start up file for serial machines once the prototype
has been perfected.
Individual:-This archive will save only machine specific machine data such
Ball-screw compensations, reference point offsets etc.
User:-This archive will save user specific data such as part programs, tool & zero
offsets etc
All:- This selection will create an archive containing all the above
Components.
The files are created with a default extension of .ard
The type of archive depends upon what the archives intended use is.
Control Components:-
This is where the it must be decided which of the four main components of the con-
troller should be included in the archive file.
The drive data can be taken out in two formats:-

ACX is a binary file and is unreadable
ASCII is a text file which can be opened with a text editor, this can be useful in
upgrade situations where new machine data might prevent the binary file from
reading in and/or the data needs to be entered manually.

Creating Archives Section 3
NC data:- The NC data consists of:- Notes
All machine and Setting data (Except for drive machine data)
Tool data,
Offsets
R parameters
Programmes.
PLC data:- This will create an archive suited to restoring the PLC user program in the
event of a problem.
Drive data:- This will create an archive containing data for the Sinamics drives.
HMI data:- This saves data that is stored on the HMI.
The list comprises of:-
Cycle storage
Texts
Templates
Applications
Configurations
Configuration
Help
Version data
Logs
User views
Dictionaries
While it is possible to create one archive of the whole machine it is not recommended
that this is carried out in practice.
The reason is that the four control components are separate items.
If a problem occurred for example with the PLC. It is better to have a PLC archive to
load rather than an archive containing the other components of the machine.
By using the data classes option along with the control classes option it is possible to
create many combinations of archives.
It is important that as much information about the archive is entered in the comment
section.
When all the selections have been made and the comments etc entered, the
“Generate archive” soft key needs to be pressed.
The destination of the file can be chosen, this can be on the controller or external
device such as a compact flash card or USB memory device.
Data saved to the “Archives\Manufact” folder is stored on the internal flashcard of the
controller. This method ensures that the data remains with the controller.

Section 3
Creating Archives
Notes A suitable name for the archive should be entered.
When the archive has been

successfully created The dialogue
box will clear. A message will be
displayed along the bottom of the
screen for a few moments.

Section 4
Reading in Archives
In the event of a hardware/software failure or the starting up of a series machine it will Notes
be necessary to read in archive files.
Before reading in an archive it is recommended that the controller is loaded with
default data.
To load default data reboot the controller and await the following screen.
In a prompt manner press the three highlighted keys in the numerical order indicated.
(Not simultaneously)
Press SELECT key to enter setup menu
1 2
The start up menu should be displayed. Use the cursor key to select what action is
required. Example:-If an NC archive is to be restored then choose the option “NCK
default data”.
Press the input key to continue

Section 4 Reading in Archives
Notes Acknowledge the dialogue box with the ”Yes” selection.
Allow the control to fully boot. This is indicated by the permanently illuminated top
green LED and the flashing orange middle LED directly above the CF and USB
sockets.
Alarms will be present (Alarm numbers 4060 & 400006) which can be ignored.
Set the password to “service” or higher.
Use the following key combination to reach the area for reading in archives
Cursor to the “Read in series start-up” option and press “OK”
Locate the archive to be read in and select “OK”.

If the “Service” password is set, only archives on the “User CF can be accessed. To
access archives on the controller use the “Manufacturer” password.
If loading several separate archives e.g. NC, PLC. The NC should be loaded before
the PLC, the NC may contain data which sets up the memory size for the PLC.

Reading in Archives
Section 4
The following dialogue box gives information about the archive selected to be read in. Notes
In this case the NC archive was made with the “All” option selected and contains all
data types. It is possible to deselect data classes prior to reading in if required.
The archive will now be read in, depending on the type of machine this will take
several minutes.
Various alarms and dialogue boxes will appear and disappear and the machine
control panel LED’s will flash which is normal
Read in any other required archives in the same manner.

When the process is complete the functionality of the machine can be tested.
It is important that the operator checks tool data, offsets, programs etc as the archive
could contain data from some time ago.

Section 5 Save Data Function
Notes To save data to the internal flash memory locate the correct area by using
the
The “Save data” function is started by selecting the “Save data” soft key:-
The data is now stored on the internal flash card.

Restore Data Function Section 6
The data saved previously can be restored in two ways. Notes
If the controller is left switched off for long periods, the GoldCap capacitor will lose
charge and result in the loss of the NC data stored in the volatile ram memory.
In this case the controller detects the loss of data and during the next switch on the
data will be automatically restored from the internal flash memory.
A message will be displayed to warn the operator that the data was reloaded.
The operator should then check that the data is compatible with the current machine
configuration (Tool data, offsets etc)
The saved data can also be manually loaded. This is done by entering the service
menu on start up:-
Reboot the controller and wait for the following screen to be displayed,
immediately this screen appears press the keys indicated in the numerical order
shown.
1 2
Cursor to the “Reload saved user data” option and press the “Input” key.

Section 6
Restore Data Function
Notes
Confirm that this is the procedure to be carried out by selecting the “Yes” option.
Allow the procedure to continue, this could take about five minutes.
When the process is complete a message is displayed warning that the backup data
has been loaded.
This message can be cleared with the “Reset” key, however it should be noted that
the data that has been restored will be old data and may contain incorrect tool data
etc. The operator should be warned of this fact and be prepared to check the data
before operating the machine.
In the event of the data being automatically reloaded due to the dissipation of the
“Goldcap” capacitor., the same message will be displayed.

Creating system image. Section 5
A FAT formatted CF card/USB stick of at least 1GB should be inserted in the front Notes
slot.
Create archives and store them in the “Archives\Manufacturer” directory. (Described

in Section 3)
To create a system backup enter the Start-up menu:-

In a prompt manner press the three highlighted keys in the numerical order indicated.
1 2
Select the option “Create software update/backup”

Press the input key to continue

Section 5 Creating system image.
Notes Continue with the “Input” key.
Enter a suitable name for the file, the “tgz” extension must remain.
The file will now be created, as the process continues the file size indicated in the
brackets will increase.
Message confirming the file was created and requesting removal of storage device
and power off/on of the controller.

Restoring a system image Section 6
In the event of the internal CF card becoming faulty it is necessary to obtain a Notes
replacement card from Siemens.
A CF card/USB stick containing the system back up image is required along with
the replacement CF card of at least 2GB.
The blank CF card should be inserted into a PG/PC using a suitable adaptor.
The software package “RCS Commander” is required and a recovery file called
“minsys.img”. This file is installed as part of the toolbax and is found within the folder
named “Recoverysys” in the toolbax directory.
Start the “RCS Commander” software.
A connection to the controller is not necessary, cancel any dialogue boxes.
The “minsys.img” file can is located in the toolbox directory.

Section 6 Restoring a system image
Notes Select the “Write file system image” button on the toolbar of the RCS Commander
Browse for the “minsys.img” file.
Specify the drive letter of the CF card.

Restoring a system image Section 6
Notes
Remove the CF card and insert it into the rear CF card slot of the controller. Switch
the controller on and allow to boot to the following screen then select the “Input” key.

Section 6 Restoring a system image
Notes Select the backup image and select “Input” It is possible that more than one image is
present on the card/USB stick, ensure that the correct one is chosen.
The data backup is now written to the internal card. Allow the process to finish
Switch off the controller, remove the front CF card/USB stick and the switch the
controller on.
Switch off the controller, remove the front CF card/USB stick and the switch the
controller on.

Restoring a system image
Section 6
The controller will boot and display fault messages, this is normal. Notes
The password will require entering and then the archive(s) will have to be reloaded as
described in section 4.
The licence key is linked to the serial number of the internal CF card. It is because of
this that the licence key message is displayed.
A new licence key is required, the only method of getting a new licence key is via the
Siemens hotline.
In order for a new licence key to be issued, the numbers of the original faulty CF and
the replacement CF card are required.
On obtaining a licence key it has to be entered, this process is described in
Module B044.
The archives used to restore the controller will more than likely contain old data. the
data should be checked and the machine tested with this in mind.

B008 Machine Control Panel Description & Configuring
1 Brief description
Module Objective:
Upon completion of this module you will know how to configure the machine control panel (MCP)
Module Description:
The 828D controller operates using one of two machine control panel variants.
The MCP483 is 483mm in length and is recommended for use with the to the horizontal variant of
828D controller.
The MCP310 is 310mm in length and is recommended for use with the vertical variant of the 828D
controller.
In order to function correctly the machine control panel has to be configured using switch settings and
machine data, this is described in this module along with various information regarding the interfaces.
Sinumerik 828D
B008
Contents:- B008
Section 2
Machine Control Panel Types Page 3
Section 3
MCP483 Front & Rear Layout Page 4
Section 4
MCP310 Front & Rear Layout Page 6
MCP483 Section 5
Input/Output Assignment table Page 8
MCP310 Section 6
Input/Output Assignment table Page 9
Section 7
MCP Configuration Page 10
Section 8
User I/O Assignment Page 11

Machine Control Panel Types Section 2
MCP 483 Notes
SINUMERIK 828D
S1
Training, Operation and Service

Page 3
MCP 310
B008
Section 3 MCP483 PN Button Layout
SINUMERIK 828D
JOG REP REF T1 T2 T3 X Y Z
Teach 4th 5th 6th

VAR 1 T4 T5 T6
Emergency in Axis Axis axis Spindle Feed
Stop Override Override
7 th 8th 9th
MDA 10 100 T7 T8 T9
Axis Axis Axis
MCS
Auto 1000 10000 T10 T11 T12
WCS
Page 4
Blank for Blank for Single Cycle Cycle Spindle Spindle Feed Feed
Reset T13 T14 T15 — Rapid +
user user block Stop Start stop start Start Stop
Note:- Cycle stop, Feed stop & Spindle stop-signals are inverted i.e. Normally closed.
Buttons T1 to T15 are free for use by the manufacturer.
The two blanks can be removed to allow the user to add extra buttons/switches/lamps.
Notes
B008
Section 3 MCP483PN Rear View
SINUMERIK 828D
X10
X53
X54
X51
X52
X55 X20
S2 X21
X50
Page 5
Interface Description:- X51 Digital inputs For manufacturer lamps/switches
X5 Key-switch interface X52 Digital inputs “ “
X10 24V DC supply X53 Digital outputs “ “
X20 Port 1 Profinet connection in. X54 Digital outputs “ “
X21 Port 2 Profinet connection out. X55 Digital inputs “ “
Notes
B008
Section 4
B008
MCP310PN Button Layout
Notes
Spindle Spindle
JOG REP REF VAR T1 T2 T3 100 %
Dec. Inc. Blank for
spindle
override/
Teach Spindle Spindle Spindle E stop
MDA T13 1 T4 T5 T6
In right stop left
Auto T14 T15 10 T7 T8 T9 X Y Z
Single 4th 5th 6th Feed

Reset T16 100 T10 T11 T12
Block Axis Axis Axis
Override
Page 6
Cycle Cycle WCS Feed Feed
1000 - Rapid +
Stop Start MCS Stop Start
Key Blank for Blank for Blank for Blank for Blank for Blank for
Switch user user user user user user
SINUMERIK 828D
Note:- Cycle stop, Feed stop & Spindle stop-signals are inverted i.e. Normally closed.
Buttons T1 to T16 are free for use by the manufacturer.
The six blanks can be removed to allow the user to add extra buttons/switches/lamps.

MCP310PN Rear View Section 4
Notes
SINUMERIK 828D
X10
X53

X31 X54
X51
X52
X55
X20
Page 7
X30
X21
S2 X5
Interface Description:- X51 Digital inputs For manufacturer lamps/switches

X5 Key-switch interface X52 Digital inputs “ “
X10 24V DC supply X53 Digital outputs “ “
X20 Port 1 Profinet connection in. X54 Digital outputs “ “
X21 Port 2 Profinet connection out. X55 Digital inputs “ “
B008
Section 5 Machine Control Panel Description & Configuring
Notes MCP483 Input/Output Assignment Tables.
MCP483Signals from machine control panel (keys)

Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
Spindle override JOG TEACH MDA AUTO

IB112
D C B A IN
REPOS REF var. INC 10000 1000 INC 100 INC 10 INC 1 INC
IB113 INC
Key- Key- Spindle *Spindle Feed *Feed NC Start *NC Stop

IB114 switch switch start stop start stop
position 0 position 2
Reset Key- Single Feedrate override
IB115 switch block
position
E D C B A
Direction keys Key Axis selection keys

switch
IB116 + - Rapid x 4th axis 7th axis
position
R15 R13 traverse R1 R4 R7
3
R14
Axis selection keys
Y Z 5th axis Traverse R9 8th axis 6th axis
IB117 R2 R3 R5 command R8 R6
MCS/
WCS
R12
Unassigned customer keys

IB118
T9 T10 T11 T12 T13 T14 T15

IB119
T1 T2 T3 T4 T5 T6 T7 T8
MCP483 Signals to machine control panel (LEDs)

Machine function Operating mode
QB112 1000 INC 100 INC 10 INC 1 INC JOG TEACH MDA AUTO
IN
Feed *Feed NC Start *NC REPOS REF var. INC 10000
QB113 start stop Stop INC
Direction X 4th axis 7th axis Single Spindle *Spindl
QB114 key block start e stop
Minus
Z 5th axis Travel 8th axis 6th axis Direction

command key
QB115 MCS/ Plus
WCS

QB116
T9 T10 T11 T12 T13 T14 T15

QB117
T1 T2 T3 T4 T5 T6 T7 T8
QB118 Reset

Machine Control Panel Description & Configuring
Section 6
MCP310 Input/Output Assignment Tables Notes
MCP310 Signals from machine control panel (keys)

NC Stop Spindle - Spindle Spindle + Single JOG MDA AUTO

IB 112 100% block
NC Start Spindle Spindle Spindle Key- REF REP Teach IN

right stop left switch
IB 113 position 3
Feed Feed INC VAR Key-

IB 114 start stop switch
INC 1000 INC 100 INC 10 INC 1
position 0
Feedrate override
IB 115 RESET Key- Key-
switch switch E D C B A
position 2 position 1 (16) (8) (4) (2) (1)
Direction keys
Rapid KT5 KT4 KT3 KT2 KT1
IB 116 + - traverse (X52.2) (X52.1) (X51.3) (X51.2) (X51.1)
Axis selection
IB 117 T16 KT6
(X52.3) 6 axis 5 axis 4 axis Z axis Y axis X axis
T9 T10 T11 T12 WCS T13 T14 T15

IB 118
MCS
IB 119 T1 T2 T3 T4 T5 T6 T7 T8
IB 120
IB 121
Spindle Override
IB 122 E D C B A
(16) (8) (4) (2) (1)
MCP 310 Signals to machine control panel (LEDs)

NC Stop Spindle Spindle Spindle Single JOG MDA AUTO
QB112
Dec. 100% Inc. Block
NC Spindle Spindle Spindle RESET REF REPOS Teach In
QB113 start right Stop left
Feed Feed Inc INC INC INC INC
QB114 Start Stop Var 1000 100 10 1
QB115
Minus Plus Rapid
QB116 Direction Direction traverse
QB117 T16 6th axis 5th axis 4th axis Z Y X
T9 T10 T11 T12 MCS/ T13 T14 T15

QB118 WCS
QB119 T1 T2 T3 T4 T5 T6 T7 T8

Section 7 Machine Control Panel Description & Configuring
Notes MCP Configuration

The MCP is part of the Profinet network and as such needs to be addressed so that
the system associates the various I/O with the correct function.
To introduce some compatibility the default start address for inputs and outputs is
defined as 112.
This is determined by the setting of switch S2 on the MCP. Each profinet device has
an IP address of 192.168.214.xxx . The S2 setting determines the last part of the IP
address (xxx)
For Profinet applications switch positions 9 and 10 need to be set to on.
Switch S2 Binary
Position Value
1 1
2 2
3 4
4 8
5 16
6 32
7 64
8 128
Machine Data Index IP address Switch S2

Input Address Range Output Address Range
12986[x] 192.168.214.xxx Setting
0 9 0 to 8 0 to 5 1 & 4 on
1 8 9 to 17 6 to 11 4 on
2 7 18 to 26 12 to 17 1, 2 & 3 on
3 6 27 to 35 18 to 23 2 & 3 on
4 5 36 to 44 24 to 29 1 & 3 on
5 20 96 to 111 96 to 111 3 & 5 on
6 64 112 to 129 112 to 119 7 on
To assign the default start address of 112, switch S2 should be set to 64 (S1.7 set to
on). To release the I/O for use by the MCP the relevant machine data should be set to
a value of –1
In this case this is machine data 12986[6]. By default this will have the value of 112.
The machine data is activated with an NCK power off.
The machine control panel is now ready for use providing the interface signal have
been utilised within the user PLC program.

Machine Control Panel Description & Configuring
Section 8
User I/O pin assignment. Notes
The 9 inputs and 6 outputs available on plugs X51 to X55 are designed for use with
switches/buttons and indicator lamps which can be installed in the blanked holes of
the MCP.
Below shows the I/O assignment of each individual plug.
All signals are based on a nominal +24Vdc supply from the MCP
I122.0 I122.3 I122.6

1 1 1
I122.1 I122.4 I122.7
2 2 2
I122.2 I122.5 I123.0
3 3 3
P24 +24volts P24 +24volts P24 +24volts
4 4 4
X51 X52 X55
Q119.0 Q119.3
1 1
Q119.1 Q119.4
2 2
Q119.2 Q119.5
3 3
M 0volts M 0volts
4 4
X53 X54
The outputs are capable of supplying 1.2 Watts per output, it is not permissible to
connect relays, valves or other inductive devices.

B026 Creating and Loading a PLC program
1 Brief description
Module Objective:-
Upon completion of this module you will understand how to create a PLC program and load it to the
controller.
Module description:
The programming tool PLC828 is used in the creation of a PLC program. This module
describes how to use this programming tool.
Sinumerik 828D
B026
Contents:- B026
Creating a Section2
PLC program Page 3
Loading a Section 3
PLC program Page 9

Section 2
Creating a PLC program
The PLC program is created using the Programming Tool PLC828 software package Notes
which was installed earlier as part of the toolbox.
To start the software, locate the program icon in the start menu of the PC\PG
A blank project will open.
The blank project is called “Project1” by default. It is advisable that this is saved
under a different and appropriate name.
To save the project select “Save as” from the drop down menu.
The name of the project can be entered then saved.
The destination of the file can be changed to suit.

Section 2 Creating a PLC program
Notes
The larger window to the right (SIMATIC LAD) is where the PLC ladder logic is
inserted. It is only possible to write the program in ladder format.
By default the blank project contains two empty blocks:-
MAIN (OB1) is the Organisation Block (OB), calls to other blocks should be made
from here. This block runs once every PLC cycle.
SBR_0 (SBR0) Is a blank Subroutine (SUBR). Subroutines should be used for all
PLC logic.
Subroutines need to be called otherwise the code contained in them will not be
executed.
It makes sense to split the program into subroutines. For example, a subroutine could
be written which contains only the code for enabling the axes of a machine.
By right clicking on the SBR a suitable name can be entered to assist with fault
diagnosis.

Section 2
To start entering PLC code we have to ensure the correct block is selected via the Notes
tabs at the bottom of the “SIMATIC LAD” page.
The SBR is split in to networks in which the PLC code is entered. The network can be
given a title to help with identification. This is done by double clicking on the network
title. Further comments can be entered if desired. Select “OK” to confirm.
To be able to stat the programming operation, the

network should be selected using the left mouse
click function. A black box should appear to show
the selected network
A selection of operands is available in the

instructions menu. The required operand is selected
by the double clicking or drag and drop functions.
There are many mathematical functions and logic
operations available. By hovering the mouse pointer
over a particular operand/instruction a short
description will be displayed.

Section 2 Creating a PLC program
Notes
The selected operand will now be entered into the network. The operand then has to
be given the correct identifier.
Position the rectangle at the place where the next operand is to be inserted and then
select an operand in the same way as before.
To insert branches use the following buttons found on the toolbar.
When the SBR is complete it will need to be called in the “Main” blockOB1.
It is necessary to have an operand in the network before

the SBR is inserted. SM0.0 (Special Marker) is always
equal to one and is commonly used for this
purpose.
The Subroutines are stored in the Subroutines folder
and are inserted in the network in the same way as
operands

Section 2
Symbol Tables Notes
A symbol table is available to the user, this can greatly assist maintenance personnel
with the fault finding process.
Information about individual operands can be entered..
Information about individual operands can be entered.
If “Symbolic Addressing” is selected via the “View”

menu or the “Ctrl+Y” shortcut, The operand will be
displayed in text format.
If “Symbolic Information Table” or shortcut “Ctrl+T”
is selected, a table will be displayed at the bottom of
the network containing the information from the
symbol table.

Section 2
Notes Cross References
A Cross Reference table can be created, this lists information about individual
operands such as which blocks they are used in and can greatly assist maintenance
personnel with the fault finding process.
Compiling is done by selecting the compile button on the toolbar.
Providing that there are no errors in the program then the cross reference table will
be displayed.
Double clicking an element will automatically open the block where that element is
used
The “Symbolic Addressing” option described earlier also functions with the Cross
Reference table.

Loading a PLC program
Section 3
Making an ethernet connection Notes
Once the PLC program is complete it can be loaded into the controller.
An Ethernet cable is required to connect between X127 of the controller and the PG/
PC. Depending on the type of network adapter this cable may have to be a crossed
type.
On the PG/PC locate and select the “Communications” button.
The correct network adapter needs to be selected, if the correct adapter is not
shown, double click the following icon:-
The adapter should be selected from the

list and confirmed with the “OK” button.
Note:-Different PG/PC’s will have different

adapter types and not necessarily the
ones shown in this example.
A dialogue box opens giving the

opportunity to cancel the changes
Accept by selecting the “OK” button

Section 3
Notes The correct adapter should be shown on the right of the dialogue box.
The IP addres of the controller should be entered in the “Communication
Parameters\Remote Address” section.
The default IP address of X127 is 192.168.215.1
After entering the IP address, double click the “Double click to Refresh” icon.
If the connection is successful an icon of the controller will appear.

Clicking the at the top right of dialogue box will close it down.
Loading the program.

Select the “Download” button on the toolbar.
Ensure that the option “Blocks (MAIN, SBR, INT, DB)” is selected and select the
“OK” button

Section 3
A dialogue box warns about the dangers of downloading with the PLC in run mode. Notes
Select the “Place the PLC in STOP mode” option.
The program is then downloaded to the controller followed by a dialogue box,

acknowledge this with the “OK” button.
The PLC is still in stop, to restart it select the “run” button on the toolbar followed by
the “Yes” button on the dialogue box that appears.
The controller will carry out a warm restart, when this complete there should be no
errors relating to the PLC and the machine control panel should be operational
The functionality of the machine can now be tested with caution.

B019 PLC828 Programming Tool Instructions
1 Brief description
Module Objective:-
Upon completion of this module you will understand the PLC828 Programming Tool instruction list.
Module Description:
The Sinumerik 828D operates using the in-built S7-200 PLC. Programming is performed with the
software package PLC828. This modules describes the instructions available to the user.
Module B026 should be consulted in conjunction with this module.
Sinumerik 828D
B019
Contents:- B019
Bit Logic Functions Page 3
Compare Functions Page 8
Convert Functions Page 9
Counter Functions Page 11
Floating Point
Page 16
Number Functions
Integer Functions Page 18
Interrupt Functions Page 20
Invert Functions Page 20
And Functions Page 21
Or Functions Page 22
Move Functions Page 24
Program Control
Functions Page 25
Shift/Rotate
Page 28
Functions
Timer
Page 29
Functions
Libraries Page 32
Rewire Function Page 34
General Information Page 36

Section 2
General Information
Address Formats:- Notes
Bit- This refers to a single element of logic e.g. I6.0, Q5.5, M100.6, V38040002.1
The Bit part is the number after the decimal point. The value of a bit is either 1 or 0
Byte– A Byte is a collective of 8 bits of logic in the same group. e.g.

Input Byte 6 (IB6) contains the bits I6.0, I6.1, I6.2, I6.3, I6.4, I6.5, I6.6, I6,7.
When working with bytes it must be remembered that the numbering counts up from
the left as shown below.
IB6
Bit no 7 6 5 4 3 2 1 0
Value 1 0 1 0 0 1 0 1
In this example I6.1, I6.2, I6.5 & I6.7 are equal to 1. Another term for being equal to 1
is that these bits are High
The bits equal to 0 are termed as being Low
Output Bytes (QB), Marker Bytes (MB) and Variable Bytes can also be used in the
same way.
Word– A Word is a collective of 16 bits of logic which encompasses two

consecutive Bytes.
A Word can only be addressed as 0 or an even number, (IW0, IW2, IW4, etc) odd
numbers are not
allowed.
As with the Byte format the numbering starts from the right
Example IW6
IB7 IB6
Bit no 7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0
Value 1 0 1 0 0 1 0 1 0 1 1 1 0 0 1 1
In this example I6.1, I6.1, I6.4, I6.5, I6.6, I7.1, I7.2, I7.5, I7.7. are equal to 1.Output
Words (QW), Marker Words (MB) and Variable Words can also be used in the
same way.
Double Word– A Double Word is a collective of 32 bits of logic which encompasses
two consecutive Words (Four consecutive Bytes).
A Double Word can only be addressed as 0 or an even number which is a multiple of

four, (ID0, ID4, ID8, ID12 etc) odd numbers are not allowed.
Example ID6
IB9 IB8 IB7 IB6
Bit no 7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0
Value 1 0 1 0 0 1 0 1 0 1 1 1 0 0 1 1 1 0 1 0 0 1 0 1 0 1 1 1 0 0 1 1
Output Words (QD), Marker Words (MD) and Variable Words (VD) can also be used
in the same way.

Section 2 Bit Logic Functions
Notes Instruction Tree:-
The instructions are found in the menu tree to the left of the main programming area.
The instructions are divided into different sections, these are expanded by clicking on
the “+” symbol.
Mouse pointer placed on the operand Right clicking on the operand gives the
reveals the type. chance to see a help file.
Selecting Hide will make the whole
instruction tree disappear.
The PLC program is built up of a series of blocks called subroutines. The blocks
contain networks, the user PLC is written into these networks.
The first instruction category in the list is Bit Logic. This group is the simplest of the
instructions.
The individual items in the Bit Logic area are referred to as Operands.
These operands need to be addressed, the type of address depends upon the
operand.
Terminology
Inputs:- Typically they are represent the physical state of the machine i.e. Limit
switches, buttons, pressure switches, door switches etc. and are identified by the
letter I e.g. I7.0. They can also appear in Byte, Word and Double Word formats.
Outputs:- Outputs are used to switch on relays, contactors, solenoids, lamps etc.
and are identified by the letter Q e.g. Q4.1. They can be used as coils or contacts,
they can also appear in Byte, Word and Double Word formats
Markers:- These are internal memory operands which can be used as contacts and
coils. They are represented by the letter M e.g. M20.0. They can also appear in Byte,
Word and Double Word formats

Bit Logic Functions
Section 2
Program Status Notes
The status of an operand can be checked by selecting the “Program status” Icon.
The centre of the operand becomes highlighted with a colour when it is true.
Program Status Icon

Q4.0 = 0 or Low Q4.0 = 1 or High
Coils: As the names suggests, “Coils” are switched on/off by “Contacts”.
Typical coil operands are Outputs, Markers, Variables, Data Blocks, Timer & Counters.
It is also possible to have an input as a coil but this can be deemed as bad
practice.
Right: Output Q4.0 as a coil
Contacts:
The most commonly used operands are “contacts”. Combinations of contacts are used
to achieve the end result of activating an output.
These contacts can be assigned to system/user variables, markers, physical outputs or
inputs and can be of the normally open or normally closed types.
Normally open contacts.
When the operand is high (Equal to one) the contact will be closed and the logic will be
true.
When the logic is true the centre of the contact will be coloured.
In the terms of an electrical service the contact will be closed and current can flow.
I6.0 = 0 or Low I6.0 = 1 or High
Normally Closed Contacts.
In this situation when the status of the operand is high (Equal to one) the logic will be
false.
In terms of an electrical circuit, the contact will be open and current cannot flow
through to the next operand.
This is the opposite of the Normally Open operand.
I6.0 = 0 (Low) I6.0 = 1 or (High)
Set and Reset example:-
I6.5= 0, however Q4.5 remains high I6.6 = 1, this has the effect of
because it is a “Set” output resetting Q4.5 to 0

Section 2 Bit Logic Functions
Notes Immediate Contacts.
These operands are effective immediately upon activation, they are not subject to the
PLC scan cycle time. They are identified by the letter “I”.
Normally Open Immediate Normally Closed Immediate
Not operands.
The Not operand is used to reverse the state of the logic. i.e. A status of one will
Become a status of zero while a status of zero will become a status of one.
I6.2 = 1 but Q4.2 remains low because the not operand inverts the signal.
I6.2 = 0 but Q4.2 is high because the not operand inverts the signal.
Positive Transition operands.
The Positive Transition operand monitors the preceding operand status for a rising
edge (Signal state change from 0 to 1) on seeing a rising edge the logic will become
true for one scan of the PLC
When I6.3 changes from 0 to 1, Q4.3 will become high for one scan of the PLC cycle
Negative Transition operands.
The Negative Transition operand monitors the preceding operand status for a falling
edge (Signal state change from 1 to 0) on seeing a falling edge the logic will become
true for one scan of the PLC
When I6.3 changes from 1 to 0, Q4.4 will become high for one scan of the PLC cycle

Section 2
Bit Logic Functions
No Operation Operand (NOP):- Notes
A network cannot be left in an unfinished state, this leads to errors when the program
is compiled and prevents the program from being loaded.
An unfinished network.
If the program is in the development stages then a “No Operation” operand can be
inserted, this prevents the network from being operational and allows the program to
be compiled and loaded to the controller
An unfinished network with a NOP operand.

When a NOP operand is inserted it has to be given an numerical identifier.
This identifier can be selected from the range of 0-255
Immediate Outputs.
These operands are effective immediately upon activation, they are not subject to the
PLC scan cycle time. They are identified by the letter “I”.
Output Immediate Set Immediate Reset Immediate

Section 2 Compare Functions
Notes Compare functions are used to compare two values. The compare values can be
Byte, Integer (Single and double) or Real format.
The available compare types are:-
Equal To
Not Equal To
Greater Than or Equal To
Less Than or Equal To
Greater Than
Less Than
The following example is using the Compare Byte function to compare Input
bytes 6 & 7.
Compare bytes for being equal
IB6 = 14 and IB7 = 15, they are IB6 = 14 and IB7 = 14, they are
not equal so the status is low. equal so the status is high.
Q5.0 = 0. Q5.0 = 1.
Compare bytes for not being equal.
IB6 = 14 and IB7 = 14, they are IB6 = 15 and IB7 = 14, they are
equal so the status is low. Q5.1 not equal so the status is high.
= 1. Q5.1 = 1.
Compare bytes for being greater than or equal.
IB6 = 14 and IB7 = 15, IB6 is IB6 = 15 and IB7 = 14, IB6 is
less than IB7 so the status is greater than IB7 so the status is
low. Q5.2 = 0 high. Q5.2 = 0.
This would also be the case if
the values were equal
Compare bytes for being less than or equal.
IB6 = 14 and IB7 = 7, IB6 is IB6 = 6 and IB7 = 7, IB6 is less

greater than IB7 so the status is than IB7 so the status is high.
low Q5.3 = 0. Q5.3 = 1
This would also be the case if
the values were equal.

Section 2
Compare Functions
Compare bytes for being greater than Notes
IB6 = 6 and IB7 = 7, IB6 is less IB6 = 15 and IB7 = 14, IB6 is
than IB7 so the status is false. greater than IB7 so the status is
Q5.4 = 0 high. Q5.4 = 1
Compare bytes for being greater than
IB6 = 15 and IB7 = 14, IB6 is IB6 = 6 and IB7 = 7, IB6 is less
greater than IB7 so the status is than IB7 so the status is high.
low. Q5.5 = 0 Q5.5 = 1
The same principle applies to the other number formats of Integer, Double Integer
and Real
Convert Functions
Convert functions are used to change one number format into another.
The functions available are:-
Double Integer to Real
Truncate
Binary Coded Decimal to Integer
Integer to Binary Coded Decimal
When the block is inserted into the network it needs to be parameterised. The input is
the number that is to be converted, the output is the result of the conversion.
The number format of the input and output is dependant on the type of conversion i.e.
word, double word, byte.
The source and destination of the input/output can be a System/User Variable,
Input, Output or Marker.
Converting Double Integer to Real.
When I6.0 is true the integer value in MD0 will be converted into a real number and
the result placed into MD4.
It is also possible to extend the network via the “ENO” output to other operands. The
“ENO” output will be high if the convert function was successful.
Section 2
Convert Functions
Notes Truncate (Converts 32-bit real to 32 bit signed integer).
The Truncate Function takes a 32 bit Real number and coverts it into a 32 bit Double
Integer which is signed. In other words only the whole number portion of the real
number is transferred. The fraction is discarded.
Example:-
When input I6.1 is true the value of –1.1 in MD0 was transferred to MD8 as a value of
–1. Output Q4.5 was set high by the ENO output
Binary Coded Decimal to Integer.
This function will convert a value from BCD to an integer.

Permitted ranges:-
BCD Decimal Hex

Minimum 0000 0000 0000 0000 0 0
Maximum 1001 1001 1001 1001 9999 9999
Example:- When input I6.2 is true the value in MW0 (0000000001010100 = 54) will
be converted into an integer and the result placed in MW12. Output Q4.6 will become
high provided that the value in MW0 is within the ranges specified above and I6.2
remains true.
Integer to Binary Coded Decimal.
This function will convert a value from an integer to BCD .

Permitted ranges:-
BCD Decimal Hex

Minimum 0000 0000 0000 0000 0 0
Maximum 1001 1001 1001 1001 9999 9999
Example:- When input I6.3 is true the value in MW18 (96) will be converted into an
BCD and the result placed in MW16.(96 = 0000000010010110) Output Q4.6 will
become high provided that the value in MW0 is within the ranges specified above and
I6.3 remains high.

Section 2
Counter Functions
Count up counters Notes
Count up counters are used to monitor the rising edge of a signal, each time a rising
edge is detected on the CU input the count value will increment by one.
The count can be reset at any time by setting the R input from low to high.
When the counter is first selected in the user program it needs to be given a name
(Available range C0 to C63)
A preset value is entered in the PV input field as an integer, when the count value is
equal to or above this value the counter will be true. The counter operand (e.g. C1)
can then be used elsewhere in the user PLC program.
Below:-A counter selected in the user program but not yet parameterised.
The name of the

counter needs to be
entered here e.g. C1
A preset value is
entered here e.g 10
Below:-Network 19 count up counter C1. The count value can be seen to be equal to
six, this mean that the CU input (I6.4) has detected a rising edge on 6 occasions
since the reset (I6.4) was triggered.
Network 20 is an example of how the counter can be used in the PLC logic. In this
case the preset value (PV) of 10 has not been reached so the status is low.
Counter C1 with a
count value of 6.
Preset value (PV) = 10

Section 2 Counter Functions
Notes Below:-Network 19 count-up counter C1. The count value can be seen to be equal to
ten, this means that the CU input (I6.4) has detected a rising edge on 10 occasions
since the reset (I6.4) was triggered.
Network 20 is an example of how the counter (C1) can be used in the PLC logic. In
this case the preset value (PV) of 10 has been reached so the status is high,
this results in output Q4.7 being switched high.
The C1 operand will remain high until the reset input R (I6.5) detects a rising edge.
The count value stored in C1 will then be set back to zero.
C1 count value = 10
Below:-The reset input has been switched from low to high resulting in the count
value being reset to zero and the C1 operand becoming false. No further counting
can take place until the reset signal is set to low.
C1 count value = 0
Countdown counters
Countdown counters are used to monitor the rising edge of a signal, each time a
rising edge is detected on the CD input the count value will decrement by one.
When the count value reaches zero the counter operand becomes high.
Prior to using the countdown counter a value has to be entered into the Preset Value
PV input field.
This value has is then transferred into the counter when the LD input (I7.1) changes
from low to high.
The count value can be reloaded at any time by setting the LD input from low to high.
When the counter is first selected in the user program it needs to be given a unique
name (Available range C0 to C63).

Section 2
Counter Functions
Below:-Count down counter C2 with a PV of two, this PV value will be entered into the Notes
counter when the LD input I7.1 switches from low to high.
This count value will decrease by one on each positive edge detection of the CD input
I7.0.
Below:-Countdown counter C2 showing a count value of 4. This means that the CD

input has detected a rising edge from I7.0 on 6 occasions since the preset value of 10
was entered.
Counter C2 with a
count value of 4.
Below:-Countdown counter C2 showing a count value of 0. This means that the CD

input has detected a rising edge from I7.0 on 10 occasions since the preset value of
10 was entered. The result of this is that the C2 operand is now true as shown in
network 22. In this case output Q5.6 is now high.
Counter C2 with a
count value of 0.
Output Q5.6 set high as a

result of countdown counter
C2 reaching zero.

Section 2
Counter Functions
Notes Below:-Countdown counter C2 showing a count value of 10 after the LD input
detected a rising edge from input I7.1. This also results in the C2 operand becoming
false as seen in network 22.
C2 count value = 10
Countdown/count-up counters
Countdown/count-up counters are used to monitor the rising edge of two signals. One
signal (CU) increases the count value while the other signal (CD) decreases the
count value.
A preset value (PV) can be entered. The counter operand will become high if the
actual count value matches or is above this preset value. As soon as the value less
than the preset value the counter operand will become low.
The stored count value can be reset at any time by setting the reset input (R) to high
The counter C3 has a

count value of 10
which is equal to the
preset value.
The C3 operand is high due to the

counter value and the preset value
being equal. In this example the output
Q5.7 is set by the C3 operand.

Section 2
Counter Functions
Below:- When the count value is less than the preset value the C3 operand will be Notes
low. In this example the count value is 9 after the countdown input I7.4 was switched
from low to high.
count value of 9 which
is less than the preset
value.
The C3 operand is low due to the

counter value being less than the preset
value. In this example the output Q5.7 is
not set by the C3 operand.
Below:- When the count value is more than the preset value the C3 operand will be
high. In this example the count value is 11 after the count-up input I7.3 was switched
from low to high.
count value of 11
which is more than
the preset value.
The C3 operand is high due to the

counter value being more than the
preset value. In this example the out-
put Q5.7 is set by the C3 operand.

Section 2
Mathematic Functions-Floating Point Numbers
Notes Addition of real numbers
Below:- The function requires parameterisation on first selection.
Values to be added:
IN1 32 bit real number
IN2 32 bit real number added to IN1
Result:-
OUT 32 bit real number
Confirmation:-
ENO Bit goes high if operation successful
Below:- The ADD function prior to parameterisation.
Below:- Example of a parameterised ADD function before being run.

When input I9.0 goes high, the value in MD100 (IN1) in this case 16, will be added to
the value in MD104 (IN2) in this case 2. The result will be placed in MD108 (OUT)
MD100 has been assigned to

IN1 and has a value of 16.0
Below:- Input I9.0 is high and the ADD function has been performed. The result is
placed in MD108. The ENO output is high which sets output Q6.0 high, this indicates
that the ADD function was a success.
MD108 = 18 Result of the ADD function
Subtraction of real numbers
The SUBTRACT function is parameterised in the same way as the ADD function.
When the function runs the IN2 value will be subtracted from the IN1 value and the
result placed in OUT.

Section 2
Mathematic Functions-Floating Point Numbers
Below:- Example of the subtract function. MD100 - MD104 = MD112 (16 - 2 = 14) Notes
Output Q6.1 is high
Multiplication of real numbers
The Multiply function is parameterised in the same way as the ADD function.
When the function runs the IN1 and IN2 values will be multiplied together and the
Below:- Example of the multiply function. MD100 x MD104 = MD112 (16 X 2 = 32)
Output Q6.2 is high
Division of real numbers
The Divide function is parameterised in the same way as the ADD function.
When the function runs the IN1 value will be divided by the IN2 value and the
Below:- Example of the divide function. MD100 ÷ MD104 = MD112 (16 ÷ 2 = 8)

Output Q6.3 is high
Square root of real numbers

The Square Root function calculates the square root of a real number. The number to
be calculated goes to the IN signal, the result is output to the OUT signal.

Section 2
Mathematic Functions-Integers
Notes Below:- Example of the Square function. √MD100 = MD112 (√16 = 4)
Output Q6.4 is high.
Integer Mathematic Functions

Addition and Subtraction of integers.
Below:- The function requires parameterisation on first selection.
It is also possible to add/subtract/multiply/divide integers in the same way as real

numbers. The inputs and outputs act in the same way, only the number format
changes.
IN1 16 bit integer or 32 bit double integer

IN2 16 bit integer or 32 bit double integer
Result:-
OUT 16 bit integer or 32 bit double integer
Confirmation:-
ENO Bit goes high if the operation was successful.
Below:-Examples of adding/subtracting Integers and double integers.
Adding Integers
MW200 + MW202 = MW204

(100) + (25) = (125)
Adding Double Integers
MD200 + MD202 = MD204

(9000) + (3000) = (12000)
Subtracting Integers
MW200 - MW202 = MW204

(100) - (25) = (75)
Subtracting Double Integers
MD208 - MD212 = MD240

(9000) - (3000) = (6000)

Section 2
Mathematic Functions-Integers
Multiplication of integers. Notes
This function multiplies two words and converts the result into a double word.
MW200 x MD202 = MD240

(100) x (25) = (2500)
Division of integers.
This function divides one word by another and converts the result to a double word.
The result is in two parts, the high word section of the double word represents the
whole number while the low word represents the remainder. The format is
hexadecimal.
In the example below the result of 100 ÷ 8 shows a value of 000C in hex format which
is equal to 12 as an integer. The remainder is 0004 which is equal to 4 as an integer.
MW200 ÷ MD204 = MD252

(100) ÷ (8) = (000C0004)
= 12 remainder 4
Increment and Decrement Functions.

These functions allow a number to be incremented or decremented by a value of one.
The formats can be Byte, Word or Double Word.
This is a once only occurrence, further switching of the control bit does not result in
further increments/decrements.
Below:- Examples of increment and decrement functions.
Incrementing Byte
The value in MB100 is incremented by

one and the result sent to MB232
Incrementing Word
The value in MB100 is incremented by

Incrementing Double Word
The value in MD208 is incremented by

one and the result sent to MD212
Decrementing Byte
The value in MB200 is decremented by

Decrementing Word
The value in MW200 is decremented

by one and the result sent to MW208

Section 2
Interrupt Function
Notes Increment and Decrement Functions (Continued)
Decrementing Byte
The value in MD212 is decremented

by one and the result sent to MD236
Interrupt Function
The interrupt function will freeze the processing of the PLC in all networks after the
network containing the interrupt. This is only effective in the Sub routine where the
interrupt is used .
Examples:-
With the interrupt active, the output Q8.1 is not set even
though the proceeding element, Input 11.2 is true.
With the interrupt active, the output Q8.1 remains set

even though the proceeding element, Input 11.2 is no
longer true.
Invert Functions
The invert function inverts the bit pattern of a byte, word or double word. When
viewed in the program status area this is not very clear.
It is better to look in the chart status area.
Invert Byte
Invert Word
Invert Double Word
To locate the chart status area select the following icon on the toolbar.

Section 2
Invert Function
The addresses to be monitored need to be typed in the Address column and the Notes
format set to binary.
In the example below it can be seen that the status of the inputs is the exact opposite
of the output status
And Functions
The AND function compares two bytes, words or double words. If two corresponding
bits are high the relevant output bit will be set.
And Byte
And Word
And Double Word
This is better seen in the Chart Status area.
I7.0 and I9.0 are high

which sets M238.0
This equivalent operation when written in ladder is seen below:-

Section 2
Or Functions
Notes The OR function compares two bytes, words or double words. If either one or both of
the corresponding bits are high the relevant output bit will be set.
OR Byte
OR Word
OR Double Word
If either input or both are

high M238.x will be set
This equivalent operation when written in ladder format is seen below:-

Section 2
Or Functions
Exclusive Or Functions Notes
The Exclusive OR function compares two bytes, words or double words. If either one
but not both of the corresponding bits are high the relevant output bit will be set.
Exclusive OR Byte
Exclusive OR Byte
Exclusive OR Double Word
If either input but not both

are high M238.x will be set
This equivalent operation when written in ladder format is seen below:-

Section 2
Move Functions
Notes Move functions are used for transferring data between from byte to byte, word to word,
& double word to double word.
Below:-Standard Move examples

Move Byte
Move Word
Move Double Word
Move Real Number
Immediate move functions as the name suggests, have an immediate effect on the
PLC. They are only available for use with bytes.
The Immediate Read function is used to read physical inputs, these can then be read
out to Markers, Variables, Inputs, Outputs, Accumulators and Load instructions.
The Immediate Write function writes only to an output byte from Markers, Variables,
Inputs, Outputs, Accumulators and Load instructions.
Move Byte Immediate Read
Move Byte Immediate Write
The Swap function takes the lower byte data and places it in the higher byte and vice
versa. The swap is initialised via the EN input. The swapping continues every PLC
cycle as long as the input is high. A positive edge instruction can be used to control
the swapping of data more effectively.
Swap Function
MW68 prior to running the Swap function.
MW68 after running the Swap function.

Program Control Functions
Section 2
Jump Instruction & Labels Notes
The Jump Instructions and labels are used together. When the Jump is activated the
program will skip to the Label specified by the Jump.
The Jump Instruction needs to be parameterised with the number of the label to be
jumped to. The available range is from 0 to 255.
Jump Instruction has to be used in the same programming block.
Example of how a Jump/Label might be used.
Jump Instruction to Label 1 is not active.
I7.2 switches Q8.7 in the expected manner
Jump Instruction to Label 1 is active.
I7.2 does not switch Q8.7 because the program jumps

to Label 1.
I7.2 does switch Q8.7 because it was high before the

program Jump Instruction was activated.
Q8.7 remains high despite I7.2 being low this because

I7.2 was set low after the program Jump Instruction was
activated.

Section 2
Notes Conditional Return Instruction.
The Conditional Return Instruction is used to terminate a subroutine.
Example of how a Conditional Return Instruction might be used:-
The Conditional Return Instruction is not active.
I7.7 switches Q9.3 in the expected manner
The Conditional Return Instruction is active.
I7.7 does not switch Q9.3 as the subroutine has been

terminated by the Conditional Return.
Q9.3 remains high despite I7.7 being low. This is

because I7.2 was set low after the program Conditional
Return was activated.
Q9.3 remains low despite I7.7 being high. This is

because I7.7 was set high after the Conditional Return
was activated.
Conditional End Instruction.

The Conditional End Instruction is used only in OB1 and results in the program scan
restarting at the beginning of OB1. No further operations after the Conditional End will
be processed
Example of how the Conditional End Instruction might be used.
The Conditional End Instruction is not active.
I6.2 is high which switches Q4.1 high

Section 2
Notes
The Conditional End Instruction is active.
I6.2 is high which but Q4.1 remains low. This is because

program end is now in the previous network.
When the Conditional End Instruction is active, no further processing takes place.
Outputs, markers etc which were already high will remain so until influenced from
elsewhere in the program.
Shift Left Byte.

The shift Left Byte function allows the bits within a byte to be moved to the left by up to
8 places. In the example below the contents of IB9(IN) will be shifted left by 4 places
(N). The result will be placed in MB100 (OUT) The maximum number of places that
can be moved is eight. If a larger number is entered the value will default to eight.
The example below shows the result when viewed in ladder status, a better idea of
this is seen in Chart Status.
Byte to be shifted (IB9) The result of the Shift Byte Left

instruction will be stored in MB100
No of places to be shifted (4)
Below:-The Chart Status shows that status of IB9 has been shifted left by four places
and the result placed in MB100.
Below:-The Chart Status shows that status of IB9 has been shifted left by four places
and the result placed in MB100.
Shift Right Byte.
The Shift Right Byte function operates in the same way as the Shift Left Byte, except
that the move is to the right.
Below:-Example of a Shift Right Byte by 2 places operation.

Section 2
Shift & Rotate Functions
Notes Shift Left Word & Shift Right Word.
The contents of a Word can be shifted left or right in the same way that the contents of
a Byte can be shifted. The maximum number of moves is 16.
Below:-Examples of shifting words.
Shift Left:
Shift Right:
The Results:
Shift Left Double Word & Shift Right Double Word

The contents of a Double Word can be shifted left or right in the same way that the
contents of a Byte or Word can be shifted. The maximum number of moves is 32.
Below:-Examples of shifting Double Words.
Shift Left:
Shift Right:
The Results:

Section 2
Timer Functions
Timer are used to delay the effects of a signal when it switches. There are a total of Notes
128 timers available (T0 to T127).
T0 to T15 have an input resolution of 100ms with a maximum preset time (PT) value
of 327.67 seconds.
T16 to T127 have an input resolution of 10ms with a maximum preset time (PT) value
of 3276.7 seconds.
On-Delay Timer
When a timer is selected it needs to be given a name (To to T127) and a Preset
Time value (PT)
Timer name - Txxx
Preset Time (PT)
Below:-On-Delay timer T1 has been a PT value of 50 this equates to a delay of

5 seconds (50 x 100ms).
When Input I7.0 becomes high, T1 will start to count, when the PT value is reached
the T1 operand will switch high. As a result Q5.0 will be come high (Network 8)
As long as I7.0 remains high T1 will continue to count and the T1 operand will re-
main high. When I7.0 becomes low, the count value of T1 will reset to zero and the
T1 operand will go low.
Below:- Input I7.0 is high and T1 has started to count. The T1 operand in network 8
is still low as the PT value of 50 has not been reached.
T1 value has reached 20

Section 2
Timer Functions
Notes Below:- The time value of T1 has gone beyond the PT value. As a result the T1
operand in network 8 is high and has switched output Q5.0 high.
T1 value has surpassed the

PT of 50
T1 operand is now high, Q5.0

is also high as result
Below:-Input I7.0 has gone low and the T1 time value is reset to zero. The T1
operand also goes low as a result.
Retentive On-Delay Timer
The Retentive On-Delay Timer works in the same way as the ON-Delay Timer
except that when the IN signal is removed the Timer operand remains high. The
Timer operand will need to be reset by the user which also resets the time value to
zero.
Below:- Retentive On-Delay timer T2 has been triggered by I7.1 and the time value
has passed the 10 second PT value (100 x 100ms = 10 seconds). The T2 operand is
high and has switched Q5.1 high.

Section 2
Timer Functions
The Input I7.1 is now low, T2 has stopped counting but retains the count value. The Notes
T2 operand remains high. If I7.1 becomes high again the time value in T2 will
continue.
Timer retains the count value
Timer operand remains high
The timer is reset using the Reset function which can be seen in network 8 below.
Timer reset by I7.2
Timer count value reset to zero
Timer operand goes low
Off-Delay Timer
The Off-Delay Timer T3 shown below monitors the IN input. When this input is high,
the T3 operand is also high as seen in network 12.
When the timer detects a falling edge on the IN input the time value in T3 will count
up, when this value reaches the value of PT (75 x 100ms = 7.5 seconds) the T3 oper-
and will be set to zero.
Timer value sits at zero
Timer operand T3 is high
The Off-Delay Timer T3 shown below monitors the IN input. When this input is high,
the T3 operand is also high as seen in network 12.
When the timer detects a falling edge on the IN input the time value in T3 will count
up, when this value reaches the value of PT (75 x 100ms = 7.5 seconds) the T3 oper-
The IN signal has gone low,

T3 starts to count up
Timer operand T3 remains high

Section 2
Libraries
Notes The Timer has counted up to the PT value, as a result the T3 operand has been reset
to zero. The timer value is reset to zero when the IN input goes from low to high.
The time value has reached

the value set in PT
T3 operand is now zero
The Timer has counted up to the PT value, as a result the T3 operand has been reset
to zero. The timer value is reset to zero when the IN input goes from low to high.
Libraries.
The Library contains system blocks for executing specific tasks. These
blocks consist of Interrupt Routines and Data Blocks.
Interrupt Routines.
INT_0 Executed synchronously with the servo cycle.

INT_100 Executed immediately prior to the MAIN routine (OB1)
INT_101 Executed immediately after the MAIN routine(OB1)
Data Blocks
TM_CTS (DB9900 Constant traverse step table for tool change

TM_VTS (DB9901) Variable traverse step table for tool change
TM_ACK (DB9902) Acknowledgement step table for tool change.
SP_INI (DB9903) Start data for service planner
SP_ACT (DB9904) Actual data for service planner
EE_IFC (DB9905) Interface for Easy Extend.
The various data blocks are explained in the relevant modules.

Section 2
Libraries
Interrupt routine INT_100 & INT_101 Notes
The S7-200 PLC works cyclically, at the beginning of the scan the status of the
inputs is copied to the Process Image Table (Inputs). This is then applied to the
user PLC logic. The Subroutines are processed in the order they appear in
OB1. This means that, for example an output set early in the scan might be
reset later in the scan. It is the command that appears later in the scan that
takes precedent.
When the scan is complete the results are transferred to the Process Image
Table (Outputs) which is then physically output to the machine periphery
devices.
The diagram below shows the position of the Interrupt Blocks INT_100 and
INT_101.
Their position enables them to be used to influence the state of the inputs and
outputs without making changes to the main user programme.
Beginning
Of
Scan
At the beginning of the scan, the status of

Process Image Table (Inputs) the inputs is transferred to the Process
Image Table
The INT_100 interrupt block can be used to

Interrupt INT_100 influence the Process Image Table (Inputs)
Main Routine OB1

Subroutine
Subroutine
Subroutines are processed

in the order they appear in
Subroutine OB1
Subroutine
Subroutine

Interrupt INT_101 Influence the Process Image Table
(Outputs)
At the end of the scan, the status of the

Process Image Table (Outputs) outputs is transferred to the Process Image
Table
End
Of
Scan

Section 2
Rewire Function
Notes The Rewire Function allows the user PLC programme to be automatically
rewired. It is sometimes necessary to “Rewire” the PLC due to differences in
operand assignments.
Example: A subroutine might be suitable for use in several machine
Variants that have different I/O assignments, by using the rewire function the
subroutine can be made ready in a short space of time. This saves rewriting
the subroutine for each machine variant.
It is possible to rewire Inputs, Outputs, Markers, Variables, Data Blocks,
Counters and Timers.
The Rewire Function is located by right clicking inside a program block and
selecting the Rewire option.
A dialogue box will open. The program blocks where the rewire function is to
be used need to be selected.
Rewiring Individual Bits.
The old and new addresses then need to be entered.

The “Rewire” button should then be selected to run the rewire function.
Choose the blocks to which

the rewire function should be
applied
Enter the new and old

addresses
The results of the operation can be seen in the “Rewire Results” area.

Section 2
Rewire Function
Notes
Rewire Results
The changes can also be seen in the subroutines.
Rewiring Bytes, Words, Double Words.

By selecting the “All accesses within the specified range” option it is possible
to rewire Byte, Words and Double Words.

Section 2
General Information.
Notes It is possible to “Daisy chain” several blocks together, this saves on the
number of networks used. It must be remembered that in order to make the
PLC programme more user friendly for maintenance personnel, the networks
should be able to be viewed fully over the width of the screen.

B034 PLC Interface Structure
1 Brief description.
Module Objective:
Upon completion of this module you will be know the Sinumerik 828D PLC interface structure and
use it to help write the PLC.
Module Description:
Information to and from the different system areas of the controller is handled by interfaces. This
module describes how the different areas operate together.
Sinumerik 828D
B034
Contents:- B034
Section 2
Interface Structure Overview Page 3
Section 3
Operand Description & Ranges Page 4
Section 4
Interface Description Page 4

PLC Interface Structure-Brief Description
Section 2
To enable the user to influence the system, an interface is provided. This interface operates with variables in Bit, Byte, Word & Notes
SINUMERIK 828D
Double Word formats. e.g:-
Bit:-DB1600.DBX0.0
Byte:-DB1600.DBB0
Word:-DB1600DBW0
Double Word:-DB1600.DBD0
The interface is used to control/monitor the NC, HMI & Drive areas of the system via the user PLC
Interface Structure:-
PLC User NC
Interface
PLC Interface Structure Overview.
Page 3
PLC User
Program
Periphery Drives
Devices-
PP72/48, MCP.
HMI
B034
Section 3 PLC Interface Structure-Detailed Description
Notes Operand Description & Ranges.
Operand identifiers Description Area
DB Data DB1000 to DB7999
DB9000 to DB9036
DB9900 to DB9905
T Timers T128
T0 - T15 = 100ms
T16 - T127 = 10ms
C Counters C0 to C63
I Digital Inputs I0.0 to I256.3
Q Digital Outputs Q0.0 to Q256.3
M Marker M0.0 to M511.7
SM Special Marker SM0.0 to SM 0.6 (see below)
A ACCU AC0 to AC3 (Dword)
Structure of Data Blocks

The 8-Digit Data Block made up of different sections.
DB3801.DBX1000.7
Bit Number (0 to 7)
Offset (000 to 999) Axis/channel
Section (0 to 9) Axis/channel
Area Number (00 to 99) Axis/channel
User Area (10 to 99)
The format of the can be written in different ways.
Type Format No of bits
Bit DB3801.DBX1000.7 1
Byte DB3801.DBB0 8
Word DB3801.DBW2 16
Double Word DB3801.DBD3004 32
Special Markers
The interface structure also consists of “Special Markers” (Flags) which are a set of
operands to be used at the convenience of the user throughout the PLC program
SM bits Description
SM0.0 Flag with defined ONE signal
SM0.1 Initial setting: first PLC cycle ’1’, following cycles ’0’
SM0.2 Buffered data lost - only valid in first PLC cycle (’0’ data ok, ’1’ data
lost)
SM0.3 Power On: first PLC cycle ’1’, following cycles ’0’
SM 0.4 60 s cycle (alternating ’0’ for 30 s, then ’1’ for 30 s)
SM 0.5 1 s cycle (alternating ’0’ for 0.5 s, then ’1’ for 0.5 s
SM 0.6 PLC cycle (alternating one cycle ’0’, then one cycle ’1’)
General
Variables that can only be read are identified with [r]
Variables that can be read and written to are identified with [r/w]

PLC Interface Structure-Detailed Description Section 4
Machine Control Panel (MCP483) Notes
During commissioning the MCP address range is set to start at Input and
output Bytes 112
Signals from machine control panel (keys)
IB 112 Spindle speed override Operating mode
D C B A JOG TEACH MDA AUTO
IN
IB 113 Machine function
REPOS REF var. INC 10000 1000 INC 100 INC 10 INC 1 INC
IB 114 Key- Key- Spindle *Spindle Feed *Feed NC Start *NC Stop
switch switch start stop start stop
IB 115 Key- Feed rate override

switch
position 1
Reset Single E D C B A
block
IB 116 Direction keys Key Axis selection keys
switch
position 3
+ - Rapid x 4th axis 7th axis
R15 R13 traverse R1 R4 R7
R14
IB 117 Axis selection
Y Z 5th axis Traverse R9 8th axis 6th axis
R2 R3 R5 command R8 R6
MCS/
WCS
R12
IB 118 Unassigned customer keys
T9 T10 T11 T12 T13 T14 T15
IB 119 Unassigned customer keys
T1 T2 T3 T4 T5 T6 T7 T8
Signals to machine control panel (LEDs)

QB 112 Machine function Operating mode

1000 INC 100 INC 10 INC 1 INC JOG TEACH MDA AUTO
QB 113 Feed *Feed NC Start *NC Stop Machine function
REPOS REF var. INC 10000
QB 114 Axis selection LED Single Spindle *Spindle

start stop
Direction X 4th axis 7th axis
key R1 R4 R7
-
QB 115 Axis selection LED

Z 5th axis Travel R9 8th axis 6th axis Direction
R3 R5 command R8 R6 key
MCS/ +
WCS R15
R12
QB 116 Unassigned customer keys Y
T9 T10 T11 T12 T13 T14 T15 R2
QB 117 Unassigned customer keys
T1 T2 T3 T4 T5 T6 T7 T8
QB 118 Reset

Notes Machine Control Panel (MCP310)
During commissioning the MCP address range is set to start at Input and
output Bytes 112
Signals from machine control panel (keys)
NC Stop Spindle - Spindle Spindle + Single JOG MDA AUTO
IB112 100% Block
IB113 NC Start Spindle Spindle Spindle Key- REF REFP Teach

switch IN
Right Stop Left
Position 3
IB114 Feed Feed stop INC VAR Key- INC 1000 INC 100 INC 10 INC 1
start switch
Position 0
Key- Key- Feed rate override

switch switch
Reset E D C B A
IB115 position 2 position 1
(16) (8) (4) (2) (1)
Direction keys
Rapid KT5 KT5 KT5 KT5 KT5
IB116 traverse
(X52.2) (X52.2) (X52.2) (X52.2) (X52.2)
+ - R14
R15 R13
Axis selection
T16 KT5
IB117 (X52.3) 6th axis 5th axis 4th axis Z axis Y axis X axis
T9 T10 T11 T12 WCS T13 T14 T15

IB118 MCS
IB119 T1 T2 T3 T4 T5 T6 T7 T8
Spindle override
IB122 E D C B A
(16) (8) (4) (2) (1)
Signals to machine control panel (LEDs)

NC Stop Spindle Spindle Spindle Single JOG MDA AUTO
QB112 Dec. 100% Inc. Block
NC Spindle Spindle Spindle RESET REF REPOS Teach In

QB113 Start right stop left
Feed Feed Inc Var INC INC INC INC

QB114 Start Stop
1000 100 10 1
QB115
Minus Plus Rapid
Direction Direction Traverse
QB116
QB117 T16 6th axis 5th axis 4th axis Z Y X
QB118 T9 T10 T11 T12 MCS/ T13 T14 T15

WCS
QB119 T1 T2 T3 T4 T5 T6 T7 T8

User Data Areas Notes
There are two areas set aside for free use within the user PLC
DB1000 User Data 1[r/w]

0000
User Data
up to
0011 User Data
DB1100 User Data [r/w]

0000
User Data
up to
0007 User Data
Reading/Writing of NC data.
It is possible to read/write data too/from the NC &PLC. Variables are
available to facilitate this function.
Below:- Defining read or write, how many variables and setting the start
Signal.
DB1200 PLC interface NCK [r/w]

0000 Write Start
variable
0001 Number of variables to be read/written
0002
0003
Below:-Information regarding the variable has to be written to the following

areas. Up to eight sets of data can be moved in one go.
DB1200- PLC interface NCK [r/w]
1203

1000 Variable Index
1001 Area Number
1002 Line index for NCK variable x (Word)
1004 Column index for NCK variable x (Word)
1006
1008 Data to be written to NCK

Notes The results of the task are output to the following areas:-
DB1200 NCK PLC interface

12002000 Error in Request
job Comp.
12002001
12002002
DB1200 NCK PLC interface

120x3000 Fault Valid
Variable
120x3001 Access results (0-No error, 1-Illegal access, 5-Invalid address, 10-Object does not exist)
120x3002
120x3004 Data that was read from the NC variable
PI Services:- Selecting and Starting
DB1200 PLC NCK interface [r/w]

4000 Start
4001 PI-Index
4002
4003
4004 PI-Parameter 1
4006 PI-Parameter 2
4008 PI-Parameter 3
4010 PI-Parameter 4
4012 PI-Parameter 5
4014 PI-Parameter 6
4016 PI-Parameter 7
4018 PI-Parameter 8
4020 PI-Parameter 9
4022 PI-Parameter 10
DB1200 NCK PLC interface [r]

5000 Fault Finished
5001
5002

Retentive Data Area:- Notes
DB1400 [r/w]

User area
0000
User area
0001
User area
0002
User area
0004
etc
User area
0126
User area
0127

Notes User Alarms
DB1600. Activating alarms (Alarm number range 700000 to 700240)
PLC interface HMI
0000 700007 700006 700005 700004 700003 700002 700001 700000
0001 700015 700014 700013 700012 700011 700010 700009 700008
0002 700023 700022 700021 700020 700019 700018 700017 700016
0003 700031 700030 700029 700028 700027 700026 700025 700024
etc
etc
etc
0030 700247 700246 700245 700244 700243 700242 700241 700240
DB1600. Variable for alarm.

1000 Variable for alarm 700000 (4 bytes)
etc
etc
DB1600. Alarm reaction

2000 Acknowl- Acknowl- PLC Stop Em. Stop Feed Read-in NC start
edge with edge with disable disable disable
power DB1600.D
BX3000.0
ON
2001-2003
Program Control Signals

DB1700. HMI signals
HMI PLC interface
0000 Test run M01 DRF
Feedrate Selected Selected
selected
0001 Program Feedrate

test override
selected (Rapid)
selected
0002 Skip Skip Skip Skip Skip Skip Skip Skip

block 7 block 6 block 5 block 4 block 3 block 2 block 1 block 0
selected selected selected selected selected selected selected selected
0003 Measuring Skip Skip

in jog block 9 block 8
active selected selected

Messenger Notes

Interface messenger PLC
3000 Control Byte
3001
3002
3003
Easy Extend

Interface messenger PLC

4000 Word (16 bit)
4002 Word (16 bit)

4004
4030 Word (16 bit)
Signals from HMI

DB1800. HMI interface PLC [r]

0000 Reset JOG MDA AUTO
mode mode mode
0001 Machine Machine
function:- function:-
REF TEACH
IN
0002
0003

Notes Signals from PLC
DB1800. Signals from PLC [r]

1000 Start- Power Power
up ar- up with up with
chive saved default
data values
1001
1002
1003
1004 PLC cycle time in micro seconds

1008 Year (Tenths) BCD Year (Units) BCD
1009 Month (Tenths) BCD Month (Units) BCD
1010 Day (Tenths) BCD Day (Units) BCD
1011 Hour (Tenths) BCD Hour (Units) BCD
1012 Minute (Tenths) BCD Minute (Units) BCD
1013 Second (Tenths) BCD Second (Units) BCD
1014 Millisecond (Hundredths) BCD Millisecond (Tenths) BCD
1015 Millisecond (Units) BCD Weekday BCD (1, 2…….7) 1 = Sunday
DB1800. Deactivate the Service Interval [r/w]
Deactivate Service Task

2000
8 7 6 5 4 3 2 1
2001
16 15 14 13 12 11 10 9
2002
24 23 22 21 20 19 18 17
2003
32 31 30 29 28 27 26 25
DB1800. Alarm for Service Task [r]
Alarm
3000
8 7 6 5 4 3 2 1
Alarm
3001
16 15 14 13 12 11 10 9
Alarm
3002
24 23 22 21 20 19 18 17
Alarm
3003
32 31 30 29 28 27 26 25

Maintenance Planner Notes
DB1800. Acknowledge the Service Task [r]
Service Task
4000
8 7 6 5 4 3 2 1
Service Task
4001
16 15 14 13 12 11 10 9
Service Task
4002
24 23 22 21 20 19 18 17
Service Task
4004
32 31 30 29 28 27 26 25
DB1800. Disable the Acknowledgement of the Service Task [r]
Service Task
5000
8 7 6 5 4 3 2 1
Service Task
5001
16 15 14 13 12 11 10 9
Service Task
5002
24 23 22 21 20 19 18 17
Service Task
5004
32 31 30 29 28 27 26 25
Signals from operator panel (retentive area)
DB1900. HMI interface PLC

0000 MCS/ Simula- Cancel
WCS tion
selection active
[F-K1]
0001 Active HMI area
0002
0003
0004 Active jobshop area
0006
0007

Notes General selection/status signals from HMI (retentive area)
DB1900. HMI interface PLC
1000
1001
1002
Axis number for hand-wheel 1

1003
Machine Hand- Contour C B A
axis wheel hand-
selected wheel
Axis number for hand-wheel 2
1004
Machine Hand- Contour C B A
axis wheel hand-
selected wheel
General selection/status signals to HMI (retentive area)

DB1900. PLC interface HMI
5000 WCS is OP key

Active disable
5001 External No exter-
viewers nal view-
allowed ers al-
lowed
5002
5003 PLC Hardkeys (Range of values 1….255, 0 is start position

5004
5005
5006
5007
5008
5009
5010
5011
5012
5013
5014
5015
5016
5017
5018
5019
5020

Auxiliary functions from NCK channel (Read only) Notes
DB2500. NCK interface PLC

0000
up to
0003
0004 M fcts.5 M fcts.4 M fcts.3 M fcts.2 M fcts.1
change change change change change
0005
0006 S fcts.1
change
0007
0008 T fcts.1
change
0009
0010 D fcts.1
change
0011
0012 H fcts.3 H fcts.2 H fcts.1
change change change
0013
up to
0019
Decoded M signals (M0-M99)


1000 Dynamic M functions [F-H2]
M1=5 M1=4 M1=3
M7 M6 M5 M4 M3 M2 M1 M0

M15 M14 M13 M12 M11 M10 M09 M08
M23 M22 M21 M20 M19 M18 M17 M16
etc
Dynamic M functions [F-H2]

1012
M99 M98 M97 M96
1013
up to
1015

Notes Transferred T functions

5000 T function 1 (DINT) [F-H2]
5004
up to
5007
Transferred M functions
DB2500. M functions from NCK channel
NCK interface PLC

3000 M function 1 (DINT) [F-H2]
3004 Extended address of M function 1 (Byte)




Transferred S functions

4000 S function 1 (REAL) [F-H2]
4004 Extended address of S function 1 (Byte)
4008 S function 2 (REAL) [F-H2]

4016
4020
Transferred D functions

5000 D function 1 (DINT) [F-H2]

Transferred H functions Notes

6000 H function 1 (REAL) [F-H2]
6004 Extended address of H function 1 (Byte)


NCK Signals
DB2600. PLC interface NCK

Protection level [F-A2] Ackn. Emerg. Braking
emerg. stop along
0000 stop [F-N2] contour in
4 5 6 7 [F-N2] event of
Emerg.
stop
Request Request INC

axis Actual Inputs in
0001 distances values Mode
to go Group
range
active 1
[F-H1]
0002
0003

0000 Emerg.
Stop
active
0001 INCH Probe 2 Probe 1

dimesion actuated actuated
on
system
0002 Drive Drives in

ready cyclic
operation
0003 Air temp. NCK

alarm alarm is
active
0004
0005
0006

Notes NCK Signals-continued

0007
0008
0009
0010
0011
0012 Modification counter for motions of hand-wheel 1
0013 Modification counter for motions of hand-wheel 2
0014
0015 Modification counter, inch metric unit system.
etc
0019
Signals to fast inputs and outputs


Disable digital NCK inputs
0000
Input 8 Input 7 Input 6 Input 5 Input 4 Input 3 Input 2 Input 1
Values from the PLC for the NCK inputs

0001
Disable digital NCK outputs

0004
Output 8 Output 7 Output 6 Output 5 Output 4 Output 3 Output 2 Output 1
Overwrite screen form for digital NCK outputs

0005
Values from the PLC for the NCK outputs

0006
Set-point screen-form for the NCK outputs

0007

1000
Input16 Input15 Input14 Input13 Input 12 Input11 Intput10 Input 9

1001
Input16 Input15 Input14 Input13 Input12 Input11 Input10 Input 9
Disable digital NCK outputs

1008
Ouput16 Output15 Output14 Output13 Output12 Output11 Output10 Output9

1009
Output16 Output15 Output14 Output13 Output12 Output11 Output10 Output 9

1010
Set-point screen-form for the NCK outputs

1011

Signals From Fast Inputs & Outputs Notes

Actual values of the digital NCK inputs
0000
Set-points of the digital NCK outputs

0004

Actual values of the external digital NCK inputs
1000
Set-points of the external digital NCK outputs

1004
Output16 Output15 Output14 Output13 Output12 Output11 Output10 Output9
Operating Mode Signals


Reset Mode Operating mode
group
0000 change-
over JOG MDI Auto
disable
Single Single Machine function
0001 block– block
Type A Type B REF Teach in
Machine function
Continu- INC INC INC INC INC INC

0002
ous Variable 10000 1000 100 10 1
travel
0003

Active mode
0000 828D
Ready
JOG MDI Auto
Active Machine function

0001
REF Teach in
Machine function
Continu- INC INC INC INC INC INC

0002 ous Variable 10000 1000 100 10 1
travel
0003

Notes Channel Signals

Activate Activate Activate Activate Activate Activate
0000 dry run M01 single DRF feed reverse
feedrate block forward travel
Activate Enable Activate

0001 program protection referenc-
test zones ing
Activate Activate Activate Activate Activate Activate Activate Activate

0002 skip skip skip skip skip skip skip skip
block 7 block 6 block 5 block 4 block 3 block 2 block 1 block 0
Feed-rate override
0004
H G F E D C B A
Rapid traverse override

0005
H G F E D C B A
Feed- Rapid Limited Program Delete Delete Read-in Feed-rate
0006 rate traverse path level number distance disable disable
override override velocity abort of sub- to go
active active routine
cycles
Suppress NC stop NC stop NC stop NC start NC start
0007 Start axis plus at block lock
Lock spindle limit
Activate machine related protection zone

0008
Area 8 Area 7 Area 6 Area 5 Area 4 Area 3 Area 2 Area 1
Activate machine related protection zone

0009
Area 10 Area 9
Activate channel specific protection zone
0010
Activate channel specific protection zone

0011
Area 10 Area 9
0012
Do not Deactivate
0013 disable workpiece
tool counter
Activate contour hand-wheel

(bit/binary coded
No tool Circle Activate Neg. Sim. Handwheel Handwheel

0014 change Jog associated direction contour 2 1
commands M01 for contour hand
hand wheel ON
wheel
Activate Activate
0015 skip block skip block
9 8
0018
0016
0017
0018
0019

Control signals to geometry axis (Axis in WCS) Notes

Geometry axis 1 (Axis 1 in WCS)
1000
Traversing keys Rapid Traversing Feedrate Activate handwheel
traverse key lock stop
+ - override 2 1

1001
Machine function
Continu- Inc var INC10000 INC1000 INC100 INC10 INC1
ous travel
1002
1003
1004
+ - override 2 1

1005
Machine function
ous travel
1006
1007
1008
+ - override 2 1

1009
Machine function
ous travel
1010
1011

Notes Signal from NC channel

Last M0/M01 Approach Action Forward Reverse Program
0000 action Active block block Travel travel execution
block active activate active active from
active external
active
Program Transfer M2/M30 Block Hand- Rev. Referenc-

0001 test M active active search Wheel feed-rate ing
active active override active active
active
0002
Chanel status Program status

0003
Reset Interrupted Active Aborted Interrupted Stopped Wait Running
0004 NCK alarm Specific All axes All axes Stop Start
without NCK alarm stationary referenced Request request
processing is active
Contour hand - wheel active

0005 (Bit/binary coded)
H-wheel H-wheel
1 2
Protection
0007 zones no
longer
guaran-
teed
Machine related protection zones pre-activated

0008
Machine related protection zones pre-activated

0009
Area 10 Area 9
Channel specific protection zones pre-activated

0010
Channel specific protection zones pre-activated

0011
Area 10 Area 9
Machine related protection zones violated

0012
Machine related protection zones violated

0013
Area 10 Area 9
Channel specific protection zones violated
0014
Channel specific protection zones violated

0015
Area 10 Area 9

Section 4
PLC Interface Structure-Detailed Description
Status signals to geometry axis Notes

1000
Motion Command Travel request Active Hand-wheel
Plus Minus Plus Minus 2 1
Active machine function

1001
ous travel
1002
1003

1004

1005
ous travel
1006
1007
1008
Active Machine function

1009
ous travel
1010
1011

G00
4000 active
Travel Work-piece External

4001 request for set-point language
drive test reached mode
present active
4002 Dry run is Stop

active delayed
No tool Delay Delay

4003 manage- FST FST
ment suppress
commands
active
4004 Prog Event Display
Start after Engine run Operator Part Part pro-

search run up panel program gram start
reset end from reset
4005 Circle jog Stop StopbyColl

active condition Danger
4006 Silent Asup Any Asup

Any Asup Active
4007
4008 Active Transformation Number
4008-4011 Reserved

Notes Asynchronous sub routines:-

0000 Asup 1
start
0001 Asup 2
start
0002
0003
ASUP result

Asup 1 Asup 1 Asup 1 Asup 1
1000 start not number running finished
possible not
possible
possible not
possible
G functions from NC channel

0000 Active G function of group 1 (8 bit Integer)
00xx Active G function of group xx (8 bit Integer)
M/S functions, axis specific-spindle specific
DB370x. NCK interface PLC

0000 M function for spindle (Double Integer)
0004 S function for spindle (Real)

Signals to axis/spindle Notes
DB380x PLC interface NCK

Feedrate override
0000
H G F E D C B A
Override Measuring Measuring Follow up Axis/ Sensor for Acknowl-

0001 active system 2 system 1 mode spindle fixed stop edge fixed
disable stop
reached
Clamping Distance Controller Cam

0002 in progress to go/ enable activation
spindle
reset
0003 Axis/ Velocity/ Enable

spindle spindle approach
enable speed to fixed
program limiting stop
test
Traversing keys Rapid Traverse Feedrate Active Hand-wheel

traverse key lock stop/
Plus Minus override spindle 2 1
0004 stop
Machine function
0005
ous travel
0006
0007
Request Activation Request
0008 PLC axis signal by NC axis
byte signal
change
0009-
0011
Delay Modulo 2nd software limit switch Hardware limit switch
1000 reference Limit
point Reached
approach Plus Minus Plus Minus
1001-
1003
Signals to spindle

Clear S Spindle:- Spindle Spindle Gear Actual gear stage
value No speed resynchro- resynchro- changed
monitoring nise 2 nise 1
when
2000 switching
the gear
stage C B A
(resynchro
nise 2)
Invert M3/ Resyn- Feedrate

2001 M4 chronise override
spindle valid for
during spindle
positioning
Setpoint direction of Oscillation Oscillation

rotation speed via PLC
2002 Left Right
Spindle override
2003
H G F E D C B A

Notes Signals to PLC axis
DB380x PLC interface NCK (Read/write)

Start Start Start Start
3000 positioning spindle spindle spindle
axis positioning turning oscillating
3001 Stop Stop

spindle spindle
turning oscillating
Automatic Constant Direction Hand- Traversing G function: G function:

3002 transmis- cutting of rotation wheel dimension Shortest incre-
sion speed M4 overlap- Inch path mental
ping
Indexing G function: G function:

3003 position Absolute Absolute
position negative
direction direction
3004 Position (Real number, with indexing axis, Double word)
3005
3006
3007
3008 Feedrate (Real number)
If = 0 value is taken from machine data POS_AX_VELO
3009
3010
3011
Signals to drive

Open Speed
4000 holding set-point
brake smoothing
Pulse Speed Parameter set selection

4001 enable controller
integrator
disable C B A
4002
4003
Signals to technology functions


Positioning Automatic Specified Specified Spindle
the spindle gear stage direction of direction of STOP
5006 change rotation rotation
CCW CW

General signals from axis/spindle Notes
DB3900- NCK interface PLC (Read only)
3907
Position reached Refer- Encoder Spindle/no
0000 enced/ limit axis
With exact With exact synchro- frequency
stop-fine stop- nised 1 exceeded
coarse
Current Speed Position Axis / Follow up Axis ready Axis alarm

0001 controller control controller spindle mode
active loop active active stationary active
(n < nmin)
Power Fixed stop Activate Measure- Rotational Hand- Cam active

0002 fixed stop reached travel to ment federate wheel
limited fixed stop active overlay
active
0003
Motion command Travel request Active hand-wheel

0004

0005
ous travel
PLC axis/ Neutral Exchange New type NX axis/

0008 spindle axis/ possible from PLC spindle
spindle requested
PLC axis Position Position

0011 assigned restored 1 restored 2
firmly
Signals from axis

3907
Modulo
limit
1000 enabled
Active
1001
Rotary Indexing Positioning Path axis Lubrication
1002 axis in axis in axis pulse
position position
1003
Signals from spindle

3907
Gearbox Set gear stage
2000 change-
over C B A
Actual Speed Spindle in Supporting Geometry Set-point Set-point Speed

2001 direction of monitoring the range limit monitoring speed speed limit
rotation is Set-point violated increased limited exceeded
clockwise range
Active spindle mode Rigid SUG active Constant
tapping cutting
2002 velocity
Control Oscillation Positioning Synchron.
mode mode mode Mode active
2003 Spindle in
position

Notes Signals from PLC axis
DB390x NCK interface PLC (Read only)

Positioning Position Error Axis
3000 axis active reached during cannot be
traversing started
3001
3002
3003 Error number
Signals from drive


Holding
4000 brake
open
4001 Pulses Speed Drive Active parameter set

enabled controller ready
integrator
disabled C B A
Variable nact = nset nact < nx nact < nmin Md < Mdx Ramp up Temperature
4002 message completed pre-warning
function 1
Heat Sink Motor
4003 Uzk < Uzkx
Signals from technology functions

5000
5001
ESR Accelera- Velocity Overlaid
5002 reaction tion warning movement
initiated warning threshold
threshold reached
reached
Max. Max. Synchroni- Axis

accelera- velocity sation acceler-
5003 tion reached running ated
reached
5005
5006
5007
5008

PLC machine data Notes
INT values (MD14510 USER_DATA_INT)

DB4500 NCK interface PLC (Read only)

0000 Int values (Word/2 bytes)
Up to Int values (Word/2 bytes)

0062
HEX values (MD14512 USER_DATA_HEX)


1000 Hex value (Byte)
1001 Hex value (Byte)
Up to Hex value (Byte)

1031
FLOAT values (MD14514 USER_DATA_FLOAT)

1000 Float value (Real/4 bytes)
1001 Float value (Real/4 bytes)
Up to Float value (Real/4 bytes)

1031
Configuration (MD14516 USER_DATA_PLC_ALARM)

3000 Alarm reaction/cancellation criterion-Alarm 700000
3001 Alarm reaction/cancellation criterion-Alarm 700001
Up to Alarm reaction/cancellation criterion-Alarm 700031

3031
Reading and writing PLC variables
DB4900 PLC interface (Read/write)

0000 Offset 0
0001 Offset 1
0002 Offset 2
Up to Offset 1023
1023

Notes Tool management functions from NC channel
Change signals for tool management functions

Tool limit Tool
value warning
0000 reached limit
reached
Transferred tool management functions
DB5300 NCK interface PLC [r]

1000 T number for tool warning limit (DINT)
1004 T number for tool limit value (DINT)
1000
1004
Axis actual values and distances to go.

Signals from axis/spindle
DB5700- NCK interface PLC [r]

5704

0000 Axis actual value (Real)
0004 Axis distance to go (Real)

B031 PLC Alarm & Message structure.
1 Brief description
Module objective:
Upon completion of this module you will be able to configure and activate and set the attributes of
messages and alarms.
Module description:-
Alarms and messages are essential to inform operators, maintenance personnel etc of the state of
the machine.
Messages usually deal with non critical states while alarms often inhibit the machine from
functioning.
This module describes how the alarms and messages are activated. The effect an alarm has on the
system is shown as well as the method of resetting an alarm.
Sinumerik 828D
B031
Contents:- B031
Section 2
Alarm Configuration. Page 3
Entering the Alarm Section 3

Text Page 5
Locating the Alarms Section 4

and Messages Screen. Page 8
Section 5
Alarm log. Page 9

Section 2
Alarm configuration.
The following shows information required for setting and configuring alarms. Notes
Alarm Number Activation bit Configuration Variable for extended
Machine Data alarm function
700000 DB1600DBX0.0 14516[0] DB1600.DBD1000

700001 DB1600DBX0.1 14516[1] DB1600.DBD1004
700002 DB1600DBX0.2 14516[2] DB1600.DBD1008
700003 DB1600DBX0.3 14516[3] DB1600.DBD1012
700004 DB1600DBX0.4 14516[4] DB1600.DBD1016
700005 DB1600DBX0.5 14516[5] DB1600.DBD1020
700006 DB1600DBX0.6 14516[6] DB1600.DBD1024
700007 DB1600DBX0.7 14516[7] DB1600.DBD1028
700008 DB1600DBX1.0 14516[8] DB1600.DBD1032
700009 DB1600DBX1.1 14516[9] DB1600.DBD1036
700010 DB1600DBX1.2 14516[10] DB1600.DBD1040
etc etc etc etc
etc etc etc etc
700247 DB1600.DBX30.7 14516[247] DB1600.DBD1998
Below:-An example of how Alarm 700000 might be activated via input I6.5
The configuration machine data is used to determine how the controller reacts to that
particular alarm. Each alarm has a machine data assigned to it for this purpose.
Machine Data 14516 functionality:-
14516[xx] Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
Acknowl- Power Acknowl- PLC Emer- Feed Read in NC start

edge/Effect off edged by stop gency disable disable inhibit
DB1600.D stop
BX3000.0
The functionality of the machine data is in two parts.

Bits 0 to 4 determine how the controller reacts to that particular alarm, while Bits 6 & 7
determine how the alarm is acknowledged.
The MD is set via a bit pattern which is revealed when the MD is highlighted and the
“Select” key is pressed.
The bit is then activated with the “Select” or “Space” key and confirmed with the “OK”
soft-key

Section 2
Alarm Configuration.
Notes
Machine Data 14516 is also used to determine whether the message/alarm appears
as on the alarm or a message screen (See page 8)
If neither bits 6 & 7 are used, then the message/alarm requires no acknowledgement
and will clear as soon as the activation bit becomes zero.
The alarm/message will appear on the message page.
If bits 6 & 7 are used then the alarm/message appears on the alarm page and an
acknowledgement is required.
The machine data is activated with a power off/on via the “Reset (po)” soft key.
It is possible to use the same alarm number for different alarms. This is done using
the variables in the “Variable for extended alarm function” column of the previous
Table.
Example:- The alarm number 700011 is to be used to signal that several axes are in
the parked position.
From the table we can see that the bit to activate this alarm is DB1600.DBX1.3 and
that the extended function variable is DB1600.DBD1044.
By selecting one of the following identifiers and entering it into the alarm text line,
when the alarm is then triggered the contents of DB1600.DBD1044 will appear in
place of the identifier of the alarm.
%d Decimal value
%x Hexadecimal
%b Binary
%o Octal
%u Unsigned integer
%f Floating point number
In the alarm text type:- “Axis %d in parked position”. Press “Input”

Section 3
Entering The Alarm Text
In the Variable DB1600.DBD1044 the value of 1 is entered. This is done by a move Notes
command.
This variable is a Double Word and as such it has to use the “MOVE_DW”
instruction. (Move Data Word)
Below is an example of how a value 2 is moved into the variable DB1600.DBD1044

when input I7.5 is equal to one. This would display the number 2 in place of the “%d”
when alarm 700011 is activated
Below is the alarm 700011 as displayed on the controller
By moving different values into DB1600.DBD1044 it is possible to use the same

alarm number to display slightly different messages.
The PLC alarm text can be created directly on the controller.

This alarm file determines the text that is displayed when a particular alarm is
activated.
Creating the text on the controller
Use the cursor key to highlight the required alarm type and select “OK”

Section 3 Entering The Alarm Text
Notes
Up to 248 alarm numbers and text can now be typed in using the key board..
Existing alarms can also be edited here
The colour of the alarm text can be either black or red. This is selected at the right of
the text input field.
When an alarm text entry is complete press the “Input” key to confirm the entry.
The vertical soft-keys offer copy, paste, delete and search functionality.

Section 3
The search function can be used to search for text or alarm numbers. Notes
The option to search forward or backward is available as well as a case sensitive
option.
The cursor are used to navigate and the select key to toggle between the choices.
The search is started when the “OK” soft key is pressed. The “Continue search” soft
key can be used to identify any further matches.
The cursor and page up/down keys can also be used for finding a particular alarm.
The search function can be used to search for text or alarm numbers.
The option to search forward or backward is available as well as a case sensitive
option.
The cursor are used to navigate and the select key to toggle between the choices.
The search is started when the “OK” soft key is pressed. The “Continue search” soft
key can be used to identify any further matches.
The cursor and page up/down keys can also be used for finding a particular alarm.
When the search soft-key is selected further options are revealed which can be used
Takes the user the beginning of the list.
Takes the user the end of the list.
Can be used to find a specific word and replace it with another.
Cancels the operation.
Confirms data entry/starts the search function.

Section 4 Locating the Alarms and Messages Screen.
Notes Select the following keys to locate the screen where the active alarms and messages
are displayed.
Depending on the configuration, there are two areas where an active alarm might be
displayed.
The “Alarm list” screen displays serious alarms which result in the
machining process being halted.
The “Messages” screen displays less serious alarms which may

not necessarily result in the machining process being halted.
Below is an example of two alarms in the Alarm list
Before a message can be displayed it needs to be triggered in the user PLC.

Each alarm number has a variable assigned to it, this variable needs to be set to 1 for
the alarm to be displayed.
Below is an example of how alarm 700000 might be activated

Alarm Log.
Section 3
A log of alarms that have occurred can be seen by selecting the “Alarm protocol” Notes
soft key
This shows the time when the alarm occurred and when it was cleared
The “Display new” soft key is used to refresh the list and display any alarms that have
recently occurred.
The “Settings” soft key is used to refresh the list and display any alarms that have
recently occurred.
There are a number of options which can be selected by using the cursor and select
keys and confirmed with the “OK” soft key:-

Section 4
Alarm Log.
Notes Number of entries– This sets the maximum number of alarms displayed on the
alarm log page.
Write mode file-off
No storing of the log file will take place to the internal flash memory (Compact flash
card)
At every event– Each time an alarm occurs this will be recorded to the compact flash
memory.
When this option is selected, a warning is displayed. By leaving this option

permanently set, the life of the internal flash card will be greatly reduced.
The controller needs to be rebooted to make the changes effective.
Time controlled– The log will be saved at the interval entered in the Write interval
area (Max 32000 seconds)
This option carries similar risk to the “At every event” option and the same warning is
displayed
The controller needs to be rebooted to make the changes effective.

Alarm Log.
Section 3
Store log-This allows the log file to be manually saved in a file which can be Notes
retrieved and used for diagnostic purposes.
The file destination is displayed at the bottom of the screen for several moments after
pressing the “Store log” soft key
Use the following soft key sequence to locate the log file:-
Use the “Cursor” and “Input” to navigate to the “alarmlog” directory.
The file can be viewed by using the “Open” soft key.
The file can be copied and pasted to other destinations such as an

external storage device. This could then, for example be forwarded
to technical personnel for fault assistance.

B032 Remote Diagnosis
1 Brief description
Module Objective:
Upon completion of this module you will be able to connect remotely to the system using the Remote
Diagnosis function and the RCS Commander software tool.
Module Description:
It may be a requirement for service personnel to remotely diagnose problems with the controller or
machine. This can be achieved by setting the Remote Diagnosis option on the controller and using
the RCS Commander software package installed on a PG/PC.
When connected, the remote user will see the exact screen that is displayed on the controller and will
be able to enter data to directly influence the system.
Sinumerik 828D
B032
Contents:- B032
Remote Diagnosis Section 2

Option Activation Page 3
Section 3
Configuring the controller Page 4
Section 4
RCS Commander Software Page 6

Section 2
Remote Diagnosis Option Activation.
The password of the system should first be set to the Manufacturer level. Notes
To check that the Remote Diagnosis option is available with the current licence
please use the following key sequence:-
Page/cursor the entry “MC Information System RCS Host”. If a green tick does not
appear in the ”Set” column this can be activated via the select key providing there is
a green tick in the adjacent “Licensed” column.
If no tick is available in the “Licensed” column then the current licence is not sufficient
and advice must be sought from your local Siemens service centre.
If the option required setting it is not active until the controller has had a warm restart
via the “Reset (po)” soft key.

Section 3 Configuring the controller
Notes Use the following soft key sequence to locate the Remote Diagnosis set up screens:-
To change the settings select the “Change” soft key. The screen is navigated and
options selected by using the cursor and select keys.
There are several possibilities available when setting up the options.
Rights for remote access:-
Do not allow remote access-Prevents remote connections.

Allow remote monitoring-The remote computer can monitor the controller.
Allow remote operation-The remote computer can access the various screens of
the controller and carry out changes
These options can be activated directly on the HMI or via the user PLC interface-
Selected by HMI
Specified by PLC
Behaviour for remote access:-
Confirmation dialog display time-When a connection attempt is made a dialogue

box will appear which requires acknowledgement, this sets the time that this dialogue
box stays on the screen.
Afterwards remote access is allowed automatically-If this is set to “Allowed” the
controller will allow the connection even when the dialogue box has not been
acknowledged. If set to “Denied” the connection will be blocked if the dialogue box is
not acknowledged.
When the settings are correct select the “OK” soft key

Section 4
RCS Commander Software
Before proceeding ensure that an ethernet cable is connected to ethernet port X127 Notes
of the controller and the ethernet port of the PG/PC.
The software is available from the toolbox supplied with the controller. Start the soft
ware by double clicking the desktop icon.
A dialogue box appears offering the chance of a direct connection via a default
Setting which is for ethernet service port X127. The IP address of 192.168.215.1 is
the default setting for this port. X127 is a DHCP server port and issues IP addresses.
The Ethernet port on the external PG/PC should be set so that it automatically
acquires an IP address
Select the “Connect” button
After a short while the connection should be established. This is indicated in several
areas. The lower half of the RCS program will show various folders (CF-Card sys-
tem, NCK-File system) which are folders on the controller
Another indicator of a connection is found on the middle of the RCS program.

Section 4
RCS Commander Software
Notes The RCS software includes a function called VNC Viewer, this is used to display the
screen of the controller on the external laptop. To start this function select the
following icon from the RCS Commander tool bar:-
Alternatively select “Start” from the “Remote control” drop down menu.
The screen of the controller will be displayed along with a dialogue box. Select the
“Yes” option.
If the “Allow remote operation” option was selected in the setup page it should now
be possible to access all areas of the system
The following keys are used to navigate the controller from the remote PC or USB
keyboard:-
F1 to F8 - Horizontal soft-keys
Shift & F1 to F8 - Vertical soft-keys
F9 - Page Back/Up
F10 - Menu Select
Shift & F9 - Page right
F12 - Help function
Escape - Alarm Cancel
Select - Space Bar

B033 PI Services & PLC Functions
Module Objective:
Upon completion of this module you will know the available PLC functions.
Module Description:
PLC Functions are tasks which are initiated from the user PLC program. These tasks include
selecting and running an ASUP, resetting the active password, saving data, exchanging data
between the NC & PLC. This modules explains these functions including the necessary interface
signals and shows examples.
Sinumerik 828D
B033
Contents:- B033
PI Services Section 2
(Program Invocation Page 3
Services)
Section 3
Reading Axis Positions
Page 7
Reading and Writing of Section 4

NC Data Page 8
Data Exchange Section 5

Between NC & PLC Page 15

PI Services.
Section 2
The following interface signals are reserved for use with the PI Services Notes
function.

0000 Asup 1
start
0001 Asup 2
start
0002
0003

possible not
possible

possible not
possible
DB1200 PLC NCK interface [r/w]

4000 Start
4001 PI-Index
4002
4003
4004 PI-Parameter 1
4006 PI-Parameter 2
4008 PI-Parameter 3
4010 PI-Parameter 4
4012 PI-Parameter 5
4014 PI-Parameter 6
4016 PI-Parameter 7
4018 PI-Parameter 8
4020 PI-Parameter 9
4022 PI-Parameter 10
DB1200 NCK PLC interface [r]

5000 Fault Finished
5001
5002

Section 2 PI Services.
Notes PI Services Description:
PI Service: ASUP1 & ASUP2 (Asynchronous User Programs)
A PLC ASUP is a program which can be selected and run from the user PLC,
independently of the normal NC operations.
Two ASUPS are available (PLCASUP1.SPF & PLCASUP2.SPF)
Selecting the ASUP:

PI Index value Function Interrupt Priority
(DB1200.DBB4001)
1 Selection of ASUP1 1
2 Selection of ASUP2 2
PI parameter.
The behaviour of the ASUP is affected by the setting of the relevant PI parameter.
PI Parameter Address (Word) Signal Permitted values

(1 to enable)
1 DB1200.DBW4004 LIFTFAST 0 or 1
2 DB1200.DBW4006 BLSYNC 0 or 1
LIFTFAST: When the ASUP is requested, fast retraction of the tool from the contour
takes place prior to the ASUP running.
BLSYNC: When the ASUP is requested, the current program block is processed prior
to the ASUP running.
PI Service: LOGOUT - Password Reset.
PI Index value Function

(DB1200.DBB4001)
3 Password Reset
There is no PI parameter required for this function.
PI Service: _N_DASAVE - Saving of Data.

(DB1200.DBB4001)
4 Saves SRAM to Flash Memory
There is no PI parameter required for this function.
PI Service: TMMVTL - Tool Reloading Via the PLC
When the service is started, the tool management performs a search for an empty
location in the ―Target magazine‖ for the tool set in the ―Source location‖. The PLC
then receives an order for tool reloading. The ―Target magazine‖ must be a real
Magazine.

(DB1200.DBB4001)
5 Initiate order for tool reloading

PI Services.
Section 2
PI Parameters for TMMVTL Notes
PI Parameter Address Function Permitted Values

1 DB1200.DBW4004 Tool Number 1 to 31999
2 DB1200.DBW4006 Source Location 1 to 31999

Number
3 DB1200.DBW4008 Source Magazine 1 to 31999
Number
4 DB1200.DBW4010 Target Location 1 to 31999
Number
5 DB1200.DBW4012 Target Magazine 1 to 32000
Number
Example: Selecting and running an ASUP.
The ASUP has to be created either offline and loaded to the controller or it can be
created directly on the controller. To create on the controller use the following
soft-key sequence
The file will open automatically to allow the program commands to be entered. In this
example a 3 second dwell is used.

Section 2 PI Services.
Notes Editing the user PLC program.
A subroutine should be created in which to write the PLC code to call the ASUP.
Select ASUP1 by putting a value

of 1 into DB1200.DBB4001
Initialise the ASUP by switching

DB1200.DBX4000.0 high.
Start ASUP1 by switching

DB3400.DBX0.0 High.
The ASUP will appear on the ―Automatic‖ machine page and will automatically be
executed. When the ASUP has finished running it will be cleared from the screen, any
program that was present prior to the ASUP running will now re-appear.

Reading Axis Positions
Section 3
Notes
The actual position and distance to go of an axis can be read in the PLC.
The following PLC interface area are reserved for this function.
DB5700- NCK interface PLC [r]

5704
0000 Axis actual value (Real)
0004 Axis distance to go (Real)
DB2600 PLC interface NCK

Request Request
0001 axis axis
distances actual
to go values
Below is an example of how the axis position and distance to go values can be read
into a marker double word. (MD100)
Address for Address for Axis

actual position. distance to go
DB5700.DBX0000 DB5700.DBX0000 1
DB5701.DBX0000 DB5701.DBX0000 2
DB5702.DBX0000 DB5702.DBX0000 3
DB5703.DBX0000 DB5703.DBX0000 4
DB5704.DBX0000 DB5704.DBX0000 5

Section 4 Reading and Writing of NC Data.
Notes
Up to eight variables can be addressed at any one time, the number (0 to 7) is
put in place of the letter ―x‖.
Below:- Interface signals used for the reading and writing of NC data
DB1200 PLC Interface  NCK (Read/write)
Read:0
0000 Start
Write:1
1200 0001 Number of variables to be transferred.
DB120x. PLC Interface  NCK (Read/write)
Variable Index:
1000 1: Tool data; 2: Tool edge Number; 3: Zero offset; 4: Number of axes, 5: R parameter
7: Location type; 8: Location status; 9: Tool number at the location specified
1001 Area Number
1002 Line Index number of NC variable x +1 (Word)
1004 Column index of NC variable x (Word)
1006
1008 Writing data to NC variable
DB1200. NCK Interface  PLC (Read)
Error in Request
2000
job complete
2001
DB120x. Line Index number of NC variable x +1 (Word)
Valid
3000
variable
Access result
3001
0: No error; 1:Illegal access to object; 5: Invalid address; 10: Object does not exist.
3002
3004 Reading data from NCK variable
There are seven types of NC variable that can be read/written. These are
described in the following tables.

Reading and Writing of NC Data. Section 4
Type 1: CuttEdgeParam– The cutting edge value of a tool can be read/ Notes
written. For the number of cutting edge parameters in use (Up to 25) use the
Type 2.
Cutting Edge Parameter (Read/write)
DB120x.DBB1000 1
DB120x.DBB1001 —
DB120x.DBW1002 (Cut. Edge No -1) * No cutting edge params. + Param. No (Word)
DB120x.DBW1004
DB120x.DBD1008 Write: Data to NCK variable x (Real number)
DB120x.DBD3004 Read: Data from NCK variable x (Real number)
Type 2:- numCuttEdgeParams (Read) - The number of parameter elements

of a cutting edge. Up to 25 parameters are available.
Number of Cutting Edge Parameters (Read)
DB120x.DBB1000 2
DB120x.DBB1001 —
DB120x.DBW1002 —
DB120x.DBW1004 —
DB120x.DBD1008 —
DB120x.DBW3004 Read: Data from NCK variable x (Word)
Type 3:- linShift - Settable work offsets (Only if MD18601

MM_NUM_GLOBAL_USER_FRAMES > 0
Number of Cutting Edge Parameters (Read)
DB120x .DBB1000 2
DB120x .DBB1001 —
DB120x .DBW1002 Frame index * numMachAxes + AxisNumber
DB120x .DBW1004 —
DB120x .DBD1008 —
DB120x .DBD3004 Read: Data to NCK variable x (Real number)
Valid frame indices for linShift:
0: ACTFRAME =
1: IFRAME = Current settable work offset.
2: PFRAME = Current programmable work offset.
3: EXTFRAME = Current external work offset.
4: TOTFRAME = Current total work offset (ACTFRAME + EXTFRAME).
5: ACTBFRAME = Current total base frame.
6: SETFRAME = Current 1st system frame (PRESET, Scratching).
7: EXTSFRAME = Current 2nd system frame (PRESET, Scratching).
8: PARTFRAME = Current 3rd system frame (TCARR and PAROT with
Orientating tool carrier).
9: TOOLFRAME = Current 4th system frame (TAROT and TOFRAME).
10: MEASFRAME = Result frame for work piece and tool gauging.
11: WPFRAME = Current 5th system frame (Work piece reference points)
12: WPFRAME = Current 6th system frame (Cycles)
The numMachAxes is obtained with the type 4 function.

Notes Type 4:- numMachAxes - The highest existing axis number.
Highest existing axis number (Read)
DB120x .DBB1000 4
DB120x .DBB1001 —
DB120x .DBW1002 —
DB120x .DBW1004 —
DB120x .DBD1008 —
DB120x .DBW3004 Read: Data to NCK variable x (Word)
Type 5:- RPA – R Parameters

R Parameters (Read/write)
DB120x .DBB1000 5
DB120x .DBB1001 —
DB120x .DBW1002 R Number + 1
DB120x .DBW1004 —
DB120x .DBD1008 Write data to NCK variable x (Real number)
DB120x .DBD3004 Read: data from NCK variable x (Real number)
Type 7:- Magazine data-Location data.
>0: Location type for virtual location

=0: ―Match all‖ (Buffer)
9999: Undefined (No virtual location)
Location type ($TC_MPP2) (Read)
DB120x .DBB1000 7
DB120x .DBB1001 —
DB120x .DBW1002 Location number
DB120x .DBW1004 Magazine number
DB120x .DBD1008
DB120x .DBW3004 Read: Data from NCK variable x (Word)

Reading and Writing of NC Data. Section 4
Type 8:- Location status Notes
DB120x .DBB1000 8
DB120x .DBB1001 —
DB120x .DBD1008
Below:- Meaning of the results in location status VW120x 3004
1. Disabled
2. Unassigned
4. Reserved for tool in buffer
8. Reserved for tool to be loaded
16. Assigned to the left half location
32. Assigned to the right half location
64. Assigned to the upper half location
128. Assigned to the lower half location
Type 9:- Tool number.

DB120x .DBB1000 9
DB120x .DBB1001 —
DB120x .DBD1008

Notes The following example shows how data is transferred to and from an R
parameter
Selection of the read or write to/from NC variable option.

1 = Write, 0 = Read.
1 = Start signal. Needs to be reset to zero on completion.
Selection of the number of

variables to be transferred.
(In this case only one)
Up to eight can be transferred
in the same operation
Selection of the type of

variable to be transferred.
(R Parameter = 5)
Selection of the variable

number + 1
(R parameter 10 + 1 = 11)
1 = Request complete signal.
1 = Error signal.
1 = Variable is valid signal.
For the example it is better to have a value other than zero in the
selected R parameter. To locate the R Parameter screen use the following
key selection:

Reading and Writing of NC Data.
Section 4
R parameter 10 is used in the example, Cursor to R10 and enter a value, Notes
confirm with the ―Input‖ key. Example R10 = 99
When the start signal is set to high, the value in R10 will be transferred to
DB1200.DBD3004
Below: Status of target variable prior to the start signal.
Start signal = 1
Request complete signal = 1
Error signal = 0
Variable valid signal = 1
The value from R10 will now appear in DB1200.DBD3004. This value remains
there only as long as the start signal is present.

Notes To write data to the NC variable it is necessary to first enter a value in the
area reserved for this function. This area is DB120x.DBD1008.
The network below shows how this can be done
The same network when viewed in Program Status.
Value of 25 placed in
DB1200.DBD1008
Confirmation that 25 has been entered into DB1200.DBD1008:
It must be ensured that the ―Read/write‖ signal is set to 1
Read/write signal = 1
Start signal = 1
The value from DB1200.DBD1008 will now appear in R10. This value remains
there when the start signal is removed.

Data Exchange Between NC and PLC.
Section 5
The 828D controller has a 512 byte memory area for use with data exchange Notes
between the NC and PLC.
The memory available is from DB4900.DBB0 to DB4900.DBB511, allowing

data to be exchanged directly between the user PLC and for example a part
program.
It is possible to use Byte, Word, Double Word and floating point numbers to
be used as shown below:
$A_DBB[n] Byte format

$A_DBW[n] Word format
$A_DBD[n] Double Word format
$A_DBR[n] Real number
[n] should be substituted for the byte number.
To test the function, the value stored in R10 will be written into $A_DBB[4]
(The 4th byte of DB4900, i.e. DB4900.DBB4
The following program code has to be typed into the MDA area of the
Controller: $A_DBR[4]=R10
When the cycle start button is pressed the value be copied from
R10 to the destination variable.
This can be checked in the Chart Status of the PLC828 programming tool:
To read data the other way is a similar operation. In the MDA area type the
line: R11=$A_DBR[4]
This will copy the contents of $A_DBR[4] into R11

Section 5 Data Exchange Between NC and PLC.
Notes
This can be checked in the R parameter area of the controller:
Notes:
1. The data structure in the data area is defined by the user.
2. Data reading by the NC can activate a pre-read stop (Internal STOPRE)
3. A maximum of 3 sets of data can be written by the NC in the same
program block

B058
PLC Onboard Diagnostics
1 Brief description
Module Objective:-
Upon completion of this module you will be able to use the 828D PLC onboard diagnostics.
Module description:
The 828D controller has on board PLC diagnostic capabilities to aid the user with the fault finding
process. It is possible to check the status of inputs, outputs etc, there is also a ladder editor which
allows minor changes to be made to the PLC.
This module shows how to locate and the diagnostic screens and how to use the ladder editor.
Sinumerik 828D
B058
Contents:- B058
Section 2
PLC Diagnostics
Page 3
Section 3
Interrupt Routines
Page 23

PLC Diagnostics
Section 2
To locate the PLC status screen use the following soft key sequence. Notes
By default the first page displayed is the “PLC-CPU” screen contains information re-
garding the PLC project and cycle time information.
Operating Status-See
Name: Taken from the PLC828D
project name.
Last Changed: Last time the
Version Information: Supplied by
Cycle Time: The cycle time of
Processing Time: The time taken
The processing time information display can be reset by the

“Reset pro. time” soft key
Operating Status:
The operating status can be in Run or Stop mode, this is indicated by in two places at
the top of the screen. It is possible to change the operating state via soft-keys.
After certain procedures the PLC may be left in STOP mode and require manually
starting. It my also be necessary to stop and start the PLC to clear PLC related faults.
PLC Run:-
PLC Stop:-
Later in the module there is detailed example of how to diagnose a problem with the
user PLC programme.
NC/PLC Status
The status of the operands/variables used within the PLC program can be checked via
the “PLC Status” soft key.

Section 2
PLC Diagnostics
Notes Address Formats:-
Before covering the PLC status in detail it is useful to know the permissible address
Formats:-
Bit- This refers to a single element of logic e.g. I6.0, Q5.5, M100.6, V38040002.1
The Bit part is the number after the decimal point. The value of a bit is either 1 or 0
Byte– A Byte is a collection of 8 bits of logic in the same group. e.g.

Input Byte 6 (IB6) contains the bits I6.0, I6.1, I6.2, I6.3, I6.4, I6.5, I6.6, I6,7.
When working with bytes it must be remembered that the numbering counts up from
the left as shown below.
IB6
Bit no 7 6 5 4 3 2 1 0
Value 1 0 1 0 0 1 0 1
In this example I6.1, I6.2, I6.5 & I6.7 are equal to 1. Another term for being equal to 1
is that these bits are High
The bits equal to 0 are termed as being Low
Output Bytes (QB), Marker Bytes (MB) and Variable Bytes can also be used in the
same way.
Word– A Word is a collection of 16 bits of logic which encompasses two

consecutive Bytes.
A Word can only be addressed as 0 or an even number, (IW0, IW2, IW4, etc) odd
numbers are not
allowed.
As with the Byte format the numbering starts from the right
Example IW6
IB7 IB6
Bit no 7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0
Value 1 0 1 0 0 1 0 1 0 1 1 1 0 0 1 1
In this example I6.1, I6.1, I6.4, I6.5, I6.6, I7.1, I7.2, I7.5, I7.7. are equal to 1.Output
Words (QW), Marker Words (MB) and Variable Words can also be used in the
same way.
Double Word– A Double Word is a collection of 32 bits of logic which encompasses
two consecutive Words (Four consecutive Bytes).
A Double Word can only be addressed as 0 or an even number which is a multiple of

four, (ID0, ID4, ID8, ID12 etc) odd numbers are not allowed.
Example ID6
IB9 IB8 IB7 IB6
Bit no 7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0
Value 1 0 1 0 0 1 0 1 0 1 1 1 0 0 1 1 1 0 1 0 0 1 0 1 0 1 1 1 0 0 1 1
Output Words (QD), Marker Words (MD) and Variable Words (VD) can also be used
in the same way.
Data Blocks (DB’s):-
System Data Blocks are used for interfacing between different areas of the controller
and the User PLC Module B034 describes this in more detail.
The user can also create Data Blocks.
Data Blocks can be written in different formats.
DB3804.DBX0.0 is the same as writing V38040000.0

DB3801.DBX1000.7 is the same as writing V38001000.7
DB3801.DBB1000 is the same as writing VB38011000
DB3804.DBW0 is the same as writing VW38040000
DB3804.DBD0 is the same as writing VD38040000

Section 2
PLC Diagnostics
The operands are typed into the left hand column. They can be viewed in different Notes
formats. The format is changed by using the cursor key to highlight the letter in the
“Format” column and then toggling with the “Select” key
B = Binary
D = Decimal
H = Hexadecimal
F = Floating point number (Only for Double Words)
By using the “Operand +” and ”Operand -” soft keys it is possible to quickly locate a
different operand in a similar range.
The “Delete” soft key will delete all entries on the list
Individual entries can be edited/deleted by using the Insert, Delete and Cursor keys
found on the keyboard
For test purposes it may be necessary to manually change (Force) an operand. This is
achieved with the “Change” soft key
The operand in question has to be highlighted and the new value entered and
confirmed with the “OK” soft key
Changing M8.0 from 0 to 1

Section 2 PLC Diagnostics
Notes The marker M8.0 should now be one.
It is useful to have this function in the commissioning stages. Sometimes after data
loss, it may also be necessary to enter values into Data Blocks using this method. This
depends upon the machine manufacturer. Caution should be taken when attempting
to manually enter data as unwanted movements may occur.
It is not possible to force operands which are being addressed by the PLC program.
The values stored in counters and timers can also be viewed. This is best done in
decimal format.
By selecting the “Display comments” soft-key it is possible to add comments to

identify the function of each operand.
Confirm the entries with the “Input” key.
Insert Variable.
The “Insert Variable” soft-key opens a list system variables which can be directly
selected for monitoring.

PLC Diagnostics
Section 2
The default screen shows all available variables. To find a particular variable the Notes
“Filter/Search” function is available
Filter:
The Filter is available to narrow down the number of variables on display. Cursor to
the filter tab, the list is revealed by selecting the “Insert” key
Confirm the filter selection with the “Input” key
Search:
Ensure the “Search” tab is highlighted and type all or part of the variable name. The
search is automatic and as soon as the first letter is entered the search will begin.
When the desired variable is found and highlighted, select the “OK” soft-key. The
variable will then appear in the NC/PLC Status List.

Notes In the example shown the first axis is displayed by default, this is seen determined by
the values within the square brackets.
[U1,1]
1 is for the 1st NC axis

2 “ “ “ 2nd “ “
3 “ “ “ 3rd “ “ etc, etc.
By selecting the “Operand +” & “Operand -” soft keys the variable can be change to
view different axes.
Further information about the variable can be displayed by selecting the “Display
Comments” and “Details” soft-key.
Further functions are available when the following soft-key is pressed:
Save Screen: The list of operands that have been typed can be saved to a file.

PLC Diagnostics
Section 2
Notes
Type a suitable name for the file.
Confirmation of the file save is displayed above the horizontal soft-keys for several
seconds.
Load Mask: Previously saved files can be loaded using this function.

Notes A further method of checking the status of operands is via the “Status list” soft key.
A default list of operands is shown. The “Set address” soft key allows this list to be
configured.
The value entered in box will become the first number at the top of the list. Each of
the three columns can be changed this way . Navigation between the columns is done
with the cursor keys.

PLC Diagnostics Section 2
Notes
The operands can also be forced as explained previously

on page 5.
The PLC program can be seen by selecting the “Window 1 OB1” soft key.
This opens up OB1 of the user PLC. The status of the PLC is shown by selecting
“Program stat. ON” soft key. The operands which are true are highlighted in blue. It is
recommended that the status be switched when not in use to free more resources for
the system. The program status mode is indicated at the top of the screen:-

Notes “Window 2 SBR0” is a second soft key for looking at the ladder diagram. This will
open subroutine 0 by default.
Both these soft keys can be changed to open up different blocks within the program.
A list of available blocks is displayed, by

highlighting a block and pressing the “Open”
soft key the selected block will be opened.
The text of the soft key will now display the
selected block.
The displayed block can be switched between “Absolute address” to “Symbolic

address” via soft keys.
By selecting the “Symbolic” option, the operands will be displayed with letter notation
taken from the symbols table.
The “Absolute” selection will display numerical notation.
Example:-Network 2 of SBR2 shown in absolute format.

Example:-Network 2 of SBR2 shown in Symbolic format. Notes
The cursor keys can be used to position the orange box around an operand. This
allows further information about the operand. In some cases the full variable number is
not displayed, by pressing the “Select” key this information is displayed.
Further information can be displayed if the “Input” key is pressed
Default display
Display after “Select” key is pressed.
Display after “Input”

key is pressed.
The display can be magnified via the “Zoom +” and “Zoom -” soft keys.
Example:-The display at
minimum magnification.

Notes
Example:-The display at
maximum magnification.
The search function allows operands etc to be located easily in the program.
By pressing the select key it is possible to choose between “Find operand”, “Go to” or
“Find subroutine command” instructions. Use the cursor keys to highlight the option
required.
The “Select” key is used to expand the menu and reveal the choices which are con-
firmed by the “Enter” key
After typing in the search target it is possible to choose between “Find all”, “Search
downwards” or “Search upwards”
It is also possible to search in the current program block or all program blocks.
When the search parameters are correct the “OK” key is selected to start the search.

After a successful search the target will be highlighted by an orange rectangle. Notes
To search for further occurrences of the target the “Continue search”

soft key is available.
When all occurrences have been found a message will be
displayed above the horizontal soft keys
The “Go to” option is used for searching for a network within the open program block
The “Find subroutine command” option is used for searching for a specific instruction
within the program.
Refer to the previous pages for examples of

search options.

Notes Symbol Info.
The symbol information for a network can be viewed by selecting the network
followed by the “Symbol info” soft key
A table will appear containing the symbol information for that particular network.
Due to space restrictions some operand names may be truncated. To view the
operand in full, use the cursor keys to select the operand and then the “Select” key
display.
The information boxes are cleared with the “Back” Soft key.
Symbol table.
The “Symbol table” soft key allows different symbol tables to be selected, the tables
can also be edited here.

PLC Diagnostics
Section 2
Notes
The “Edit” softkey allows the table to be changed.
Extra lines can be added.
Unwanted lines can be deleted.
Confirmation of the changes is with the “OK” soft-key.
A combination of these soft-keys and the “Insert” key is used to edit the
symbol table
Saving the changes.
The changes now need to be loaded into the CPU:-
The changes can be saved while the PLC is in RUN or STOP. A warning message is
displayed. Loading in RUN can be dangerous and damaging and should be carried out
by trained personnel
Make the choice between “Loading in STOP” or “Loading in RUN”

Notes A dialogue box is displayed momentarily and the PLC operating status is now in STOP.
When the dialogue box clears the PLC has to be placed in RUN.
After approximately 30 seconds the Operating Status of the PLC should change to run
The new entry should be visible when the symbol table is viewed.

PLC Diagnostics
Section 2
Different symbol tables can be selected via the “Select sym. table” soft-key Notes
The ere are two types of symbol table available, the system symbol tables are not
available for editing. these are named “SYS_SYM0”,” SYS_SYM1” etc.
The “USER_SYM0”,”SYS_SYM1” tables etc, are for the user and can be created &
edited.
To insert a new symbol table select the “Insert symbol table” soft-key. A name for the
table needs to be entered and confirmed with the “OK” soft-key.
The “Delete” soft-key” is used to remove any unwanted symbol tables. The table is
deleted immediately the soft-key is pressed, no confirmation dialogue box is shown.
To rename the symbol table use the “Change symbol table” soft-key.

Section 2
PLC Diagnostics
Notes On tables with a large number of entries it is possible to use the search function.
The cursor and select keys are used to populate the search dialogue box as described
previously in the module.
Cross Reference.
The “Cross ref.” function allows the user to see what operands are in use and in which
blocks they are used.
Operands can be located with the “Search” function or the cursor keys.

Section 2
PLC Diagnostics
If the search target appears in the cross reference list more than once, use the Notes
“Continue search” option.
When the correct place is located cancel the search function and open the program
block via the
“Open in window 1” or “Open in window 2” soft-keys
OR
OR
The cross reference list can be displayed with symbolic or absolute addresses.
The default is set to absolute as shown on the previous page.
When the “Symbolic addresses soft key is selected a text description of the operand
is displayed as seen below. This text description is taken from the symbols table. If no
symbol has been written for a particular operand the absolute address remains.
PLC in stop.
If the PLC goes into stop mode further information is available on the diagnostics
screen. To locate the diagnostics screen, use the following soft-key sequence.
Several alarms will occur, some are as a result of the PLC going into stop. The
important alarm is the one that indicates the cause of the PLC going into stop In this
case it is alarm “400010 Arithmetic error in user program: Type 1 SBR3 network 1”
This tells us that we need to examine network 1 of SBR3 (Subroutine number 3)

Section 2
PLC Diagnostics
Notes When SBR3 is opened and network 1 examined it can be seen that the “Dived”
operation is attempting to divide 200 by 0, this is not permitted and so the PLC is put
into stop mode.
The program needs to be corrected and then loaded to the controller.

Section 3
Interrupt Routines
While it is not possible to edit the PLC program on the controller, there is the Notes
possibility of influencing the PLC program by using Interrupt Blocks 100 & 101
(INT_100 & INT_101)
The S7-200 PLC works cyclically, at the beginning of the scan the status of the inputs
is copied to the Process Image Table (Inputs).
This is then applied to the user PLC logic.
The Subroutines are processed in the order they appear in OB1.
This means that for example, an output set early in the scan might be reset later in the
scan. It is the command that appears later in the scan that takes precedent.
When the scan is complete the results are transferred to the Process Image Table
(Outputs) which is then physically output to the machine periphery devices.
The diagram below shows the position of the Interrupt Blocks INT_100 and INT_101.
Their position enables them to be used to influence the state of the inputs and outputs
without making changes to the main user programme.
Beginning
of
Scan
At the beginning of the scan, the status of

Process Image Table (Inputs) the inputs is transferred to the Process
Image Table

Interrupt INT_100 influence the Process Image Table (Inputs)
Main Routine OB1

Subroutine
Subroutine
Subroutines are processed

in the order they appear in
Subroutine OB1
Subroutine
Subroutine

Interrupt INT_101 Influence the Process Image Table
(Outputs)
At the end of the scan, the status of the

Process Image Table (Outputs) outputs is transferred to the Process Image
Table
End
of
Scan

Section 3
Interrupt Routines
Notes To use the interrupt blocks they must exist in the user PLC program. to check
their existence use the following soft-keys:-
OR
The above list shows that the blocks are not loaded. To load the blocks select
the “Add” soft-key.
The option to add interrupt block INT100 is given. Details can be added to
identify the author and indicate the purpose of the block. Use the “OK” soft-key
to complete the action.
The interrupt should now appear in the list.

Section 3
Interrupt Routines
To add interrupt INT101 the same procedure is followed. Notes
Use the mouse to reveal the list under the „Number of interrupt program” heading.
Select the number “101” with the mouse and press the “OK” soft-key.
The interrupt should now be shown in the “Program block” list.
To open a block first highlight it and then select the “Open” soft-key.

Section 3
Interrupt Routines
Notes The selected block will open in readiness for editing.
Select the “Edit” soft-key.
A number of choices are available:-
OR
For inserting or deleting networks.

Insert:- A network is added after the network that is highlighted.
Deleting:- The highlighted network is deleted.
Networks are automatically re-numbered.
To add logic to the block the “Line” in the network has to be highlighted and the
“Insert operation” soft-key selected.
A choice of a Normally Closed or Normally Open operation is available. (Revealed

by the “Select” key)
For this example a normally open operation is to be used.
Confirm this with the “OK” soft-key.

Section 3
Interrupt Routines
The operation now appears in the network Notes
The “Operand” soft-key should be pressed to assign the operation an operand.
Type the name of the operand in to the box, in this example I6.0 is used.
The value is confirmed with the “Input” key.
To add the next operation the next part of the network should be selected with the
cursor key and the “Insert Operation” soft-key
The available operations are limited to:-

NOT
Positive Edge
Negative Edge
Standard Coil
Set Coil
Reset Coil.
This example is using a standard coil.
The operation should be assigned an operand e.g. I7.0

Section 3
Interrupt Routines
Notes This function can be used in the event of a hardware failure of the periphery
components.
Example:-
I7.0 fails to change state when the +24V signal is applied/removed.
I6.0 is an unused input, remove wire from I7.0 and connect to I6.0
Use the interrupt INT_100 as shown so that I7.0 is the same state as I6.0.
The position of interrupt INT100 in the PLC scan means that the logic contained within
takes precedent over the PII table.
This solution can save time waiting for replacement hardware and unnecessary editing
of the PLC.
Interrupt Routine INT101

Editing of the INT101 interrupt routine is exactly the same as for INT100.
This function can also be used in the event of a hardware failure of the periphery
components.
Example:-
Physical output Q4.0 fails to change state in line with the PLC logic.
Q5.0 is an unused input, remove wire from Q4.0 and connect to Q5.0
Use the interrupt INT_100 as shown so that Q5.0 is always the same state as Q4.0.
The position of interrupt INT101 in the PLC scan means that the logic contained within
takes precedent over the logic in the standard program blocks and writes directly to
the PIQ table.
This solution can save time waiting for replacement hardware and unnecessary editing
of the PLC.
Saving the changes.
The changes now need to be loaded into the CPU:-
The changes can be saved while the PLC is in RUN or STOP. A warning message is
displayed. Loading in RUN can be dangerous and damaging and should be carried out
by trained personnel
Make the choice between “Loading in STOP” or “Loading in RUN”
This is described in more detail on page 17.

B041 Machine and Setting Data
Module Objective:
Upon completion of this module you will be able to locate the different Machine/Setting data areas
and be able to carry out adjustments if required.
Module Description:
Machine & Setting data are used in many ways to influence the operation of a machine.
During commissioning some of the machine data is automatically set while other machine data has to
be set manually.
Over time, as the machine mechanically wears it may be necessary to edit certain machine data such
as compensation values.
This module shows the different machine data areas and other criteria such as how to activate the
machine data.
Sinumerik 828D
B041
Contents. B041
Locating The Data Section 2

Areas. Page 3
Section 3
Data Types. Page 4
Section 4
Data Identifiers Page 5
Editing Machine & Section 5

Setting Data Page 6

Locating the data areas. Section 2
To locate the machine data screens first ensure that the relevant access level is Notes
active (Module B021 Protection Levels) then use the following key sequence:-
The display should now show the machine data area with soft-keys available to
switch between the different machine data areas.
The machine data which are available for viewing is dependant on the access/
password level. The above screen is with access level 3 in the General Machine data
area. Below shows the same screen with the access level 1 active.
Note:-
Machine Data is often referred to as “MD”
Setting Data is often referred to as “SD”

Section 3 Machine Data Types
Notes The Machine & Setting Data is separated into different groups.
General MD influences the whole system.
Channel MD influences that particular channel.
Axis MD influences the axes.
User views allows a customised list of machine data to be made.
Control Unit MD influences Drive control unit.
Drive MD influences the drives
For further data the “Menu Extension” key must be selected. This allows access to
the Setting Data and also the Display Machine Data.
General SD influences the whole system.
Channel SD influences that particular channel.
Axis SD influences the axes.
Display MD mainly influences appearance.

Data Identifiers
Section 4
The name of the machine/setting data can be viewed in system code or plain text Notes
(See section 5).
In system code the machine/setting data contains special identifiers which help the
system recognise the individual data elements.
Example: $MM_MD_TEXT_SWITCH can be identified as a Display Machine Data by
applying the information below.
1st character
$ = System variable
2nd character
M = Machine data S = Setting data
3rd character
M = Display Machine Data
N = General Machine Data / Setting data
C = Channel Machine Data / Setting data
A = Axis Machine Data / Setting Data
D = Drive Machine Data
Some machine datas have “Indexes”. This is where the machine data number is
repeated but with a different number in square brackets (Index). The index can have
additional functions depending upon the machine data in question.
Examples:-
30240[0] $MA_ENC_TYPE = The type of encoder connected to the 1st measuring
system input.
30240[1] $MA_ENC_TYPE = The type of encoder connected to the 2nd measuring
system input.
32200[0] to 32200[5] $MA_POS_CTRL_GAIN.

Six different values can be input. The required index is selected via PLC interface
signals DB380x.DBX4001 bit 0, 1 & 2.
This is used, for example, on a spindle with gear stages. The mechanics of each gear
range will be different and as such each gear range will require different gain values.

Section 5 Editing Machine & Setting Data
Notes Editing of any type of data should only be undertaken by experienced personnel and
in conjunction with the machine manufacturer.
For a detailed description of each machine/setting data refer to the “Lists” manual
found on “DoconDVD”
The correct machine data should first be located. This is done by either using the
page/cursor keys or the search function.
The search function is activated with the “Search” soft key. If the Machine Data
number is known this can be typed into the dialogue box. It is also possible to enter
part or all of the MD name in text format.
When the correct MD has been found, a value can be entered. In this example we
are going to change Display MD 9900 from 0 to 1. This will change the MD/SD
description from system language to plain text.

Editing Machine & Setting Data
Section 5
The correct machine data has to be highlighted. The number 1 is entered and Notes
confirmed with the “Input” key.
On pressing the “Input” key the text of the machine data changes immediately (See
below)
The activation of the MD & SD varies depending on the type of data being altered.
Some data is active as soon as it is entered while some require a system power off/
on. The text in the column to the right of the data value indicates when the data is
activated.
Data Activation:-
im = Active on selection of the “Input” key. (Immediate)
re = Active on selection of the “Reset” key.
cf = Active on selection of “Set MD active (cf)” soft key
po = Active on control power off/on or “Reset (po)” soft key
REMEMBER:- Create a data backup!!!!!

Section 5
Notes A filter option is available so that certain machine data can be masked out.
Soft-keys are available for selecting or de-selecting all filter options

B068 Start-up Sequence-Commissioning
1 Brief description
Module Objective:
Upon completion of this module you will be able to commission the 828D controller in the
configuration of a milling machine with a main spindle and four axes.
Module Description:
To ensure the stability of the system it is necessary to commission the controller in a particular
sequence.
Each controller is supplied with a software toolbox DVD containing the necessary software for
carrying out the commissioning sequence.
This sequence is described in the module which takes the form of a running example.
Sinumerik 828D
B068
Contents:- B068
Hardware/Software Section 2
Requirements Page 3
Section 3
Preparing the Controller
Page 4
Section 4
Connecting to the controller
Page 8
Configuring the Machine Control Section 5

Panel and Periphery Devices Page 10
Drive Configuration Section 6

(Start-up Tool) Page 11
Section 7
Axis Enables
Page 23
Section 2
Additional Axis Page 24

Hardware/Software Requirements Section 2
Certain software tools and a PG/PC are required in order to carry out the Notes
commissioning.
The software tools are obtained fro the Toolbox CD which is delivered with each con-
troller. The installation of the toolbox is described in Module B002.
Before commissioning a machine it is essential to check that the hardware has been
installed to the required specification. These specifications are found in Module B006
The commissioning is undertaken via an ethernet connection, a suitable cable is

required for this connection, this cable should be the crossover type unless the PG/
PC has an ethernet interface capable of auto sensing the connections.
The PG/PC should also be free of any restrictions imposed on the ethernet
connection.
The Start-up sequence is a series of steps designed to get the machine to a position
where the control, drives, periphery devices are all functioning.
More work will be required such as a finished user PLC program, drive optimisation
etc before the machine is fully operational
 Step 1 Preparation of the controller-Loading standard data.
 Step 2 PLC part 1-Configuring the MCP and Periphery Devices.
 Step 3 Drive Configuration-Firmware Update/Topology Recognition
 Step 4 Assignment of Direct Measuring System
 Step 5 PLC part 2-Axis Enables

Section 3 Preparing the Controller.
Notes The controller should be loaded with default data to clear any corruption which may
have occurred.
In order to load the default data the Setup menu has to be selected during boot up.
Apply power to the controller and wait until the screen below is displayed. Promptly
press the indicated soft-keys in the numerical order shown.
1 2
The setup menu will be displayed. Cursor to the “Factory settings” option and press
the “Input” key.
Confirm that this is the procedure to be carried out by selecting the “Yes” option.

Preparing the Controller. Section 3
Allow the controller to fully boot, this can take about five minutes. The green LED at Notes
the front of the controller will be lit continually to confirm this.
When the process is complete messages are displayed indicating that the controller
has been loaded with standard data.
It is possible that the system is not in the desired language, if this is the case the
language is easily changed.
Setting of the password is now necessary to enable machine data etc to be viewed
and altered.

Section 3 Preparing the Controller.
Notes The password to be typed in is “SUNRISE”, followed by “OK” soft-key.
The system password will now be set to manufacturer level as

displayed just above the horizontal soft-keys.
More information about passwords is available in Module B021.
Alarm number 120402 can be acknowledged with the “Alarm Cancel” key.
The configuration of the machine at present is a milling machine with a main spindle
and 3 axes (X, Y & Z). The 4th axis (A) needs to be added by changing machine
data. For further information about machine data please refer to Module B041
To activate the extra axis iensure that the option is available and activated. This is
checked in the licensing area of the controller as explained in
Module B044.
To check/activate the licence use the key sequence:-
In this example the possibility is available to set up to two extra axes. Only one is
required so enter a value of 1 in the “Set” column.
The control should be allowed to fully boot (green LED)
The machine data now has to be changed.
Locate the Machine Data area:-

Preparing the Controller. Section 3
The NC at present is only set for four axes/spindles. To activate an extra axis a value Notes
of 5 needs to be entered in Machine Data 20070[4]
An NCK reset is required to activate the machines data.
It is possible to make all the previous changes and activate with one NCK reset. It
makes more sense to follow a certain procedure and not make too many changes at
once.

Section 4 Connecting to the Controller
Notes Service port X127 is easily accessible on the front of the control beneath the hinged
cover.
The default address for this port is 192.168.215.1.
The port is also a DHCP server and automatically issues IP addresses in the range
192.168.215.2 to 192.168.215.9
Ethernet DHCP server port. Default

X127 address-192.168.215.1
RDY
NC LED status indicators, see table below.
CF
USB port for keyboard and memory
X125 devices.
Compact Flash port for customer data

X145 storage and service/commissioning
The external PG/PC may need to be adjusted in order to make a connection.

In the properties area of the Ethernet connection use the “Obtain an IP address
automatically” option

Configuring the Machine Control Panel/Periphery Devices Section 5
The machine control panel is connected via the Profinet network. The signals are Notes
transferred to the control via the user PLC program/interface.
In order to assist service personnel in the event of machine
breakdowns it is better to use direct addressing for the signals to and from the MCP.
The PLC programming tool PLC828 is used for writing the PLC program, this is
explained in greater detail in Modules B026.
Information about the User Interface can be found in Module B034.
Each piece of hardware connected to the Profinet network is identified by the setting
of switches. These switches give the hardware an IP address which corresponds to
General Machine Data 12986.
Item Address Machine Data Start Address (I/O)
PP72/48 No1 - 192.168.214.9 12986[0] 0

MCP - 192.168.214.64 12986[6] 112
Below:- default setting for MD12986
The hardware is activated by entering a value of –1 in the relevant machine data.
The machine datum are activated with a NCK power off.

Section 5 Configuring the Machine Control Panel/Periphery Devices
Notes A basic PLC program can now be loaded/created The minimum requirement at this
stage is to write the logic for the MCP to the User Interface.
Below:-Example of the key-switch interface.
Before uploading the programme a connection between the PC/PG and the controller
has to be made.
The MCP should be tested to ensure it has been correctly interfaced.

Drive configuration (Start-up Tool) Section 6
The drives are configured externally with the HMI Advanced Start-up Tool. Notes
This communicates via the service port X127.
The network settings are setup using the “NC connect Wizard”
A “SINUMERIK 840D” folder is created on the desktop, this folder contains the NC
Connect wizard shortcut.
Select the 828D option followed by the “Next” button.
Select the “Engineering Tools” option followed by the “Next” button.

Section 6 Drive configuration (Start-up Tool)
Notes Connection/cabling information is provided, a crossover or straight cable can be used
depending upon the network adapter of the PG/PC.
X127 has a fixed address of 192.168.215.1. Type this into the IP address area if
necessary.
The connection setting can be saved with a suitable name, do not change any other
settings. Select “Finish” to complete the task.
Ensure the correct ethernet cable is connected to the correct sockets. Run the Start-
up tool via the “Start-Up Tool” shortcut.

Allow the software to boot. The only message should be number 120402, which tells Notes
us that the CU requires commissioning. If the firmware version is not correct the
controller will carry out an automatic update. A dialogue box will be displayed if this is
the case. When the dialogue box clears, the whole system, control and drives must
be powered off/on.
The procedure can then be continued.

Notes
On completion of the NCK power on reset, the Start-up Tool will display an alarm
This can be cleared in the “Diagnosis” Area with the “Acknowledge HMI Alarm” soft-
key.
The servos that were recognised during the configuration can be seen in the start up
area of the controller.
In certain situations it is not possible for the topology to assign components correctly.
In this situation the assignment has to be done manually. The following
example is necessary because the Spindle Direct Measuring System (DMS) is
connected into another axis (A axis). The system needs to be configured so that it
associates this encoder with the spindle.
To continue select the “Drives” soft-key
Use the “Drive +” / “Drive -” soft-keys to locate the drive which has been incorrectly
assigned the DMS.
The drive required in this case is servo 6. The “Identify via LED” function can be used
to aid the identification of the correct module.

Notes
By paging down to the bottom it can be seen that this drive does in fact have two
encoders assigned to it.
To re-assign this encoder use the following sequence:-
Press the “Next” soft-key until the following screen is displayed.

Notes The page should show the two encoders assigned to the axis.
Use the mouse to deselect the encoder.
Continue with the following sequence, a series of dialogue boxes will be temporarily
displayed.
Press the “Next” soft-key until the following message box appears.
As the configuration process is not finished select “No” to the dialogue box.

The second encoder now needs to be assigned to the correct axis. Notes
In this case it is servo two.
Paging to the bottom shows that only one encoder is assigned to this axis at the
moment.
A similar procedure is carried out to assign the encoder to the correct axis.

Notes Press the “Next” soft-key until the following message box appears.
Use the cursor/select keys or mouse to select the second encoder check box and to
highlight the correct encoder from the list. Two encoders are available, one is already
assigned to encoder one so the spare one should be highlighted and confirmed with
the “Input” key followed by the sequence of soft-key presses.
When the above information box has closed select the “Next” soft-key

Section 6
Drive configuration (Start-up Tool)
The details of the encoder have to be manually entered. Notes
In this case the encoder is a rotary, incremental Sine/Cosine with 1024 pulses per
revolution.
The encoder position actual value needs to be inverted due to the mounting method
on the spindle motor.

Notes The encoder position actual value needs to be inverted due to the mounting method
on the spindle motor.
Press the “Next” soft-key until the following message box appears.
The reassignment of the encoder is completed when the system is restarted.

The drives now have to be assigned to the correct NC axis. Notes
As can be seen below the drive objects have no axes assigned to them.
Assignment is carried with the following sequence:-
Select the drive to be assigned.
Use the cursor/select keys to highlight the correct axis for the selected motor and
confirm with the “Input” key.

Notes The same selection is automatically entered into the other fields. It is not necessary to
change these on a standard installation. Confirm the selection by pressing the
“Accept” key.
If more axes are to be assigned select “No, otherwise select “Yes”
Select the next drive to be assigned and continue as previously.
The assigned axes should be as seen below

Axis Enables Section 7
The motors should only be allowed to rotate when the conditions are safe to do so. Notes
Interface signals are provided to allow the user to inhibit movement of the axis in an
unsafe condition.
In the case of the simulator the onboard switches are used to signal to the interface
that the conditions to run are OK .
Obviously more thought should be given to the conditions for release when working
with an actual machine.
The system must also be told which measuring system is in use. In the case of the
spindle this the 2nd measuring system.
More detailed information about the interface signals can be found in Module B034.
Below is a method used to enable the X axis via inputs straight to the Interface
signals.
This particular training equipment also requires output Q4.0 to be set to enable the
“OFF3” enable signal.
Enable signals explanation:-

DB380x.DBX2.1 - Controller enable
DB380x.DB4001.7 - Pulse enable
DB380x.DB1.5 - Activate 1st measuring circuit
DB380x.DB1.6 - Activate 2nd measuring circuit
The letter x is the axis identifier and has to be substituted for a valid axis number.
0 = 1st axis
1 = 2nd axis
2 = 3rd axis
3 = 4th axis
etc
etc
The 1st axis is X, this is the 1st NC axis, the other axes follow in the same pattern.
Example:- DB3802.DBX2.1 is the third axis and therefore this will be the
controller enable for the Z axis.
Once the signals for the axes are complete the changes can be downloaded to the
controller.
The switches should be activated and the motors tested in jog mode.
CHANNEL MD
20700 =0 NC start possible without referencing (Not recommended on actual
machines)

Section 8 Additional Axis.
Notes A common requirement is for an extra axis to be added. This requirement is not
always apparent until the point of sale or even later.
A machine can be initially commissioned to include all axis possibilities. The optional
axes can then be deactivated until required.
Using the Easy Extend function (Module B009), an axis can be quickly activated
when the requirement arises.
An example of how axis number five is activated/deactivated is shown below :-
<AGM>
<OPTION_MD name = "$MN_USER_DATA_INT[0]" />
<DEVICE>
<list_id>1</list_id>
<name> "Activate axis 5" </name>
<SET_ACTIVE>
<data name = "drive/dc/p105[DO5]">1</data>
<data name = "$MC_AXCONF_MACHAX_USED[4]">5</data>
<control_reset resetnc=“true” />
</SET_ACTIVE>
<SET_INACTIVE>
<data name = "$MC_AXCONF_MACHAX_USED[4]">0</data>
</SET_INACTIVE>
</DEVICE>
</AGM>
As can be seen in the example XML file, the drive parameter-“P105 Activate/
deactivate drive object” is responsible for activating/de-activating the drive part of the
system.
Drive parameter “P971Save drive object parameters” is set to 1 to save the drive
Parameters. When the data has been saved the parameter automatically reverts to a
value of 0.

Additional Axis.
Section 8
Notes
To activate/de-activate the axis in the NC part of the system, channel machine data
“20070 $MC_AXCONF_MACHAX_USED” is used.
An NCK reset is automatically carried out by the following Tag:-

This activates the new value of the changed machine data.
The deactivated axis will no longer appear on the machine page:-
Activated:-
The functionality of additional axis should be carefully tested.

B053 Drive & Axis Diagnostics
1 Brief description
Module Objective:-
Upon completion of his module you will be able to use the controller diagnostic functions to help solve
drive and axis faults.
Module Description:
In the event of a problem with the machine it may be necessary to check the status of an axis/drive.
The information obtained from these screens can be very useful to technical personnel and help
speed up the fault finding process.
Sinumerik 828D
Contents. B053
Service Overview Page 3

Screen Section 2
Axis Diagnostics Section 3

Screen Page 5
Drive Diagnostics Page 6

Screen Section 4

Section 2
Service Overview Screen
To navigate to the relevant diagnostics page please use the following key presses. Notes
The screen should now show the status of various enable/monitoring signals via
indicators.
The indicators change appearance depending on the condition of the signal.
The signal is healthy, in the case of an enable, the signal is high. For a
monitoring signal there is no fault present.
The signal is missing i.e low (Enable signals only)
The signal is indicating a fault (Monitoring signals only)
The signal is inactive/not in use.
Example:-The diagnostics page showing a motor over temperature problem.

Section 2
Service Overview Screen
Notes The displayed axes can be changed to suit personal preferences.
The “Active axes” soft-key will only display axes that are currently
active. Axes disabled via machine data or parked axes will not be
displayed.
The “All axes” soft-key will display any axes that are currently
configured as active or inactive.
The “Selected axis” soft-key allows selected axes to be viewed.

Example below shows how to view axes 1 & 3 only

Axis Diagnostics
Section 3
Axis specific information. Notes
For more detailed information regarding each individual axis select the “Service axis”
soft key
A great deal of information about a particular axis is available. This information is very
useful when a problem occurs on the machine.
Each axis is displayed separately, changing to another axis is done with the “Axis +”
and “Axis -” soft keys.
The selected axis is displayed at the top of the diagnostics screen.
An alternative method of selecting the required axis is via the “Axis selection” soft key.
This the quickest method on a machine with many axes.
Useful information about the axis in question ranging from positional data to current
and torque readings is available.
Further information can be seen by using the page/cursor keys.

Section 4 Drive Diagnostics
Notes Drive specific information.
For more detailed information regarding each individual drive select the “Service drive”
soft key
The drive diagnostics screen shows useful information regarding the motor and drive
states such as motor temperature, DC link voltage etc.
More diagnostics information is revealed by using the

page/cursor keys
Further drive diagnostic information, more specifically Sinamics related, can be found
by selecting the “Drive system” soft key.
The status of the DriveCliq drive objects can be seen.
A healthy drive object, fully enabled ready for operation. Status 0
A drive object with a problem i.e. enable missing. Status 31

Drive Diagnostics
Section 4
A typical page showing that the MSP1 drive has a status of 31. By selecting the Notes
“Details” soft key, more information is displayed.
A typical page showing that the MSP1 drive has a status of 31. By using the cursor
keys and selecting the “Details” soft key, more information is displayed.
For a list of fault numbers and their meaning please consult the following table

Section 4 Drive Diagnostics
Notes
Sinamics Fault Table (r0002)
Parameter Drive Object Value Meaning

r0002 Control Unit 0 Operation
10 Operative
33 Topology fault remedy/acknowledge
35 Carry out initial commissioning
Line Module 0 Operation - release all
32 Ready to switch ON - "ON/OFF1" = "0/1" set (p0840)
44 Switching ON interlock - provide connection EP with

24 V (Hardware)
45 Switching ON interlock - remedy fault condition,
acknowledge malfunction
Motor Module 0 Operation - release all
23 Operative - "Infeed operation" = "1" set (p0864)
31 Ready to switch ON - "ON/OFF1" = "0/1" set (p0840)
43 Switching ON interlock - "BB/AUS3" = "1" set (p0848,

p0849)
45 Switching ON interlock - remedy fault condition,
acknowledge malfunction

B084 Encoder Adjustment
1 Brief description
Module Objective:-
Upon completion of this module you will be able to synchronise/adjust the measuring system for the
Sinumerik 828D controller.
All positioning axes require referencing in order for the controller to position them. The procedures for
the referencing of incremental and absolute encoders is described along with the most important
machine data.
Sinumerik 828D
B084
Content. B084
Referencing Incremental Section2

Encoders Page 3
Referencing Absolute Section 3

Encoders Page 7
Machine Data Section 4

Information Page 9
Section 5
Automatic Referencing Page 10

Section 2
Referencing Incremental Encoders
General Information. Notes
Axes equipped with incremental encoder require referencing each time that the NCK is
powered off/on or reset.
This usually entails traversing the axis to a switch which then initiates the referencing
Procedure. Certain machine data are available to influence this procedure and tailor it
to individual requirements.
Some axes have a second encoder fitted for positioning operations. It needs to be
checked which measuring system is active as that will be the one which requires
referencing.
To check which measuring system is active we must look at the “Axis diagnostics”
area.
Confirmation that the correct axis is selected.
Look for the “Active measuring system” signal. A value of 1 indicates that the 1st
measuring system is active, typically the motor encoder. A value of 2 indicates that the
2nd measuring circuit is active, typically a linear scale.
Some manufacturers may also switch between measuring systems. If there is
uncertainty about this please contact the manufacturer for information.
If it is uncertain whether an axis has an incremental or absolute encoder fitted, this can
be checked via axis machine data 30240.
To check the machine data use the following soft key sequence.

Section 2
Notes The correct axis page must be selected.
Machine data 30240[0] & [1] should be checked depending upon the active measuring
circuit.
If the active measuring circuit is number 1 then machine data 30240[0] is the one to
note. If the active measuring circuit is 2, the machine data 30240[1] should be noted.
Incremental encoders will have a value of 1.
Absolute encoders will have a value of 4.
To reference an axis with an incremental encoder, an interface signal needs to be

switched high in the user PLC program. This is usually done with a switch connected
to the axes. The axis will traverse towards the switch and activate it. This will then
start the reference procedure for that axis.
Example of an axis reference switch input activating a reference point approach

variable.
Variable DB380X.DBX1000.7 “Delay Ref. Pt approach” interface signal needs to be

set to high to initiate the referencing procedure.
Each axis has its own variable which is identified by changing the X for a numerical
value which represents the axis, see below-
1st axis - DB3800.1000.7

2nd axis - DB3801.1000.7
3rd axis - DB3802.1000.7
etc, etc…..

Section 2
Before referencing can be initiated the controller needs to be placed into Reference Notes
Mode by selecting the “REF.POINT” button on the machine control panel. The LED
should Illuminate, the “JOG” mode LED remains illuminated.
Confirmation that the correct mode is selected can be seen at the top of the screen.
Each individual axis can be referenced separately. It is also possible to reference the
axes automatically. This usually set up by the machine builder and will be explained in
more detail later in the module.
To reference an individual axis select the correct axis via the machine control panel.
The axis must now be jogged in the direction of the reference switch. The direction is
set up via machine data. The user PLC should also prevent any movement in the
wrong direction as this would put the machine at risk of a collision.
The axis should now continue towards the reference switch. Some systems require that
the jog direction button is continually depressed throughout the reference cycle, it is
more common to find that the axis will continue to move even when the jog direction
button is released.

Section 2 Referencing Incremental Encoders
Notes Example:- Referencing diagram for incremental encoder
Note:- The example is with machine data

34040 $MA_REFP_VELO_SEARCH_MARKER = 0
34080 $MA_REFP_MOVE_DIST + 34090 $MA_REFP_MOVE_DIST_CORR = > 0
In the event of the values of machine data 34080 & 34090 equalling less than the
stopping distance of the axis, the controller will automatically readjust to the correct
position
Velocity
Reference point cam

switch activated
0 1
MD34020 Ref. point approach velocity
34070 Ref. point position velocity
MD34040 Ref. point search marker velocity
Position
Cam switch 0 1
Axis referenced. Marker pulse detected Reverse direction
The control receives a reference axis command, the axis accelerates to the
feed-rate in machine data 34020 $MA_REFP_VELO_SEARCH_CAM then
searches for the reference switch input to become high.
The reference switch is operated and the axis decelerates.
The axis reverses direction at the feed-rate set in machine data.

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

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

machine data 34070 $MA_REFP_VELO_POS to a position which is the sum
of machine data 34080 $MA_REFP_MOVE_DIST and
34090 $MA_REFP_MOVE_DIST_CORR
Once the axis is referenced the controller issues interface signals.

1st axis - DB3900.DBX0.4 1st measuring circuit is referenced
1st axis - DB3900 DBX0.5 2nd measuring circuit is referenced
2nd axis - DB3901 DBX0.4 1st measuring circuit is referenced
2nd axis - DB3901 DBX0.5 2nd measuring circuit is referenced
etc, etc…..
The position display will indicate the axis is referenced and display any values
stored in machine data 34100 $MA_REFP_SET_POS

Section 3
Referencing Absolute Encoders
General information:- Notes
Absolute encoders need referencing on first commissioning and remain referenced until
a problem occurs with encoder or the NCK. Re loading of an archive will also
necessitate the referencing of the encoder.
Procedure:-
First it must be ascertained that the encoder is of the absolute type. This can be done
checking the motor data rating plate in the case of an integrated motor encoder. Also
checking with the supplier of the encoder might help determine the correct type.
Another method is to check the machine data.
Machine data 30240[0] & [1] should be checked depending upon the active measuring
circuit. (See page 4)
If the active measuring circuit is number 1 then machine data 30240[0] is the one to
note. If the active measuring circuit is 2, the machine data 30240[1] should be noted.
Incremental encoders will have a value of 1.
Absolute encoders will have a value of 4.
The procedure requires that the axis be moved to a know mechanical position e.g.
150mm. Locate machine data 34100 $MA_REFP_SET_POS and enter 150.
Check that machine data 34200 ECN_REFP_MODE is set to 0 This enables the control
to take over the value in machine data 34100 $MA_REFP_SET_POS.
Check that machine data 34210 ENC_REFP_STATE is set to 1. This is to enable
encoder calibration to take place.
Check whether machine data 34010 REFP_CAM_DIR_IS_MINUS is set to 0 OR 1

Section 3 Referencing Absolute Encoders
Notes The axis to be referenced should be moved to the known mechanical position using
“Jog” mode in the direction determined by the value of machine data 34010
REFP_CAM_DIR_IS_MINUS. A value of 0 and the approach will be in the positive
direction, a value of 1 will make the approach negative.
The feed rate when approaching this position should be reduced to avoid inaccuracies
caused by backlash.
Before referencing can be initiated the controller needs to be placed into Reference
Mode by selecting the “REF.POINT” button on the machine control panel. The LED
should Illuminate, the “JOG” mode LED remains illuminated.
Confirmation that the correct mode is selected can be seen at the top of the screen.
Select the axis to be referenced and then press the same

direction key used to position the axis earlier.
The axis will not physically move but the position display will
change to show the axis is referenced symbol and the
reference point set position will be shown as the position of
the axis (150 mm)
Machine data 34210 will have changed to 2 to indicate a
successful procedure.

Section 4
Machine Data Information.
A list and brief description of the most common machine data. Notes
If a machine does not have reference switch cam it is possible to reference from the
zero mark by changing machine data- 34000 $MA_REFP_CAM_IS_ACTIVE (Default
value 1) A value of 0 will deactivate the cam. This is used for example on axes that
have only one reference mark along the entire traversing range and rotary axes that
have only one reference mark per revolution.
The direction that the axis approaches the reference switch can be changed by machine
data- 34010 $MA_REFP_CAM_DIR_IS_MINUS (Default value 0) The default value will
result in the reference point approach in a positive direction. To reverse the direction a
value of 1 has to be entered.
The initial approach speed for referencing is determined by machine data-

34020 $MA_REFP_VELO_SEARCH_CAM (Default value 5000.0 mm/min)
If the axis fails to reach the reference cam it is probably due to machine data-
34030 $MA_REFP_MAX_CAM_DIST (Default value 10000 mm) This is the maximum
distance to the reference cam.
The controller will issue alarm:-20000 Channel %1 axis %2 reference cam not reached.
When the reference switch is activated the axis reverses direction in search of the
reference marker. This search speed is determined by machine data-
34040 $MA_REFP_VELO_SEARCH_MARKER (Default value 300.0 mm/min).
The direction that the reference marker search direction is changed by machine data-
34050 $MA_REFP_SEARCH_MARKER_REVERSE (Default value 0) The default value
cause the axis to search for the reference cam in the opposite direction to the
direction specified in machine data 34010 $MA_REFP_CAM_DIR_IS_MINUS.
Entering a value of 1 in machine data 34050 will reverse the cam search direction.
If the axis fails to reach the reference marker it is probably due to machine data-
34060 $MA_REFP_MAX_MARKER_DIST (Default value 20 mm) This is the maximum
distance the axis can travel without finding the marker..
The controller will issue alarm:-20002 Channel %1 axis %2 zero mark missing.
When the marker is detected the axis will either stop or move to a position determined
by the values of two machine data (34080 & 34090 see below for further explanation)
The speed at which this position sought is determined by machine data-
34070 $MA_REFP_VELO_POS (Default value 10000.0 mm/min).
34080 $MA_REFP_MOVE_DIST (Default value -2.0 mm). Once the marker has been
detected it is advisable to move the axis away from the marker (Into the machining
area). This is achieved by putting a value in machine data 34080.
If the axis was asked to reference again while still on the marker this could result in the
axis going toward the end of the slide.
34090 $MA_REFP_MOVE_DIST_CORR (Default value 0.0 mm) This machine data is

used to accurately set the position and correct discrepancies caused by an encoder
exchange or mechanical work.
The values in machine data 34080 & 34090 are added together to determine how far
the axis moves.
Usually the position display shows zero after an axis has been referenced. This can be
changed by machine data- 34100 $MA_REFP_SET_POS (Default value 0.0 mm)
The value entered in here will be displayed on the screen as soon as referencing is
complete. This is used when the reference position is not the mechanical zero of the
machine. The machine data does not result in the axis physically moving.

Section 5 Automatic Referencing (Incremental Encoders)
Notes Automatic referencing cycle.
To set the automatic referencing function it has to be decided in what order you want
the axes to referencing. It is common for example that on a milling machine the Z
axis needs to be referenced first, this helps eliminate the chance of a collision.
The order is set by axis machine data $MA_REFP_CYCLE_NR (Default 1)
Possible entries:-
0 = no referencing cycle participation.
1 to 15 = allowable range for setting the sequence.
-1 = No reference required for NC/Cycle start-Danger!
Up to five axes can be referenced at the same time.
To initiate the automatic cycle the necessary interface bit has to be set. This is
variable DB3200.DBX1.0 which is channel related.
Example of how the automatic referencing cycle could be initiated.
Interface signal DB3300.DBX1.1 changes to 1 whilst the referencing cycle is active.

B020
Maintenance Planner
1 Brief description
Module Objective:-
Upon completion of this module you will be able to set up maintenance tasks using the Maintenance
Planner function.
The 828D controller has a Maintenance Planner function which allows the user to set up
maintenance tasks. The tasks require an acknowledgement to confirm that the task has been
completed, they are based on timed intervals. Each task has to be parameterised to suit the
individual requirements of that task. This module explains how the tasks are created and parameter-
ised.
Sinumerik 828D
B020
Contents. B020
Enabling The Section 2

Maintenance Manager Page 3
Setting Up The Section 3

Maintenance Tasks Page 5
Section 4
XML Data Files Page 7
Section 5
PLC Interface Signals Page 9
Confirming/Resetting Section 6
Maintenance Tasks Page 10
PLC Programme Section 7

Example Page 12

Enabling The Maintenance Manager
Section 2
In order for the maintenance planner to function the PLC user project must contain Notes
DB9903 and DB9904. These are created with the PLC828 programming tool and then
downloaded to the controller.
The PLC828D software package is explained in more detail in Module B026
To create the Data Blocks first open up the correct project and open the Data Block
folder
In this example the required Data Blocks )

(DB9903 & DB9904) are not present.
The required data block templates can be found

in the Libraries folder.
Transferring them to the Data Block folder is
achieved by double clicking the required
template.
It is possible to change the Data Class of the Data Block and add the name of the
author if needed.
The box is closed by clicking the “OK” key.

Section 2 Enabling The Maintenance Manager
Notes
Save the user project.
Download the Data Blocks to the controller

Setting Up Maintenance Tasks
Section 3
To set up a maintenance task the password level needs to be set to Manufacturer. For Notes
more information about password levels please refer to Module B021.
To locate the maintenance Planner screen use the following key sequence.
Acknowledge the Information box with the ”OK” Soft key.
The maintenance tasks are entered by selecting the “Change”, “Cursor”, “Insert” &
“OK” keys.
Various data has to be entered about the task.

Section 3
Setting Up Maintenance Tasks
Notes Input Field Explanation:- (All time values are in hours)
Maintenance Task:- A brief description of the task

Interval:- Time between maintenance tasks.
1st warning:- Interval at which a pre-warning is issued
Quantity:- Determines the number and interval of pre-warning.
Remaining time:- Indicates the time remaining to the alarm being triggered.
Example:-
In the following example, the interval is 168 hours. The 1st warning will appear after
144 hours and then every 3 hours until the alarm is triggered after 168 hours.
The interval for between the warning is obtained by the following:-
“Interval” minus the “1st warning” divided by the “Quantity”
168 - 144
=3
8
To confirm the data, use the “Input” key, to navigate the dialogue boxes use the cursor
keys. When the data required fields have been entered press the “Enter” key.
The red clock symbol will be replaced with a green tick

Section 4
XML Data file
When a task is created the details are stored in an XML file. This file can be viewed Notes
and edited on the controller or offline.
To reach the file use the following soft-key sequence.
The information entered earlier via the screen can be seen in the text of the file. It is
possible to use an XML editor for creating an offline file. The file should then be placed
in the correct folder.
Below is the “oem_maintenance_data.xml” file containing the data of the example
used in Section 3.

Section 5 PLC Interface Signals
Notes The data entered on the screen is stored in the data blocks created earlier. This can
be seen in the PLC diagnosis area:-
For a maintenance task to have an effect on the controller the interface signals have
to be used in the user PLC program
When a first warning or interval is reached a message must be generated to warn/
advise the operator of any action required.
Data Blocks and variables are available to assist with this.
When values are entered via the HMI they are transferred into DB9903 (Initial Data
Table) The system uses these values to determine when the interface bits need
setting.
DB9903 uses 4 data words per maintenance task.
DB9903 Initial Data Table For Service Planner
Word Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0

0 Task 1: Interval (Hours)
2 Task 1: 1st warning
4 Task 1: Quantity
6 Reserved
12 Task 2: Quantity
14 Reserved
20 Task 3: Quantity
22 Reserved
The sequence continues up to the maximum number of tasks (Task 32, data words
248 to 254)

252 Task 32: Quantity
254 Reserved

PLC Interface Signals
Section 5
Data Block 9904 is used to report the status of the maintenance tasks. Notes
DB9904 Actual Data Table For Service Planner

Word Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
0 Task 1 Residual time (Hours)
2 Task 1: Number of warnings issued
4 Reserved
6 Reserved
8 Task 2: Residual time (Hours)
12 Reserved
14 Reserved
The sequence is continued up to Task 32 and data word 254.

248 Task 32: Residual time(Hours)
252 Reserved
254 Reserved
User interface warning signals.

When the maintenance task is acknowledged the relevant interface bit will be set for
one PLC cycle.
DB1800 Acknowledgement signals

4000 Ackn 8 Ackn 6 Ackn 5 Ackn 4 Ackn 3 Ackn 2 Ackn 1 Ackn 0
The following interface signals are used for signalling that an alarm or message has
been activated. Example: by checking that the remaining time is not zero then the
user PLC can be written to produce a message can be issued. If the remaining time is
zero then an alarm can be issued in the same way. The signal is active for one PLC
cycle.
DB1800 Warning/Alarm signals
3000 Alarm 8 Alarm 6 Alarm 5 Alarm 4 Alarm 3 Alarm 2 Alarm 1 Alarm 0
It may be necessary to deactivate a task, switching the signal high will result in the
task being frozen.
DB1800 Deactivation signals

2000 Deact 8 Deact 6 Deact 5 Deact 4 Deact 3 Deact 2 Deact 1 Deact 0

Section 6 Confirming/Resetting a Task
Notes When a task has reached the time limit, it requires, depending on the task type, some
kind of action to be completed.
Once this is done then the task can be acknowledged and the time limits reset.
Only qualified personnel should reset the task after the maintenance action has been
completed. Simply resetting the task without completing the task could result in
damage to the machinery.
The user PLC program should trigger a PLC user alarm when a task has reached a
time limit. If it is a pre-warning the message response can usually acknowledged by
the “Alarm Cancel” key with no interference to the machine operation.
When the Interval time has expired completely the PLC user message should be
configured to match the importance of the maintenance task.
When the status of the task is checked in the Maintenance Planner screen, a red clock
symbol should have appeared in the “Status” column and the remaining time column
will be zero.
Once the maintenance task is complete then it can be acknowledged by pressing the
“Maintenance Completed” soft-key.
This will reset the interval time back to the original and the interface bit will remain
high for one PLC cycle. This can be used by the user PLC to acknowledge user
alarms etc. It is possible to reset a maintenance task at ant time prior to the interval
Task can be changed or deleted at any time with the “Change task” &
“Delete task” soft-keys.
B020 Page 10 SINUMERIK

Confirming/Resetting a Task
Section 6
Notes
The „Reset all” soft-key will reset the remaining times for all the tasks
SINUMERIK 828D Page 11

Section 7 PLC Programme Example
Notes Below is an example of how to activate and reset messages using the Maintenance
Planner.
Setting the
alarm
Setting the
message
Resetting the
alarm
Resetting the
message
Deactivating the
service interval
B020 Page 12 SINUMERIK

B009 Easy Extend
1 Brief description
Module objective:
Upon completion of this module you will be able to set-up options using the Easy Extend function.
Module description:
Easy Extend is a function of the Sinumerik 828D which allows the manufacturer to setup machine
options. Typically a prototype machine would be commissioned with all available options. Each
option would then be assigned to an Easy Extend device.
When a requirement for an option arises, the Easy Extend device is easily enabled and activated via
user friendly screens.
It is also possible to protect each option via a password.
The function relies upon xml scripts and User PLC logic .
This module shows working examples of how the Easy Extend function can be used, including
descriptions of the various xml script instructions.
Sinumerik 828D
B009
Contents:- B009
General Information Page 3

Section 2
Page 4
User PLC Requirements. Section 3
Page 8
Creating XML scripts. Section 4
Enabling and Testing Page 9

the Devices. Section 4
Page 12
Examples of XML Scripts. Section 6
Creating and Restoring A Page 20

“Rollback” archive. Section 7
Page 22
Addressing of Variables. Section 8
Page 25
General Tag Descriptions. Section 9
Tag Descriptions for Page 32

Dialogue Screens. Section 10

Section 2
General Information
A maximum of 64 devices (Options) can be managed by the system. Notes
The device may be an additional axis or simply a screen that allows the operator to
enter or edit data.
Easy Extend allows each device to be enabled and activated through user friendly
customised screens.
The OEM must ensure that the user PLC logic is available and has been tested for
each device.
The PLC logic is responsible for the handling of the device interface
signals between the HMI and the user PLC.
It is also used when enabling of the device is to be password protected.
Device enabling can also be achieved via user plc machine data.
The xml script files should also be fully tested before machine dispatch. The xml files
contain the instructions that are required to enable/disable/activate/deactivate a
device.
Extended Mark-up Language (xml) is used as the script language.
This offers features such as:-
 Archiving of NC/PLC commissioning data

 Reading and writing of NC/PLC/Drive data
 Conditional jumps within an xml block
 Execution of programme loops
 Execution of arithmetic operations
 Setting up of local variables
 Displaying messages
It is possible to set up some very complex operations using the xml scripts. This
module is aimed at giving confidence to inexperienced users who can then go on and
develop their own skills. The course CD provides examples of some of these complex
script files which can be used as a reference.
As always, before embarking upon tasks of this nature it is always a good idea to save
the original status of the machine use the archiving functionality.

Section 3
User PLC Requirements.
Notes For the Easy Extend option to be able to function a system Data Block (DB9905) is
required. This is found in the Libraries area of the Programming Tool.
Double clicking the DB will open up the properties

and allow the Data Class to be selected, also the
author can enter details if required.
The DB9905 now appear in the Data Block folder of the project.
By double clicking the DB, the contents can be

viewed. Up to 64 devices can be handled by the DB.
A set of signals are assigned to each device which
are to be used in the user PLC for activating,
deactivating and monitoring functions.

Section 3
User data blocks need to be created to handle the enabling of the devices and the Notes
setting of passwords. When right clicking on the Data Block folder, the option to “Insert
Data Block” is available.
The name and number of the data block can be changed along with details about the
author. The data class and retentive/non-retentive properties can also be set.
The data block now has to be populated with data. In the example below a bit has
been designated for each of the sixteen devices. (Up to 64 devices can be addressed
in this way) These bits will be used later in the user plc programme and the XML files.
A data block for the password entry should also be created. An example of this is seen
below. The user PLC programme will be used to compare the entered and assigned
values and providing they match, the device will be enabled.

Section 3 User PLC Requirements.
Notes
Right click on the “Program Block” folder and

select the “Insert Subroutine” option.
The properties of the new subroutine can be changed, including the name and
number, a password can also be set.
The sub routine has to be called in OB1.
Open the subroutine so that the logic can be written.

The following logic is only an example and can be modified to suit individual needs.
The first stage is the enabling of the option via the password. When the “Activate”
soft-key is selected on the Easy Extend screen, certain interface signals will be set by
the system, others will require setting by the user PLC. This is also the case when the
“De-activate” soft-key is selected.
Creating the password. In this example

the password is 1111 and is stored in
DB9000.DBD8
HMI to PLC - If the entered password

and the actual password match, the
option is enabled.
Resetting the fault bit at initial power on
HMI to PLC - Activation Request
HMI to PLC - Deactivation Request
HMI to PLC-Reset the Password

Section 3
The next step is to create an “xml” file which then needs to be placed in a certain Notes
directory on the controller.
There are many types of editors available for creating XML files, some are free while
others have to be purchased..
In order for the Easy Extend to function operate, a file named “agm.xml” is necessary.
Only one file with this name is allowed, this file is responsible for all Easy Extend
devices.
It is possible to have separate xml files for use with each Easy Extend function. These
files have to be then called from within the agm.xml file and will be shown later in the
module.
The xml files operate using tags. These tags are responsible for different operations.
A description of the tags can be found in Sections 8 & 9
Every tag needs to be opened before any script is written. When the script is complete
the tag has to be closed.
Examples:-
Open Tag <name of tag>
Enter script in here
Close Tag </name of tag>
Short Version <name of tag...Enter script in here.../>
The agm tag is the root element of the agm.xml. All other tags are written inside this
tag.
Creation of the xml file can be done in several ways depending on personal choice.
To create directly on the controller it is necessary to locate the system data area. Use
the following key selection in order to do this:-
The correct directory is found under the following path:

System CF card\oem\sinumerik\hmi\dvm
The correct directory is found under the following path:

System CF card\oem\sinumerik\hmi\dvm.
The AGM.XML is created by selecting the “New” & “Any” soft-keys:

Section 4
Creating XML Scripts.
Notes Type in the name-”agm.xml” (Lower case!) and confirm with the “OK” soft-key.
The new file will automatically be opened for editing.

For the password test only a few lines of code is required. When this has been
entered the file is saved/closed with the “Exit” soft-key.
The xml files can also be created remotely and then saved to the controller with the
RCS Commander software.
When the software is running and connected, the lower half of the programme shows
the controller contents. Locate the “dvm” folder as seen below.
The top half of shows the files on the host computer. Locate the required file and copy
it to the controller using the standard “Copy/paste” function.

Section 5
Enabling and Testing Devices.
When creating the xml file offline it is possible to use a number of editors from simple Notes
text editing software to software designed specifically for editing xml files.
The entries made so far in the agm.xml file are explained below:-
 Any text written after the exclamation mark is ignored.
<!Data blocks DB9000 9001& DB9905 are required in the user plc-->
<AGM> The AGM tag is the first one to be opened.

<OPTION_MD name = "plc/db9000.dbd0" /> OPTION tag, specifying the option for
enabling the device.
<DEVICE> Opening the DEVICE tag
<list_id> 1 </list_id> Device identifier (From 1 to 64)
<name> "Test Password" </name> Naming the device.
<password refvar = "plc/db9001.dbd4" /> PASSWORD tag, specifying the
variable where the password entry is stored.
</DEVICE> Closing the DEVICE tag.
</AGM> Closing the AGM tag.
When used in conjunction with the previously written PLC it will be possible to see the
device in the Easy Extend area.
The option is enabled by the “Enable function” soft-key. Enter the password
determined earlier via the PLC program, in this example the password is 1111.

Section 5
Notes The successful enabling of the device is indicated by the green tick appearing in the
“Function” column.
By looking at the PLC in status mode it can be seen that the option enable bit has
been set.
The entered password matches the required

password and the option enable bit
becomes high.
The device is enabled but it is not operational until it is activated. This is achieved by
pressing the “Activate” button.
A green tick will appear in the “Activated” column to confirm this.

Section 5
When the activation is successful the “Activate” interface signal will be high for one Notes
PLC cycle. This should be used in the logic to set the “Activated” interface signal.
The “Activate” interface bit

(DB9905.DBX0.1) has been
used to set the “Activated”
interface bit (DB9905.DBX2.0)
When the “Deactivate” soft-key is pressed the “Deactivate” interface signal is high for
one PLC cycle. This should be used in the PLC logic to reset the “Activate” signal
The “Deactivate” interface bit

(DB9905.DBX0.2) has been
used to reset the “Activated”
interface bit (DB9905.DBX2.0)
In this example the “Deactivate”

interface bit (DB9905.DBX0.2) has
been also used to reset the
password. It is up to the users to
decide if this is suitable for their
applications.

Section 6
Examples of XML Scripts.
Notes Rather than have one file containing all the code for many options, it makes sense to
have one file for each option. These separate files can then be called from within the
AGM.XML file.
Example of an AGM.XML file:-
<AGM>
Declaring the PLC variable for
<OPTION_MD name = "PLC/DB9000.DBD0" index="0" /> enabling the devices.
<!OPTION_MD name = "PLC/DB9000.DBD0" index="1" /> Index 0 - Devices 1 to 16 Bits 0 to 15
<!OPTION_MD name = "PLC/DB9000.DBD0" index="2" /> Index 0 - Devices 17 to 32 “ “
Index 0 - Devices 33 to 48 “ “
<!OPTION_MD name = "PLC/DB9000.DBD0" index="3" /> Index 0 - Devices 49 to 64 “ “
Determining which individual XML

<?include src= "Password_test.xml" ?> files are required.
Example:”Password_test..xml”

</AGM>
The xml file for each individual device should be placed in the same directory as the
AGM.XML file. This file will contain the code for activating the device.
Example:-
Password_test.xml:
<DEVICE>
<list_id> 1 </list_id>
<name> "Test Password" </name>
<password refvar = "plc/db9001.dbd4" />
</DEVICE>
There are a large number of functions that can be performed depending on what is
written in the xml files. These functions have to be tailored for each device by using
the relative tag . A list of tags and functions is available in sections 8 & 9
The Set_Active tag is used to action these functions. This tag becomes active when
the “Activate” soft-key is selected. Likewise, the “Deactivate” soft-key runs the
functions included in the Set_Inactive tag.
Configuring a message box using the file “MessageBox_test.xml”
The AGM.XML file has to be modified to include the new file:-
<AGM>
<OPTION_MD name = "PLC/DB9000.DBD0" index="0" />

<!OPTION_MD name = "PLC/DB9000.DBD0" index="1" />
<?include src= "MessageBox_test.xml" ?>
</AGM>

Section 6
Creating the file for the device: Notes
<DEVICE>
<name> "Messagebox" </name>
<password refvar="plc/db9001.dbd4"></password>
<SET_ACTIVE>
<LET name = "var_return"> 0</LET>
<MSGBOX text="Activate Option 1. %n Press OK" caption="Activation of Option"
retvalue="var_return" type="BTN_OK" />
</SET_ACTIVE>
<SET_INACTIVE>

<MSGBOX text="Deactivate Option 1. %n Press OK" caption="Deactivation of
Option" retvalue="var_return" type="BTN_OK" />
</SET_INACTIVE>
</DEVICE>
Message Box Information:-
Attributes:-
text - The text to be displayed in the message box.
Using the characters “%n” results in a new line.
caption - The header of the text box.
retvalue -
Defines the variable where the return value is copied.
Return values– OK = 1, CANCEL = 0.
type - Acknowledgement possibilities.

“BTN_OK” - OK button.
“BTN_CANCEL - CANCEL button.
“BTN_OKCANCEL” - OK & CANCEL buttons
When the “Activate” soft-key is pressed a message box will appear containing the
specified text. To activate the device select the “OK” soft-key. The device will then be
activated in the usual way.

Section 6
Notes Switching on an output using the file “Write_PLC_output.xml”
Modify the AGM.XML to include the new file.
<?include src= "Write_PLC_output.xml" ?>
Create the device file containing the function for switching a PLC output. This example has also
been configured with a cancel soft-key. The functions IF, THEN & ELSE are used to evaluate
whether the OK or Cancel key was pressed. If the cancel key is pressed the system variable
“$actionresult” is set to 0. This interrupts the processing of the function.
<DEVICE>
<name> "Write PLC output" </name>
<SET_ACTIVE>
<MSGBOX text="Activate Option 1. %n Press OK%n%nAbort press Cancel"
caption="Activation of Option" retvalue="var_return" type="BTN_OKCANCEL" />
<IF>
<condition> var_return==1 </condition>
<THEN>
<DATA name = "PLC/Q4.7"> 1</DATA>
</THEN>
<ELSE>
<OP>"$actionresult" = 0</OP>
</ELSE>
</IF>
</SET_ACTIVE>
<SET_INACTIVE>
<MSGBOX text="Deactivate Option 1. %n Press OK%n%nAbort press Cancel"
caption="Deactivation of Option" retvalue="var_return" type="BTN_OKCANCEL"/>
<IF>
<THEN>
</THEN>
<ELSE>
<OP> "$actionresult" = 0 </OP>
</ELSE>
</IF>
</SET_INACTIVE>
</DEVICE>

Section 6
The status of the output that was changed can be checked with the PLC programming Notes
tool in the chart status area.
Another option is to create “Global” files. These files should contain commands that
standard for every or most of the devices. Two types of file which can be used:-
Global Functions and Global Variables,

Each would be called from with the AGM.XML file using the “Include” function as
shown below. The contents of these file are then available to all devices and avoids
repetition in each device file.
<?include src= "global_variables.xml" ?>
<?include src= "global_functions.xml" ?>
An example is to check that the machine is in Emergency Stop and Reset conditions
before proceeding with the enabling of certain options.
The Test Tag.
This tag is used to check that the requested actions have been successfully achieved. In the
example below the tag has been used to check that the output Q4.7 is set to one.
<DEVICE>
<name> "Write PLC output" </name>
<SET_ACTIVE>
<MSGBOX text="Activate Option 1. %n Press OK%n%nAbort press Cancel"
caption="Activation of Option" retvalue="var_return" type="BTN_OKCANCEL" />
<IF>
<THEN>
</THEN>
<ELSE>
<OP>"$actionresult" = 0</OP>
</ELSE>
</IF>
</SET_ACTIVE>
<SET_INACTIVE>
<MSGBOX text="Deactivate Option 1. %n Press OK%n%nAbort press Cancel"
caption="Deactivation of Option" retvalue="var_return" type="BTN_OKCANCEL"/>
<IF>
<THEN>
</THEN>
<ELSE>
<OP> "$actionresult" = 0 </OP>
</ELSE>
</IF>
</SET_INACTIVE>
</DEVICE>

Section 6 Examples of XML Scripts.
Notes
<TEST>
<IF>
<condition> Within the TEST tag the condition of
"PLC/Q4.7" == 1 Q4.7 is checked for a value of 1
</condition>
<THEN> If the above condition is true, a value
<op> "$actionresult" = 1 </op> of 1 is written to the system variable
</THEN> $actionresult
<ELSE> If the condition is false, a value of 0

<op> "$actionresult" = 0 </op> is written to the system variable
</ELSE> $actionresult
</IF>
</TEST>
To run the Test function first enter the “Start up” area of the Easy Extend area. The
“Function test device” soft-key should be pressed to initiate the test. A dialogue box
will display the result of the test.
Q4.7 = 1 Q4.7 = 0
The Form Tag.
One custom screen can be defined for each device, this is done using the form tag.
The custom screen is can include texts and bitmaps. Input fields can be linked to
different machine variables allowing the operator to set machine specific parameters.
The “Addition. parameter” soft-key is reserved for the instructions contained in the
Form tag.
Within the Form tag the following tags can be utilised:-
LET
INIT
PAINT
TIMER
CLOSE
CAPTION
SOFTKEY_OK
SOFTKEY_CANCEL

Section 6
The following example shows how a bitmap is selected and positioned on the screen:- Notes
<DEVICE>
<name> "Picture Test" </name>
<FORM>
<init>
<caption>Easy Extend Picture Test</caption>
</init>
<paint>
<img xpos = "155" ypos = "90" name = "tiger.bmp" height="250" width="250"/>
</paint>
</FORM>
</DEVICE>
The above script will result in a device named “Picture Test” appearing in the easy
extend list at position one. When the device is enabled the “Addition. parameter” soft-
key the “tiger.bmp” picture will appear on the screen in the position specified by the
IMG tag. The caption “Easy Extend Picture Test” will be displayed in the title bar.

Section 6 Examples of XML Scripts.
Notes In the next example, variables (R parameters 0 to 5) are added to the screen. To
make room for these the picture has been resized and repositioned:-
<DEVICE>
<name> "Picture Test" </name>
<FORM>
<init>
<caption>Easy Extend Picture Test</caption>
<control name = "r_param_0" xpos = "100" ypos = "30" refVar = "nck/channel/parameter/
r[0]" />

r[1]" />

r[2]" />

r[3]" />

r[4]" />
</init>
<paint>
<text xpos = "40" ypos = "30">R0</text>
<img xpos = "155" ypos = "50" name = "tiger.bmp" height="180" width="180"/>
</paint>
</FORM>
</DEVICE>
The screen below shows the result of the new script. The variables can be edited by
the operator. The values are written to the variables when the “OK” soft-key is pressed
or can be set to be immediately written. For information on this see the “Hotlink”
element under the “Control” tag description.

Section 6
Notes
The “Undo” and “Repetition” soft-keys are available to switch each single entry
between its new and original value.
The “Last configuration” soft-key is available to restore all the entries to their original
values.
These values can be checked in the “User variable” area.
It is possible to write to other system variables, addressing these variables is

described in Section 8.

Section 7 Creating and Restoring “Rollback” archives.
Notes Creating a “Rollback” archive.
It is the possible to create a complete NC/PLC/Drives/HMI archive from within the
Easy Extend\IBN Start up area. This is achieved by selecting the “IBN Start-up”
soft-key. This will be followed by a dialogue box which needs to be acknowledge.
An archive file with the name of “Rollback.arc” will now be created and stored in the
Archives folder where the AGM files are stored.
Storage location of the “Rollback.arc” file:-
Restoring a “Rollback” archive.

In the event that the previously created archive needs to be restored, the “Restore”
soft-key can be selected and the dialogue box acknowledged.

Creating and Restoring “Rollback” archives.
Section 7
The file will now be loaded, it is normal for this to take longer than it did to crate the Notes
archive. The progress of the read-in is displayed on the dialogue box. On completion
the green run LED should be lit and the control be without alarms.

Section 8 Addressing of variables.
Notes PLC Addressing:-
x = variable numeric identifier, b = Bit number.
Data Blocks:- DBxxxx.DBX.b Inputs:- Ix.b Outputs:- Qx.b

DBxxxx.DBBxx IBx QBx
DBxxxx.DBWxx IWx QWx
DBxxxx.DBDxx IDx QDx
Variables:- Vx.b Markers:- Mx.b

VBx MBx
VWx MWx
VDx MDx
Examples:-
<data name = “plc/mb200”> 1 </data> Writing a value of 1 to MB200

<data name = “plc/db9905.dbx2.4”> 1 </data> Writing a value of 1 to db9905.dbx2.4
<data name = “plc/i0.5”> 0 </data> Writing a value of 1 to I0.5
NC Variables:-
<LET>name = “tempStatus”><LET Declaring a temporary variable with the LET tag.

<OP>TempStatus = “nck/channel/state/chanstatus” </OP> Writing the channel status
in to the variable.
Drive Addressing:-
The drive path starts with the component identifier.

CU for the Control Unit.
DC for a drive component.
The object number should be placed in square brackets.

The drive object number differs from the actual drive number because the CU, ALM
DriveCliq Hubs etc are all assigned an object number.
Representation Example: Parameter 970 for drive object 2 = p0970[do2]
The dive index number can also be read from a local variable:-
Example: Parameter p0970 with the drive object number obtained from the variable
called “drive”.
This would be written as p0970[do$drive]
Examples:-
<data name=“drive/cu/p0092”>1</data> Writing a value of 1 to the cu, p0092

<data name=“drive/dc/p0092[do1]”>1</data> Writing a value of 1 to do1 p0092
Indirect Addressing:-
<let name=“driveIndex”>0</let> Declaring a temporary variable called “driveindex”

and setting the value to 0.
<op>driveIndex = $ma_ctrlout_module_nr[0, AX1]</op> Reading the value of the
NC variable (ctrlout_module_nr Axis 1) into the temporary variable (driveindex)
<data name =“drive/dc[do$driveIndex]/p0092”>1<data> Using the temporary
variable to determine the drive object number and writing a value of 1 into p0092.

Addressing of variables.
Section 8
Addressing machine and setting data. Notes
The $ character must be used before the name of the data.
Machine data addresses:- $MX_<Name[index, AXyy]>
MN - General machine data

MC - Channel machine data
MA - Axis machine data
Setting data addresses:- $SX_<Name[index, AXyy]>
SN - General setting data

SC - Channel setting data
SA - Axis setting data
Index - Specifies the index number of the variable.

AXyy - Specifies the axis number in the case of axis specific data.
The axis index number can also be read from a local variable:-
Example: Axis index with the index number obtained from the variable called “axis”.
This would be written as AX$axis.
Usage Examples:-
<data name=“$MN_AXCONF_MACHAX_NAME_TAB[0]”>X1</data> Writing a

value of X1 to general machine data $MN_AXCONF_MACHAX_NAME_TAB[0]
<data name=“$MA_CTRLOUT_MODULE_NR[0, AX1]”>1</data> Writing a value of

1 to axis1 machine data $MA_CTRLOUT_MODULE_NR, index 0.
Indirect addressing:-
<let name=“axisindex”>1</let> Declaring a temporary variable called “axisindex” and

setting the value to 1.
<data name=“$MA_CTRLOUT_MODULE_NR[0, AX$axisindex]”>1</data> Using
the temporary variable to determine the axis index number and writing a value of 1 into
axis1 machine data $MA_CTRLOUT_MODULE_NR, index 0.
Addressing user data.
The GUD path is first specified followed by the specific area. If a field is to be used,
this follows next and is contained in square brackets.
The following GUDS can be addressed:-
SGUD Siemens GUDS.

MGUD Manufacturer (OEM) GUDS.
UGUD User GUDS.
GD4
GD5
GD6
GD7
GD8
GD9
Examples:-
<data name=“gud/channel/mgud/syg_rm[0]”>1</data> Defining the channel
manufacturer gud - syg_rm, index 0 and writing a value of 1 to it.
<op>“gud/channel/mgud/syg_rm[0]” = 5*2</op> The result of the multiplication of two
numbers (5 x 2) is written to the syg_rm[0] gud.

Section 8 Addressing of variables.
Notes Special XML characters.
Some XML editors can incorrectly display certain characters. These have to be
re-written.
The following characters are affected:-
Character XML Notation

< < (Less than)
> > (Greater than)
& & (Ampersand)
“ " (Quotation)
, ' (Apostrophe)
Operators.
The following operations are available for use:
Operator Significance
= Assignment
== Equal to
<, &lt Less than
>, &gt Greater than
<=, <= Less than or equal to
>=, >= Greater than or equal to
I Logical OR operation (Bitwise)
II Logical OR operation
&, & Logical AND operation (Bitwise)
&&, &&amp Logical AND opertaion
+ Addition
— Subtraction
* Multiplication
/ Division
! Not
!= Not equal to
Operations are executed from left to right. Brackets can be used to define the priority
of expressions.

Section 9
General Tag Descriptions
Notes
Tag Function
Main Tag, defines the device. All other tags are contained
AGM
within this tag.
BREAK Conditional Interrupt.
For reboot of the NC (resetnc) or Drive (resetdrive)
CONTROL_RESET Eg <control_reset resetnc=“true” />
<control_reset resetdrive=“true”/>
For writing directly to the NC, PLC, GUD and Drive areas.
Attributes: name variable address
All alphanumeric values can be used as tag values. When

writing directly from a local variable the $ symbol should be
used immediately in front of the variable name.
DATA
Examples:
<data name=“plc/mb160”>1</data> (Writing a value of 1
into mb160.
<let name= “tempvar”>7</let> (Declaring a variable named
“tempvar” and loading a value of 7 into it.)
<data name= “plc/mb170”>$tempvar</data> (Writing the
contents of the variable into marker byte 170.
For saving/restoring the listed drive and machine data. Up to
20 addresses can be listed line by line.
Attributes:
Action=“read” - saves the value of the variable into
temporary memory.
Action=“append” - Attaches the value of the listed
variable to an existing list.
Action=“write” - writes the saved values into the
machine data
Id=“name” - Label given to the temporary memory

DATA_LIST
Examples: Reading the values of R200, R201 & R202 into
the temporary memory called “name”:-
<data_list action=“read” id=“<name>”>
nck/channel/parameter/r[200]
</data_list>
Writing the values back into the listed machine variables:-
<data_list action=“write” id=“<name>”>

DEVICE Used to describe the device.
The version number of the drive is copied into the
DRIVE VERSION
$driveversion variable that is valid within the Device tag
A condition used if the instruction was not fulfilled

ELSE
(Used in conjunction with IF, THEN)

Section 9
Notes
Tag Function
For the creation and restoring of archive files.
Attributes:
Create=“true” - Command to create an archive
Name=“filename.arc” or “filename.ard”- Filename
specified by user (.arc = complete archive, .ard = dataclass
archive)
Class - Specifies that the archive will be a “Data class”
archive.(Choice of User, Manufacturer or Individual)
If a class is not specified a standard archive containing NC,
PLC, HMI & Drive data will be created.
Group - Specifies the data groups to be included in the
Archive.(Choice of NC, PLC, HMI & Drive data)
Examples:-
FILE Read in a standard archive called “complete.arc”-
<file name=”complete.arc/>
Read in a data class archive called “dataclass.ard”-

<file name=”dataclass.ard/>
Create a standard archive called “user.arc”-

<file name=”user.arc create=“true” />
Create a data class archive called “user.ard”-

<file name=”user.ard” create=“true” class=“user manu-
facturer individual” group=“nc plc hmi”>
The archives are stored in the following path:- System CF

card\OEM\Sinumerik\HMI\DVM\Archives.
The Form tag contains the user dialogue description. One dia-
logue is permitted per device. The “Addition. Parameter” soft-
key displays the user dialogue that is entered under this tag.
Attributes:
color - Background colour of the dialogue screen.
label - Optional name for the form.
xpos - X Position of the upper left-hand corner of the
FORM
dialogue box
ypos - Y Position of the upper left-hand corner of the
dialogue box.
width - Extension in the X direction (Pixels).
height - Extension in the Y direction (Pixels).
Example:- <FORM name=“dialog name” color=“#ff000”/>

Function call-
Executes the functions within the “name” attribute.
FUNCTION Attribute:
Name - “Name of the function body”.
Example:- <FUNCTION name=“function name”/>

Section 9
Notes
Tag Function
Contains the function body of a sub-function. This should be
programmed within the AGM or DEVICE tags. Globally used
functions should be set up in the AGM tag.
Attribute:
name = “Name of the function body”
FUNCTION BODY
Example:
<FUNCTION_BODY name=“function name”>
…
…
</FUNCTION_BODY>
ID Dialogue screen index of the device.
Conditional instruction (IF, THEN, ELSE)
Used with the THEN and ELSE tags.
Following the IF tag, a condition is declared. If this condition is

true, the THEN tag is executed. Should the condition be false
the ELSE tag will be executed.
Example:
The following example checks IF MB120 has a value not
equal to 5. If this id true, the THEN tag contains the
instruction to load a value of five to MB120.
IF MB120 was already had a value of 5, the THEN tag would
IF
be ignored and the code in the ELSE tag would be auctioned.
<IF>
<CONDITION> “plcmb120” !=5 </CONDITION>
<THEN>
<OP> “plc/mb120” =5 </OP>
</THEN>
<ELSE>
…
…
</ELSE>
</IF>
This tag is used to call other XML files from within the
AGM.XML
INCLUDE
Example:-
<?include src=“name of xml file to be included”?>
For displaying a message specified in the tag
MSG
This can be used in the case of alarm numbers, the dialogue
box would display the text associated with the alarm number.
The NAME instruction defines the name of a device to be
NAME
displayed in the dialogue screen.

Section 9
Notes
Tag Function
Setting up of a local variable with a user specified name.
Attribute:
name - variable name
type - The format of the variable can be integer (INT),

double (DOUBLE) or string (STRING). The default of INT is
assumed if no format is specified.
Examples:
<LET name=“variable_name” type=“STRING”/>
It is possible to assign a value to the variable eg 99:

LET
<LET name=“variable_name” type=“STRING”>99</LET>
NC and PLC variables can be saved in a local variable using

the “=“ operation. The format of the local variable
automatically takes the format of the NC/PLC variable.
Variable that are required to be globally available should be

set up directly after the AGM tag.
When used with a dialogue box, processing of the message

opens up the corresponding DEVICE tag, this tag is closed
after the message is executed and as such deletes all
variables within the DEVICE tag.
A message box is opened with this tag, the return value can
be used to make a branch.
Attributes:
text - The text to be displayed in the message box.
Using the characters “%n” results in a new line.
caption - The header of the text box.

MSGBOX
retvalue - Defines the variable when/where the return value
is copied. 0 - CANCEL, 1- OK,
type - Acknowledgement possibilities.

“BTN_OK” - OK button.
“BTN_CANCEL - CANCEL button.
“BTN_OKCANCEL” - OK or CANCEL buttons.
Execute instruction. For carrying out mathematical
Operations with system and temporary variables.
Examples:
Setting a temporary variable equal to PLC system variable
MB100
<op> tmpVar=“plc/mb100” </op>
OP
Multiplying a variable by 2.
<op> tmpVar= tmpvar * 2 </op>
Setting PLC system variable MB100 equal to a temporary

variable.
<op> “plc/mb100”=tmpVar </op>

Section 9
Notes
Tag Function
Text can be output in the dialogue line or copied into a variable.
Attributes:-
name - Name of the variable where the text is to be saved
(optional)
text - The text to be output.
Values:- Number of variables whose values should be inserted

PRINT in the text.
Format:- d Integer
f Floating point value
s String
Example:
<print name=“variable name” text=“text” %formatting”>
variable..</print>
SET_ACTIVE Data within this tag is used to activate the device.
SET_INACTIVE Data within this tag is used to de-activate the device.
START_UP Data within this tag is used to commission the device.
STOP Stops a sequence at this position
The switch tag allows the value of a variable to be compared

SWITCH with a number of constants. If a match is found the value will be
written into the variable specified in the DATA tag.
Used for testing that a device is functional.. The test result
should be entered into the $actionresult variable. If the variable
TEST
contains a value of one, then the device is functional. A value of
zero indicates a faulty device.
THEN Used with the IF, & ELSE commands. See the description for IF
VERSION Version Information
For Loop – This tag checks for a condition, if the condition is

false, the loop will end.
Example:- Declaring a local variable as “count” with an initial

value of 0. Set the condition to check that the variable is less
than or equal to 7. Increment the count by increments of one.
When the value of the variable is more than 7 (False) add 1 to
the count value and place the result in output byte 10.
<let name=“count=0”</op>
FOR
<for>
<init>
<op> count=0 </op>
</init>
<condition> count <= 7 </condition>
<increment>
<op count = count +1</op>
</increment>
<op “plc/qb10” = 1+count</op>
</for>

Section 9 General Tag Descriptions
Notes
Tag Function
Defining the option machine data is done with this tag.
By default the system uses the following machine data:-
$MN_USER_DATA_INT[0] to $MN_USER_DATA_INT[3]
The devices are assigned to the machine data in logical

Order, each machine data handles 16 devices-
$MN_USER_DATA_INT[0] Devices 1 to 16 (Bits 0 to 15)

“ “ “ “ [1] “ 17 to 32 (Bits 0 to 15)
“ “ “ “ [2] “ 33 to 48 (Bits 0 to 15)
“ “ “ “ [3] “ 49 to 64 (Bits 0 to 15)
Bit assignment examples:

$MN_USER_DATA_INT[0] bit 15 = device 16
OPTION_MD
Attributes:-
name - machine data address - $MN_USER_DATA_INT
Index - index of machine data - [x]
Example:-<option_md name=“$MN_USER_DATA_INT0[0]/>
Defining the option machine data to a PLC variable:-

Variable DB9005.DBD0.
When only devices 1 to 16 are in use, no index is required:
<option_md name=“PLC/DB9005.DBD0”/>
When more than 16 devices are in use, the index must be

specified:
<option_md name=“PLC/DB9005.DBD0” index=“0”/>
When this tag is used for a device and the option is not set, a
soft-key is available which allows the entry of a password.
The entered password is placed in the specified variable and

should be verified by the user PLC. Acknowledgement of this to
the HMI is required using the relevant interface bit (DB9905).
PASSWORD
Attribute:
refvar - name of the reference variable
Example: Declaring DB9000.DBD4 as the target for the entered

password-
<password refvar=“plc/db990.dbd4”/>
The interface signals are handled as standard by DB9905. This
tag allows the interface to be re-defined.
Attribute:
PLC_INTERFACE
Name - Address of the new interface.
Example:
<plc_interface name=“address of the new interface”/>
With this tag a message will appear instructing the operator to
POWER_OFF power down the system. The message text is fixed by the
System.

Section 9
Notes
Tag Function
While Loop - This tag executes a sequence of instructions for a
multiple number of times providing that a certain condition is
true. The sequence is halted when the condition becomes false.
Example:- Set the condition that IB9 should be equal to 0. Pro-

viding that this is the case, write a value of 15 into QB11 using
WHILE
the data tag.
<while>
<condition> “plc/ib9” ==0</condition>
<data name “plc/qb11> 15 </data>
</while>
Do-While Loop - This tag executes a sequence for instructions
and then checks for a condition, if the condition is true, the in-
structions will be processed again. The processing stops when
the condition is false.
Example:- Write a value of 15 into QB11 using the data tag.

Then check the condition that IB9 should be equal to 0.
DO_WHILE
Providing that this is the case, again write a value of 15 into
QB11. When the condition is false, stop the loop.
<while>
<data name “plc/qb11> 15 </data>
<condition> “plc/ib9” ==0</condition>
</while>
Update Agent Syntax -
?UP

Section 10
Tag Descriptions for Dialogue Screens
Notes
Tag Function
The Form tag contains the user dialogue description. One
dialogue is permitted per device. The “Addition. Parameter”
soft-key displays the user dialogue that is entered under this
tag.
The following tags are processed by the Form tag:-
LET
INIT
PAINT
TIMER
CLOSE
CAPTION
SOFTKEY_OK
FORM SOFTKEY_CANCEL
Attributes:
color - Background colour of the dialogue screen.
name - Optional name for the form.
xpos - X Position of the upper left-hand corner of the
dialogue box
ypos - Y Position of the upper left-hand corner of the
dialogue box.
width - Extension in the X direction (Pixels).
height - Extension in the Y direction (Pixels).
Example:- <FORM name=“dialog name” color=“#ff000”/>

The INIT tag is executed immediately after the generation of
INIT the dialogue box. All the screen input elements and hotlinks
should be written in here.
The PAINT tag is executed when the dialogue box is
PAINT Displayed. All texts and graphics for the dialogue box should
be written in here.
The CAPTION tag contains the title of the dialogue box and
should be used within the INIT tag.
CAPTION
Example:- <caption> Title of Dialogue box </caption>
The CONTROL tag generates the control elements.
Attributes:-
name:- label of the field. The label also represents a local
variable.
xpos:- X position of the upper left hand corner.
zpos:- Y position of the upper left hand corner.
fieldtype:- Field type (Optional).
“edit” - Data can be changed
“readonly” - Data cannot be changed.
CONTROL “combobox” - A drop down list with text that can
accept a value or be used for selection purposes.
If no type is specified, the default is set to “edit”.
refvar – label of the reference variable that can be linked to

the field. (optional)
hotlink – “TRUE“ the field is automatically updated when

data is changed (optional)

Section 10
Notes
Tag Function
format – formatting data, refer to the print tag (optional)
time – specifies the refresh rate of the data (optional)

The following refresh rates are possible:
“super fast“ - refresh time < 100ms
“fast“ - refresh time, approx. 100ms

“normal“ - refresh time, approx. 200ms
“slow“ - refresh time, approx. 500ms
If the combo box field type is selected then the expressions to

be displayed also have to be defined. The tag <item> should
be used for this purpose. The combo box saves the index of
the currently selected text in the variables belonging to the
control (variable name). Indexing starts with the value 1.
Syntax:
<item>Expression</item>
Example:
<control name = "button1" xpos = "10" ypos = "10" fieldtype=”

combobox “>
<item>text1</item>
<item>text2</item>
<item>text3</item>
CONTROL <item>text4</item>
</control>
If any integer value should be assigned to an expression then

the value=“value“ attribute must be added to the tag.
Instead of the consecutive numbering - the control variable
now contains the assigned value of the item.
Example:
<control name = "button1" xpos = "10" ypos = "10" fieldtype=”

combobox “>
<item value = “10” >text1</item>
</control>
Note:
The hotlink attribute results in the appropriate control being

cyclically updated. This means that if a value is entered, then
the next update cycle overwrites the value that has been
entered. In order to avoid this, use the DATA_ACCESS tag to
activate the function where entered data is immediately saved.
An additional possibility is to include the SOFTKEY_OK tag in
the form. This tag is then run before the dialog box is closed.
In this block - using the UPDATE_CONTROLS instruction -
data can be aligned between the control and reference vari-
ables.

Section 10
Notes
Tag Function
The tag controls the behavior of the dialog screens when
saving user entries.
The behavior should be defined within the INIT tag.
If the tag is not used then the entries are always buffered.
Exception: The hotlink attribute is set to true.

DATA_ACCESS
Attribute:
type = "TRUE" – values that have been entered are not
buffered. The dialog screen directly copies the values that
have been entered into the reference variables.
type = "FALSE" – the values are only copied into the refer-
ence variable when tag UPDATA_DATA type = "FALSE"
The tag is used to display a text at the specified position on
the screen.
If the text is to be read from a text file, then the “$$” character
string should be placed in front of the label.
If the contents of a string variable are to be displayed, then
the “$$$” character string should be located in front of the
variable.
Syntax:
<text xpos = "X position" ypos = "Y position"> Text </text>
Attributes:
xpos - X position of the upper lefthand corner
ypos – Y position of the upper lefthand corner
color – text color (refer to Chapter ‎1.3.4

‎ for the color coding)
Value: Text to be displayed
Example: Direct text output

TEXT
<text xpos=“10“ ypos=“20“> Hello World </text>
Example: Indirect text output with text from a file:

The text to be output should be set-up in the
oem_aggregate.ts file and available in all of the supported
languages. This file should be placed in the following
directory- System CF card\oem\sinumerik\hmi\lng
<message>
<source> MY_TEXT_SYMBOL</source>
<translation> Hello World </translation>
<chars>20</chars>
</message>
<text xpos=“10” ypos=“20”>$$MY_TEXT_SYMBOL </text>
Example: Indirect text output with text form a variable:
<LET name=“TextVar” type=“string”> Hello World </text>
<text xpos=“10” ypos=“20“>$$$TextVar </text>

Section 10
Notes
Tag Function
The tag is used to display an image/graphic at the specified
position.
The bit maps in the BMP or PNG format should be saved in

the directory CF-Card/oem/sinumerik/hmi/dvm.
Linux: Lower case letters should be used for all file names.
Syntax:
<img xpos = "X position" ypos = "Y position" name=“name“ />
Attributes:
IMG
xpos - X position of the upper lefthand corner
ypos – Y position of the upper lefthand corner
name – bit map name
Optional: If the display of an image/graphic deviates from the

original size then the dimensions can be defined using the
width and height attributes.
width – width in pixels
height - height in pixels

The tag draws a solid square at the specified position in the
specified color.
Syntax:
<box xpos="X position" ypos = "Y position" width=“X exten-
sion“ height=“Y extension“ color=“color code“ />
Attribute:
BOX xpos – X position of the upper left hand corner
ypos – Y position of the upper left hand corner
width – extension in the X direction (in pixels)
height – extension in the Y direction (in pixels)
color – color coding

Dialog box message
TIMER
The tag is cyclically executed.
Dialog box message
CLOSE
This tag is executed before the dialog box is closed.
Using the tag, a variable is included in the cyclic read utility
(hotlink).
This tag is only valid within the INIT instruction of a form.
REQUEST Attribute:
Name - address label
Syntax:
<REQUEST name = “NC Variable“ />

Section 10
Notes
Tag Function
The tag synchronises data between the operator
elements and the reference variables.
Attribute:
type – the attribute defines the direction of the data
alignment.
TRUE – data is read out of the reference variables and
copied into the operator elements.
FALSE – data is copied from the operator elements into the
UDATE_CONTROLS reference variables.
Syntax:
<update_controls type="<direction>"/>
Example:
<softkey_ok>
<update_controls type="false"/>
</softkey_ok>
This tag overwrites the standard behavior when closing a
dialog box using the "OK" softkey.
The tag should be programmed in the first sub-level of a
form tag.
The following functions can be executed in this tag:
 Data manipulation
 Conditional processing
 Loop processing
Syntax:
<SOFTKEY_OK>
…
…
</SOFTKEY_OK>
Example:
SOFTKEY_OK <form>
….
….
….
<softkey_ok>
<update_controls type="false"/>
<let name="msgbox_result">0</let>
<MsgBox text="Execute NCK Reset!! " caption = "NCK Re-
set" retvalue = "msgbox_result" type= "BTN_OKCANCEL" /
>
<if>
<condition> " msgbox_result " == 1 </condition>
<then>
<CONTROL_RESET resetnc="TRUE"/>
</then>
</if>
</softkey_ok>
</form>

Section 10
Notes
Tag Function
This tag overwrites the standard behavior when a dialog box
is closed using the "Cancel" softkey.
The tag should be programmed in the first sub-level of a form
tag.
The following functions can be executed in this tag:
 Data manipulation
 Conditional processing
 Loop processing
SOFTKEY_CANCEL Syntax:
Example:
<form>
<softkey_cancel>
<data name=”plc/mb170”>2</data>
</softkey_cancel>
</form>

Notes

B018 Easy Messenger
1 Contents
Module Objective:
Upon completion of this module you will be able to set up the modem and controller so that the SMS
messaging function can be used.
Module Description:
It is possible to send SMS messages from the controller to report certain events that occur on the
machine.
It is also possible to send and receive an SMS message to the controller which can then be used to
influence the machine by means of changing PLC variables.
This module shows how the modem is set up and configured for sending/receiving SMS
messages.
Sinumerik 828D
B018
Easy Messenger B018
Section 2
Activating the Modem Page 3
Section 3
Configuring the Modem Page 5
Section 4
Testing the Modem Page 7
Setting PLC variables via Section 5

SMS Page 9

Activating the Modem.
Section 2
A sim card is required which has to be fitted inside the Modem. Notes
To dismantle the modem two clips have to be released.
The sim card slot can be seen below, once inserted the modem can be clipped back
together.
The Modem should be connected to the controller with a 9-pin modem cable.
The cable should be connected to Port X140 of the controller and X1 of the modem.
Port X140 is a female connector.
Port X1 is a male connector.
There is a connection for an antenna, three status LED’s and a switch for changing
the functionality.
Type:- Sinaut MD720-3

Modem part number:- 6NH9720-3AA00
Cable part number:-6NH7701-5AN
The modem is set to a default transmission mode

known as Terminal Mode.
The “SET” switch should not be pressed as this can
change the modem settings and cause it to stop
functioning.
LED information:-
S (Status)
Q (Quality
C (Connection)
During normal operation:-

S - Off
Q - On
C - Flashes every 2 seconds (Terminal mode active)

Section 3 Activating the Modem.
Notes The modem setup screens are reached through the following key combination:-
When the “Messenger active” soft key is selected the control will start to
communicate with the modem.
The status of the connection can be seen.

Configuring the Modem. Section 3
To identify the controller to the SMS recipient a name can be added in the settings Notes
screen.
A limit on the number of SMS messages sent can also be entered and confirmed with
the “OK” soft key.
When the limit has been exceeded a message box will be displayed.
The counter will then have to be reset to zero with the “Reset SMS counter” soft key.

Section 3 Configuring the Modem.
Notes A user profile must now be added.
Details about the recipient of the SMS messages should be entered as well as the
events which result in the message being sent.
The screen is navigated using the cursor and select keys.
More information about some of the events can be seen by pressing the “Details” soft
key.

Testing the Modem. Section 4
A test message can be sent to test the connection. When the details have been input Notes
they are saved by pressing the “OK” soft key.
The newly created user will appear on the screen. The “Active” soft
key needs to be pressed to make the user active.
This results in a green tick appearing before the name.
The user profile can be edited or deleted, further profiles can also be added.
A list of text messages that have been sent and received can be seen when the
“SMS Protocol” soft key is selected.

Section 4 Testing the Modem.
Notes Example:-
To send a message from part program first ensure that this option is set in the user
profile.
Select MDA mode and type in the following text:-
MSG(“SMS: TYPE YOUR TEXT IN HERE”)
Then press “CYCLE START”
The text should then be displayed at the very top of the screen.
A message containing the same text should then be received by the designated
phone.

Setting PLC variables via SMS Section 5
The possibility is available to set a variable in the PLC via SMS. Notes
This function could be used for example to activate a user message.
Variable DB1700.DBB3000 is reserved for this function.
The format can be in Binary, Hexadecimal or Decimal.

Format required for writing to the variable
Binary 2#00000000
Hexadecimal 16#00
Decimal 10#00
In the text editing area of the SMS device the ID of a user has to be input followed by
the value to be sent to the variable.
Example:-DB1700.DBX3000.4 is to be set to a 1, the profile to be used has the ID of

12345.
Text to be typed in the SMS device:- 12345 plc 2#00010000
Now send the message.

Providing that the user exists and is active the SMS protocol screen of the controller
will display the received message, a few moments later the controller will send a
message to the sender to inform them that the task was successful.
The variable should also have changed to the requested setting.
It is also possible to activate and deactivate users in the same way:-
12345 deactivate or 12345 activate.
The controller sends out confirmation that the task was successful.
A record of these texts can be found in the alarm log page.

B007 Electronic Logbook
1 Brief Description
Module Objective:
Upon completion of this module you will be able to set up the Electronic Logbook function and know
how to enter data into the Logbook.
Module Description:
In the past the logging of system faults and hardware failures has been recorded to a Logbook.
These Logbooks are usually then left on the machine and can become damaged or lost.
The 828D allows the Logbook to be stored on electronically on the controller. The Logbook file can
then be saved externally and saved remotely from the controller.
Sinumerik 828D
B007
Contents:- B007
Entering The Machine Section 2

Information Page 3
1st Commissioning- Section 3

Start-up Complete Page 5
2nd Commissioning- Section 4

Machine Installed Page 6
Recording a Service Section 5

Visit Page 7

Entering The Machine Information.
Section 2
Notes
To locate the Logbook use the following soft-key sequence:-
To input the machine details select the “Change” soft-key
The machine, manufacturer, dealer and customer details can now be entered. The
default selection when first entering the Logbook is “Manufacturer” as shown by the
vertical soft-keys.
To change between the different fields of the screen use the cursor keys. To enter the
data use the “Input” key.
When the full details have been entered press the “OK” soft-key

Section 2 Entering The Machine Information.
Notes The Dealer and End User may not be known until after the machine has been built.
These areas should be filled in when this information is available.
Example:- Dealers information
Example:- End User information

1st Commissioning-Start-up Complete. Section 3
A summary of the information can now be seen. Notes
1st Commissioning-Start-up Complete.
When the machine has been commissioned at the manufacturers the

“Start-up Complete” soft-key is selected. This automatically logs the current time and
date. It is important that the time and date is set correctly, please refer to Module
B025 for information about setting the time and date.
To confirm that 1st Commissioning is complete.
To cancel the procedure.
The information is now added to the main logbook page.

Section 4 2nd Commissioning-Machine Installed
Notes
When the machine has been installed at the end-user (2nd commissioning) the
“Machine Installed” soft-key is selected. This automatically logs the current time and
date. It is important that the time and date is set correctly, please refer to Module
B025 for information about setting the time and date.
To confirm that 2nd Commissioning is complete.
To cancel the procedure.
The information is now added to the main logbook page.

Recording a Service Visit. Section 5
Whenever an engineer visits the machine to carry out maintenance etc, a record of Notes
the visit and information about the work carried out should be entered in the Logbook.
To do this select the “New Entry” soft key.
The name and company/department of the engineer should be entered followed by a

detailed description of the fault and work carried out.
The details of the service visit are now shown on the Logbook page.

B067 Preparation of Series Machines
1 Brief description
Module objective:
Upon completion of this module you will know how to serially commission machines of the same
type.
Module description:
Once the prototype of a particular machine is complete and has been satisfactorily tested, the data
from this machine can be transferred quickly into other machines to aid the production process.
Sinumerik 828D
SINUMERIK 828D Training, Operation and Service Page 1 This document was produced for training purposes.
B067
Contents:- B067
Section2
Overview Of The procedure. Page 3
Creating The Series Start-up Section 3

Archives Page 4
Loading The Controller With Section 4

Default Settings Page 6
Loading The Series Start-up Section 5

Archives Page 7
B067 Page 2 SINUMERIK 828D Training, Operation and Service

Section 2
Overview of the procedure.
Notes
Completed prototype
machine
Empty storage device Storage device containing

(CF card/USB stick) series start-up archives.
Data easily transferred from prototype to series machines
Compact Flash and USB port locations.

The ports are located on the left hand front face of the controller beneath the
hinged cover
USB port X125
Compact Flash port X145

Section 3
Creating a series start-up archive
Notes To create a Series Start-up Archive locate the correct area by using the following key
sequence.
Ensure that the option “Create series start-up” is selected and select “OK”
A number of choices are available regarding what to include in the archive you are
about to create.

Section 3
Creating a series start-up archive
To create a series start-up file which contains the correct data select the Notes
“Manufacturer” option. See description below:-
Manufacturer:- This will create an archive containing all manufacturer

relevant data of the machine. This will not contain any individual machine specific
data. This file can be used as a start up file for serial machines once the prototype
has been perfected.
Control Components:- Separate archives can be made of each of the four areas of
the controller or a single archive containing all the areas can be created. This down to
personal preference as the different areas can be individually selected/de-selected
during the read-in procedure.
Comments and the archive creator can be entered.
Select the destination of the archive, as the file is to be transferred between

machines this should be the USB or CF.
Enter the name of the archive.
The archive will now be created and saved in the selected target area.

Section 4 Loading the controller with default settings
Notes Interrupt the boot process by pressing the keys indicated below in the numerical
sequence indicated. (Not simultaneous key presses)
1 2
The service menu will be displayed, from this menu select the option “Default data”
and press “Insert”
Allow the control to fully reboot.

This action will reset the NCK, PLC, Drives and HMI to factory settings in preparation
for the loading of the series start-up archive.

Section 5
Loading the archive into the controller
Insert the device containing the archive then select the following soft-key sequence. Notes
Cursor to the “Read in series start-up” option and press “OK”
Locate the archive to be read in and select “OK”.
Acknowledge that the correct file has been selected by pressing “OK”.
A dialogue box appears which allows the individual components of the archive to be
de-selected. When using the archive to create series machines all the components
should be selected.

Section 5
Loading the archive into the controller
Notes The archive file will now start to read in. A series of dialogue boxes show the various
stages of the procedure.
When the read-in is complete the dialogue boxes will clear and the “RDY” Led to the
left of the screen will be permanently green, the “NC” Led will flash orange at
approximately 1Hz.
Machine specific data can now be entered. Once this is complete further archives
should be created as instructed in Module B017.

B100 Sinumerik 828D
Basic Servo Optimisation
1 Brief description
Module Objective:- To ensure the necessary level of compatibility and consistency between
machines configured with the Sinumerik 828D controller. A defined optimization procedure
should be adhered to and this procedure is defined in this module
Caution:- These procedures result in axis movement. All necessary safety precautions must
be taken into account. Make sure that that you read through and understand the entire
procedure before beginning.
This module explains the step by step procedure to optimise the current, speed and position con-
troller loops within the Sinumerik 828D/ Sinamics S120 ………...
Content of the module:
 Current Controller Optimisation

 Speed Controller Optimisation
 Position Controller Optimisation
 Velocity Feed Forward
Sinumerik 828D
 Acceleration
 Circularity test
 Spindle optimisation
 Advanced Surface
B100
Content:-
B100
Section 2
Introduction Page 7
Section 3
Current Controller Optimisation
Page 6
Speed Controller Optimisation

 Proportional Gain
 Integral Gain Section 4
Page 9
 Reference Model
 Current Setpoint Filters
Position Controller Optimisation Section 5

Page 23
Velocity Feed Forward

Section 6
 Axis Jerk Page 29
 Equivalent Time Constant
Section 7
Acceleration
Page 34
Section 8
Circularity Test Page 36
Section 9
Spindle Optimisation
Page 41
Section 10
Advanced Surface Page 57

Section 2
Introduction
Activating Machine Data changes Notes
Throughout this procedure, certain machine data changes need to be activated.

To the right of each parameter value there is an indication of how the particular
change takes effect. The following is a list of these indications and their meaning.
po The relevant machine data requires an ―NCK Reset‖ to take effect

re The relevant machine data requires activation of the ―Reset‖ key to take
effect
cf The relevant machine data requires activation of the ―Set MD active‖ soft-
key to take effect.
im The relevant machine data is immediately active.
Saving Drive settings
Every time the S120 drive is powered on or a ―Drive Reset‖ is performed, the S120
drive data is loaded to the relevant drive from a stored file. Therefore when drive
machine data are altered, the drive data must be saved so that the change is re-
tained after the next power off/on or ―Drive Reset‖. NOTE:- an ―NCK Reset‖ does
not affect the drive data.
In order to save drive data:-

In the ―Drive MD‖ area, press the ―Save/Reset‖ then the ―Save‖ then the ―Drive
System‖ softkeys. Messages at the bottom left of the screen indicate the status of
the save process. When the save process is complete, the message ―All drive ob-
jects backed up‖ appears.
Controller Block Diagram
828-D SL/ S120 controller structure: The 828-D SL CNC and S120 drive controller
structure contains three cascaded closed loop controllers (current, speed and po-
sition). Each controller must be optimized in succession starting with the inner-
most current controller, then the speed controller and finally the position controller.
The machine dynamic limits for velocity, acceleration and jerk are set in the inter-
polator. The speed control loop is always closed via the motor encoder while the
position control loop can be closed via the motor encoder or direct measuring sys-
tem.
SINUMERIK 828D SL PROFIBUS –DP DRIVE

Section 2
Introduction
Notes
828D HMI Advanced Start Up tools:
- To get to the start up tool selection page from the “Machine page” press the
“Menu Select” key.
- Press the “Start Up” softkey and then the “Optimiz / test” softkey. From this
page, the relevant start-up tool can be selected
Note: Only some of the available tools are used during these procedures.
- Press the “Axis +” or “Axis - ” softkey to select the desired axis.
Current control Description Active

loop tools: Mode
"Ref. Frequency The closed loop frequency response tool is used to optimize the Jog
respo. (after cur- current controller proportional gain. The current setpoint filters
rent setpoint filter) have no influence on the measurement result.
Speed control Description Active
loop tools: Mode
―Speed controller This tool measures the open frequency response of the mechan- Jog
path (active after ics as seen by the motor shaft, without the influence of the cur-
current setp filter) rent setpoint filters.
"Ref. Frequency This tool measures the closed loop speed controller frequency Jog
respo ( after response including any mechanical resonance. Used for setting
speed setpoint the speed controller proportional gain, integral time and current
filter)" setpoint filters. The speed setpoint filter has no influence on the
measurement.
"Disturbance step Speed controller torque disturbance step change. Used to Jog
change (after measure the speed controller response to a torque or ―load‖ step
current setpoint change.
filter)"
Position control Description Active
loop tools: Mode
"Ref. Frequency Position controller closed loop frequency response used to opti- Jog
respo" mize the position controller proportional gain, (KV factor).
―Circularity Test‖ Used for circle analysis from either the motor encoder or direct MDA
measuring system. Automatic
―Servo Trace‖ The servo trace tool is a built in four channel oscilloscope. Jog, MDA
Automatic
Frequency Response Tool Display:

All frequency response tools display the measurement result as db gain and phase.
Trace 1 is pre-assigned as the db gain and Trace 3 is pre-assigned as the phase. It
is normally sufficient to use a fixed scale of +20 db to –60 db for Trace 1 and +180
deg to –180 deg for Trace 3. The frequency scale is logarithmic e.g. 1 Hz at the far
left and ending with the defined bandwidth e.g 4000 Hz. The first 1% and the last
50% of the frequency response range of measurement is disregarded.
Traces can be saved and recalled easily using the ―File Functions‖ softkey.
Up to 4 traces can be displayed at one time for comparison if desired.

Section 2
Introduction
MD DESCRIPTION Notes
10200 $MN_INT_INCR_PER_PER_MM 100000
10210 $MN_INT_INCR_PER_PER_DEG 100000
20150[3] $MC_GCODE_RESET_VALUES[3] 3 FIFOCTRL
20150[9] $MC_GCODE_RESET_VALUES[9] 2 G64
20150[20] $MC_GCODE_RESET_VALUES[20] 2 SOFT
20600 $MC_MAX_PATH_JERK 10000
20602 $MC_CURV_EFFECT_ON_PATH_ACCEL 0
20603 $MC_CURV_EFFECT_ON_PATH_JERK 0
33000 $MA_FIPO_TYPE 3
32200 $MA_POSCTRL_GAIN xx
32640 $MA_STIFFNESS_CONTROL_ENABLE 1
32644 $MA_STIFFNESS_DELAY_TIME xx
33100 $MA_COMPRESS_POS_TOL 0.010
32300 $MA_MAX_AX_ACCEL xx
32310 $MA_MAX_ACCEL_OVL_FACTOR xx
32400 $MA_AX_JERK_ENABLE xx
32402 $MA_AX_JERK_MODE 2
32410 $MA_AX_JERK_TIME xx
32420 $MA_JOG_AND_POS_JERK_ENABLE xx
32430 $MA_JOG_AND_POS_MAX_JERK xx
32431 $MA_MAX_AX_JERK xx
32432 $MA_PATH_TRANS_JERK_LIM xx
32433 $MA_SOFT_ACCEL_FACTOR xx
32434 $MA_G00_ACCEL_FACTOR xx
32435 $MA_G00_JERK_FACTOR xx
32620 $MA_FFW_MODE 3
32630 $MA_FFW_ACTIVATION_MODE x
32810 $MA_EQUIV_SPEEDCTRL_TIME xx
32900 $MA_DYN_MATCH_ENABLE x
32910 $MA_DYN_MATCH_TIME x
32930 $MA_POSCTRL_OUT_FILTER_ENABLE x
32940 $MA_POSCTRL_OUT_FILTER_TIME x
P1400 bit3 Speed controller reference model enable x

P1400 bit5 Speed controller Kp and Tn adaption 0 Disable on axis
P1414 Speed setpoint filter activation x
P1421 Type of speed setpoint filter x
P1422 Speed setpoint filter time constant x
P1460 Speed controller Kp x
P1462 Speed controller Tn x
P1433 Speed controller reference model frequency x
P1434 Speed controller ref model damping x
P1656 Activate current setpoint filters x
P1657/1676 Current filter settings x
P1715 Current controller gain x

Section 3
Current Controller Optimization
Notes 3. 1 Current Controller Optimization
- The current controller gain is automatically loaded into P1715 when the motor
type is established during drive configuration.
- A reference frequency response of the current controller is a useful check of the

current controller parameterisation.
- With Siemens motors the parameters are automatically established and should
not need to be changed.
- With a current controller cycle time of 125us, The db gain should be above –3db
to where the phase passes through –90 degrees. As a minimum the –90 phase
point should be above 550Hz
- If the amplitude is greater than 0db then P1715 should be reduced. If the ampli-
tude is lower than -20db then the motor type should be checked. ( recalculate
regulator data P0340)
WARNING :- Do not carry out this test on a vertical axis unless it is supported.
During this procedure the speed controller is disabled internally, and therefore ver-
tical axes could fall if not supported.
Select ―Start up‖
Select ―Optimiz/test‖

Current Controller Optimization Section 3
Notes
Select ―Curr contr

loop‖
!!!!! Information !!!!!

Current Controller
Cycle Time
Select
―Measurement‖ and
then Type of meas-
urement ―Refer.
Frequ. Response‖
Select ―Measuring
parameters‖ and
then Select
―Standard pa-
rameters‖
The amplitude will

vary depending
upon motor type
and current limit

Section 3 Current Controller Optimization
Notes
Select
―Measurement‖
and then Select
―Start‖
You will then get a

message saying
Press NC Start.
Press ―Cycle
Start‖ on the Ma-
chine Control
Select ―Display‖
when the meas-
urement has fin-
ished to see the
result
As can be seen from the example above the amplitude stays at the 0db line until
around 900 Hz.
The db gain should be above –3db to where the phase passes through –90 de-
grees. As a minimum the –90 phase point should be above 550Hz
Example of P1715 Example of P1715

Too High Too Low

Speed Controller Optimization
Section 4
Notes
4.1 Speed Controller Optimization
- The Speed Controller proportional gain (Kp, P1460) default value is based on the
motor type. The Speed Controller integral time (Tn, P1462) default value is 10ms.
Both values are automatically loaded into the relevant parameters when the motor
type is established during drive configuration. These values are conservative to allow
a reliable start up, and they now have to be optimized.
- The end result of an optimized speed controller (Kp, Tn) is that the amplitude re-
sponse is at 0db out to as high a frequency as possible with a maximum of +3db at
frequencies below the phase response crossing below –130 degrees. If the axis is to
carry load then it is better to keep the amplitude response at 0db as the addition of a
load may change resonant frequencies.
- To help achieve this there are 4 independent current setpoint filters ( P1656 to
P1676) that can be activated as needed to suppress mechanical resonance. These
filters can be assigned as ―Low Pass‖ or ―Bandstop‖. As a default the first filter is acti-
vated and set as a ―Low Pass‖. Additional current setpoint filters can be assigned if
required and are usually configured as ‗Band Stop‖
- When using ―Bandstop‖ filters you should always try to keep the bandwidth and
notch depth conservative. If you let the filter have the full effect then this reduces the
bandwidth of the speed controller. A notch depth of –20 to –40 should be used
- Normally with a Speed Controller cycle time of 0.125 ms it should NOT be neces-
sary to use filters below 200Hz.
Speed Controller Optimization Procedure Summary
4.11 Use the ―Speed controller path (active. After setp filter) to accurately identify me-
chanical resonance ―pole ― and ―zero‖points. The result determines whether current
setpoint filters are required and also initial parameter settings.
4.12 Use the ―Refer. Frequency response (after setpoint filter)‘ to optimize the speed
controller proportional gain (Kp) separately from the speed controller (Tn) and enable
current setpoint filters if required.
4.13 Use the ―Disturbance step change (after setpoint filter)‘ to optimize the speed
controller integral time (Tn) , and then use the ―Refer. Frequency response (after set-
point filter)‘ tool to check the setting.
4.14 Use the ―Speed controller reference model‖ to reduce overshoot in response to
setpoint step changes.
Speed Controller Optimization Procedure
4.11:- Use the “Speed Controller Path (active. After setp filter)” measurement to
identify resonant ―Pole‖ and ―Zero‖Points.
- This measurement compares torque to speed and at the end you can identify the
resonant ―Pole‖ and ―Zero‖ Points so that they can be noted for use when we use the
―Reference Frequency Response‖ of the Speed Controller.
- The reason for this is that when the ―Reference Frequency Response‖ measurement
is carried out the ―Pole Points‖ can appear slightly higher in frequency than they really
are.
- Ensure that Dynamic Stiffness is disabled MD32640 = 0 and that (Tn) Drive P1462
is 100ms for horizontal axes and 30ms for vertical or inclined axes, this decreases the
influence of the speed controller integrator for this measurement.

Section 4
Notes
Select ―Speed
contr loop‖

Speed Controller
Cycle Time
Select
then ―Speed control-
ler path (active. After
current setp. Filter).
This measurement is
without the influence
of filters.
Select ―Measuring
parameters‖ and
―Values in %‖.
Then enter the val-
ues as shown.
Also switch the

display to ‖Values
in phys. quant‖ to
make sure the Off-
set and Amplitude
are not too large.
The amplitude
should be varied if
the measurement
is too noisy.
Values in %

Section 4
Notes
Move cursor bar down to enter ―Ramp-up time‖
Select
then Select ―Start‖
You will then get a

message saying
Press NC Start.
Press ―Cycle Start‖

on the Machine
Control Panel
Pole at 769 Hz Pole at 1600 Hz
When the measure-

Zero at 600 Hz Zero at 1400 Hz
ment is finished se-
lect ―Display‖
Select ―Display‖ and then make a note of the ―Pole‖ and ―Zero‖ Points as above. In
this example ―Pole‖ points are at 769 Hz and 1600 Hz and ―Zero‖ points are at 600
Hz and 1400 Hz. The first 1% and the last 50% of the measurement can be disre-
garded.

Section 4
Notes Mechanical resonance is identified by ―Pole‖ and ―Zero‖ points as shown by the ex-
ample on the previous page. The ―Zero‖ is to the left of the associated ―Pole‖ i.e the
lower frequency. At the ―Zero‖ points the db gain goes negative while the phase
shifts sharply from –90 deg towards +90 deg. At the ―Pole‖ points the db gain goes
positive while the phase shifts sharply back to –90 deg. In these cases additional
current setpoint filters configured as ―bandstop‖ may be required to allow a reason-
able speed controller gain setting.
The next step is to determine possible filter settings, do not enable them at this time.
Current setpoint filters are not normally required below 200Hz
Pole at 769 Hz Pole at 1600 Hz
Zero at 1400 Hz
Zero at 600 Hz
Estimate notch depth, here –14db & -16db
Example settings in this case are :- ( These values should be recorded )

Pole frequency 769, Zero frequency 600, notch depth –14db and
Pole frequency 1600, Zero frequency 1400, notch depth –16db.
It is now a good idea to make the same measurement up to a bandwidth of 400 Hz

to give a good overview of what is happening at lower frequencies. This also
shows the lowest natural frequency of the axis and from this value we have a good
idea of what Kv factor can be reached
Select
then ―Speed con-
troller path (active.
After current setp.
Filter)
Change the
―Bandwidth‖ from
4000 Hz to 400Hz,
and ―Meas periods‖
to 2

Section 4
Notes
Select ―Measurement‖
and then Select
―Start‖
You will then get a

message saying
Press NC Start.
Press ―Cycle Start‖ on

the Machine Control
Panel
Take a note of the fre-

quencies from 10 Hz
to 200 Hz . Here it
shows the lowest natu-
ral frequency at 66 Hz
and also another reso-
nance at 120 Hz.

Section 4
Notes 2.12:- Using the “Reference frequency response” measurement to adjust Kp
(P1460) and Tn (P1462).
- The reference frequency response displays the db gain and phase lag. This
gives an indication of how well the speed actual value follows the setpoint within a
frequency range, e.g. 1 HZ to 4000 HZ. 0 db indicates that the actual speed is the
same amplitude as the setpoint and 0 phase lag indicates that the actual speed
follows the setpoint with minimal delay. The speed controller KP and Tn settings
affect the db gain and phase response.
- With the Tn at a relative high value, e.g. 100 ms, it is ineffective. The Kp can be
adjusted independently so that the db gain is 0 to –3db at –90 deg and does not
exceed 0 at any point on the db gain graph. The db gain should not exceed 0
when the phase crosses –180 deg. Note: When the Tn setting is relatively high,
(100 ms), the db gain at low frequencies may not be on the 0 db line because of
friction. After the Tn is adjusted, the db gain at low frequencies should be 0.
- If it was necessary to use the default 10 ms for the Tn setting to get a readable
result, the KP can be adjusted so that the db gain is +3 db above the 0 db line at
frequencies below the -130 degree phase point.
To calculate a good optimization of the speed controller P-gain use the formula:
P1460=(Motor Inertia)P341*1200= Example 0.001510kgm²*1200=1,812kgm²
First measurement with high Tn=100ms (p1462). This reduces the effect of the Tn
and allows Kp (p1460) to be optimized separately.
Be sure that Dynamic stiffness control is disabled MD32620 = 0
Attention: On a vertical axis without a counterbalance e.g. the Z-axis on a ―C

Frame‖ milling machine, start Tn from a value of 30ms, to prevent the axis from
dropping and for the first measurement keep some support close to the axis
Also if working on a rotary axis only use small values for Amplitude and Offset,
quite often if you just use standard values they will be too high.
Select ―Drive MD‖

Section 4
Notes
Search for 1462 and

enter 100
This makes Tn inef-

fective during the
measurement
Then Select ― ^ ―
and then Select
―Refer. Frequency
response (after speed
setpoint filter)‖
Select ―Measuring
parameters‖ and
then ―Standard pa-
rameters‖ but
change the offset to
100 mm/min to over-
come any friction

Section 4
Notes
Change Ramp-up
time to 500 ms
Select
You will then get a

message saying
Press NC Start.

on the Machine Con-
trol Panel
When the measure-

ment is finished No Filters Filters
select ―Display‖ and
then you can see
the resonant fre-
quencies in the me-
chanics. We now
need to build in a
filter to dampen any
resonant frequen-
cies above 200 Hz.
In this example 769
Hz so Select ―Filter‖
200 Hz
In general with a speed controller cycle time of 0.125 ms no filters should be re-
quired below 200Hz, as this area falls in the bandwidth of the speed controller and
therefore we have phase in reserve. Below 200Hz the filters have too much nega-
tive influence on the speed control behaviour (they lower the bandwidth, that
means less dynamics)

Section 4
Notes
The HMI Advanced start up tool contains a user friendly mask to set filters. All 4 filters
are configured as PT2 low pass in the default state with only the first filter activated.
The 3 other filters can be added and configured as necessary. The additional filters
shown here are normally entered as ―Bandstop‖ filters.
As a default the first filter is active as a PT low pass filter with a frequency of 2000Hz
and damping of 0.7. This setting should not be changed.
We should start here with filter number 2 and configure it as a ―Bandstop‖
Select ―Filter +‖ to
reach Filter No 2.
Assign filter 2 as a
Band Stop filter and
then enter the values
for the frequency,
bandwidth and notch
depth.
Then Select ―Accept‖
For starting values use

the notch frequency of
the spike, the band-
width equal to Pole
frequency minus Zero
frequency * 2,and
notch depth to the de-
sired depth of the filter
in db.
Reduction should re-
main at 0.
The filter parameters

are automatically
loaded into the rele-
vant area and the
2nd filter is activated
Repeat the ―Reference

frequency response‖
measurement to see
the effect of the filter.

Section 4
Notes
The Kp(P1460) was now increased to 2Nms/rad with the following result:
Where the phase goes below -130° shows the range of the speed-controller.
Below this point we can go up to +3dB, above this point we should not exceed
0dB.
On series machine types that use 828D it is always best to leave some amplitude
in reserve to allow for variations in mechanical build.
0 db
-130
2.13 Use the “Disturbance step change (after setpoint filter)” to optimize Tn
(P1462).
When the Tn is reduced, the db gain normally lifts above 0 db. The Tn setting
range is dependant on the mechanics and on machines of the type that 828D is
fitted to is normally less than 10 ms but greater than 3ms. The Tn should not be
set to values below 3ms.
The end result of optimized speed controller Kp and Tn settings is that the db gain
is 0 db out to as high a frequency as possible with a maximum of +3db at frequen-
cies below the -130 phase point.
If the axis is to carry an additional load i.e. a table or a fixture, it is best to set the
db gain at 0db, as the additional load may push the db gain up to the +3db maxi-
mum.
To optimize Tn se-
lect measurement
type ―Disturb. Step-
change (interf. After
current setp.filter)
Measured quantity 1
is Actual torque
value

Section 4
Notes
Select parameters as
shown.
Also switch the display

to ‖Values in phys.
quant‖ to make sure
the Offset and
Amplitude are not too
large
and then Select ―Start‖
You will then get a

message saying Press
NC Start.
Press ―Cycle Start‖ on

the Machine Control
Panel
Tn too big 10ms
Tn correct 5ms
Tn too small 2ms
Start with Tn (P1462) at 10ms which is the standard value. Decrease Tn until you
see an undershoot in the lower graph. Then just increase Tn until you see no un-
dershoot. Most machines of the type fitted with 828D will end up with a value of
between 3 to 10ms.

Section 4
Notes Once the best setting for Tn has been established a check should be made of the
speed controller reference frequency response. This is because a low setting of
Tn will cause the amplitude at lower frequencies to rise above 0db
Select type of meas-

urement ―Refer. Fre-
quency response‖
Select
You will then get a

message saying
Press NC Start.

on the Machine Con-
trol Panel
The result shows

the amplitude re-
spose rising up to
3db in the lower
frequency area
2.14 Use of the “Speed controller reference model”

For high dynamic applications such as high speed machining and mould & die, espe-
cially those that require high position loop gain, or velocity feed forward, the speed
reference model can be implemented to reduce overshoot in response to speed set-
point changes. The reference model is a model for the P controlled speed controller.
As a rule when optimizing the speed controller, it is desired to achieve a low Tn set-
ting so that the drive can respond quickly to load changes and counteract the effects
of friction. With optimized Tn settings, there is an expected overshoot in response to
setpoint step changes. The ―speed reference model‖ reduces this overshoot while
not affecting the response to load changes. The advantage is better quality surface
finish.
P1433, (reference model frequency), can be adjusted in a range of 50 HZ to 250 HZ

and is most effective when high KV factors are required and/or when direct scale
feedback is used. The lower the value in MD 1433, the more effect the speed refer-
ence model has. The reference model should have the same value for all axes and
the main spindle.
P1434, (reference model damping factor) A setting of 0.7 should be used as a start
value. Typically values are between 0.5 to 1.0.

Section 4
Notes
First we have to switch

the speed reference
model on.
Search for P1400

―Speed control configu-
ration‖
Turn on Bit 3
―Reference model
speed setpoint‖
To get an idea of an
initial setting for P1433
take a look back at the
frequency response of
the speed controller
when P1460 was be-
ing adjusted. Take a
look where the phase
passes through –90
degrees and use this
frequency as the start
value in P1433. For
P1434 use a start
value of 0.7
In this case P1433 =

220 Hz

Section 4
Notes
Enter the values

into P1433[0] and
P1434[0]
The speed refer-

ence model will be
active if P1433[0]
>0
P1433 should be
reduced gradually
until the amplitude
response is at a
maximum of 3db in
the lower frequency
area

Section 5
Position Controller Optimization
5.1 The position loop gain, (KV factor) is optimized using the position controller Notes
―reference frequency response‖ tool. Stability and overshoot should then be
checked by making a position step and using the servo trace tool.
- The position loop proportional gain, (Kv factor MD 32200), influences the follow-
ing error and contour accuracy. the default value is 1. As the KV factor is in-
creased, the following error is proportionally reduced. For typical machine tool
applications the final KV factor setting can fall in a range of 1 to 10[m/min/mm]
- A good optimization of the position controller means small following error, small
contour deviation and no overshoot when the axis comes into position.
- Prerequisite :- That the current and speed controllers have been correctly opti-
mized.
Important! Be sure to take machine mechanical limitations as well as maximum

work-piece and fixture weight into account when setting the Kv factor and accel-
eration parameters! If the machine is optimized without load, overshoot and insta-
bility can occur when significant weight is added to the moving table. To avoid this
situation, it is recommended to optimize the KV factor with the maximum weight
securely mounted to the table. In addition, check if there are any pre-determined
mechanical limitations before beginning!
- Use the position loop ―Ref. frequency respo‖ tool to optimize the KV factor :-
The position loop ―Ref. frequency respo‖ tool is used to set the KV factor to the
optimum value based on the components that are included in the closed position
loop, including work-piece and fixture weight. The attainable results vary depend-
ing on the machine mechanics and type and mounting location of the feedback
device that is used to close the position loop, (direct scale or indirect motor en-
coder).
The following parameters should be checked :-
Deactivate Feed Forward ………………MD 32620 = 0

Deactivate Speed Setpoint Filter……….P1414 = 0
Deactivate any Position Setpoint Filter..MD 32900 DYN_MATCH_ENABLE = 0
...MD 32400 AX_JERK_ENABLE = 0
- Dynamic stiffness control should be enabled. This enables position control in a

faster cycle time. NOTE:- With Dynamic Stiffness control ENC_FEEDBACK_POL
32110 must be 1. If the feedback polarity needs to be swapped it must be done in
the Sinamics drive with P410 = 3H.
Activate DSC (Dynamic Servo Control)..MD 32640 = 1

Adjust Stiffness Delay Time …MD 32644 = 0.0000 PPU281
= -0.0015 PPU261
Select ―Position
contr. Loop‖

Position Controller
Cycle Time

Section 5
Notes
Select
then type of meas-
urement ―Ref fre-
quency response‖
Select ―Measuring
parameters‖ and then
enter tha values
shown.
Bandwidth 166 Hz for

Position controller
cycle 3ms, 333 Hz for
Position controller
cycle 1.5ms
Select
You will then get a

message saying
Press NC Start.

on the Machine Con-
trol Panel

Section 5
Notes
When the meas-

urement is finished
select ―Display‖
This example
shows that the Kv
can be increased
Increase the value

in Axis MD 32200
[0] until the ampli-
tude response is at
the 0db line for as
high a frequency
as possible, but
not rising above
0db
This results in a 0 db
correctly optimized
position controller

Section 5
Notes
Kv too high, the am-

plitude response is
rising above 0db
-The positioning response of the axis should now be checked using the servo trace
tool and a commanded position step via part program at different feedrates. In cases
where a direct scale is used, the actual slide response can easily be viewed. In
cases where the motor encoder is used to close the position loop, (indirect feed-
back), the actual response of the axis is not visible to the closed loop or the servo
trace tool.
-The test part program should traverse the axis a sufficient distance that allows the
programmed velocity to be reached, e.g. 50 mm. A check should also be made over
shorter distances e.g. 3 - 10mm. A dwell time should be used after the velocity is
reached and then after the setpoint position is reached, e.g. 0.5 second. The initial
programmed velocity can be approximately ½ of the maximum axis velocity and the
response should be checked at all of the feedrate override increments as well as the
maximum speed.
-The aim is to check the stability of the position controller and also to check position-
ing accuracy. A check is also made for any overshoot or vibration.
-The position actual value trace results should be magnified for a finer view by
changing the scale, e.g. position 0.005 mm/div
The following NC program can be used
FFWOF
SOFT
LAB:
G01 X210 F10000
G04 F0.5
$AA_SCTRACE[X]=1; trigger for servo trace
X260
G04 F0.5
GOTOB LAB
M30

Section 5
Notes
Select the NC program, in Automatic Mode so that it is ready to run when ―Cycle
Start‖ is pressed on the Machine control panel
Select ―Servo trace‖
Select
enter the trace pa-
rameters as shown.
Select ―Start‖ which

starts the trace
function and then
press ‗Cycle Start‖
on the machine
control panel to
start the part pro-
gram.
When the trace

function has fin-
ished press
―Display‖
Positioning without
Feed Forward.
Change the ―Scale

of trace 1 & 2 to
show a
Resolution
0.005mm/div
around the target
position
Without Feed For-

ward at all
feedrates, no over-
shoot is permissi-

Section 5
Notes
This is an example where the KV factor setting is adequate and the jerk limit set
too high. The oscillation that occurs upon position settling is generated from the
mechanics and should be smoothed by a lower value for jerk limit, MD 32431. MD
32431 should be set to as high a value as possible that results in smooth position-
ing response without overshoot.
This is an example where the jerk limit setting is adequate but one or more of the
controller settings are not correct. The overshoot without oscillation upon position
settling could be a result of the KV factor, (MD 32200), being set too high. This
might occur when a load weight is added to an axis where the KV factor had been
optimized without a load weight.

Section 6
Velocity Feed Forward Optimization
6.1 With Velocity Feed Forward, a high effective Kv factor (low following error), Notes
very high accuracy and contour precision can be obtained. With dynamically high
quality machines with high natural frequencies and good damping it is possible to
reduce the following error even at very high speeds.
If high precision is a requirement, then feed forward control is necessary. When

Feed Forward is activated, the servo response becomes very dynamic, thus, jerk
limited acceleration is always necessary to smooth the setpoint profile.
Before the feed forward function can be enabled and optimized, the current, speed
and position controllers must have previously been optimized!
The following parameters should be checked
MD 32200 POSCTRL_GAIN as previously optimized

MD 32300 MAX_AX_ACCEL as specified by the builder
P1460 SPEEDCTRL_GAIN_1 as previously optimized
P1462 SPEEDCTRL_ INTEGRATOR_TIME_1 as previously optimized
P1433 SPEEDCTRL_REF_MODEL_FREQ = as previously optimized
P1414 NUM_SPEED_FILTERS = 0
MD 32610 VELO_FFW_WEIGHT = 1.0
MD 32810 EQUIV_SPEEDCTRL_TIME = 0
MD 32431 MAX_AX_JERK = 100
MD 20600 MAX_PATH_JERK = 10000
MD 32620 FFW_MODE = 0
The easiest way to optimize Feed Forward control is to make a position step.
Therefore the position setpoint and the position actual value of the active encoder
have to be viewed with the servo trace. Then the machine data must be adjusted
until the position behavior (i.e. the last 20 μm when the axis goes into desired po-
sition) is satisfactory.
If positioning alarms occur during parts of the procedure then set the following MD
but make a note of the original values and put them back to original at the end.
MD 36012 STOP_LIMIT_FACTOR = 100

MD 36400 CONTOUR_TOL = 20
Experience shows that a traversing range of approx. 50 mm and a velocity of 10

m/min is useful to get a good result. A check should also be made over shorter
distances as excitation of mechanical resonance is more prevalent over shorter
distances e.g 5 - 10 mm
The following NC program can be used
FFWON
SOFT
LAB:
G01 X210 F10000
G04 F0.5
X260
G04 F0.5
GOTOB LAB
M30

Section 6
Notes
Select the NC program, in Automatic Mode so that it is ready to run when ―Cycle
Start‖ is pressed on the Machine control panel
and enter the trace
parameters as shown.
Select ―Start‖ which

starts the trace func-
tion and then press
‗Cycle Start‖ on the
machine control panel
to start the part pro-
gram.
When the trace func-

tion has finished press
―Display‖
Change the ―Scale of

trace 1 & 2 to show a
Resolution 0.005mm/
div around the target
position
Without Feed Forward

at all feedrates, no
overshoot is permissi-
ble.
Positioning without Feed Forward:-should be comparable with measurement of

position controller on the previous pages. The position controller without feed for-
ward must have no overshoot and minimal vibration.

Section 6
Now, feed forward can be switched on with MD 32620 FFW_MODE = 3. Check that Notes
the equivalent speed control time is switched off
MD 32810 EQUIV_SPEEDCTRL_TIME = 0.The optimal EQUIV_SPEEDCTRL_ TIME
depends on the mechanics and the time constants in the controller loops of an axis. It
is possible that different axis with the same EQUIV_SPEEDCTRL_ TIME show differ-
ent positioning behavior. The aim now is to find the correct equiv. time constant and
check the vibration behaviour because excitation of vibration is more likely when us-
ing feed forward
Positioning with Feed Forward

active
Resolution 0.005mm/div.
It can be seen here that the

actual value shows a crawling
behavior in the last 0.01mm to
position.
In this case the

EQUIV_SPEEDCTRL_TIME
must be decreased. It is possi-
ble to have a negative value.

MD 32810 EQUIV_SPEEDCTRL_TIME = 0.0025

active

actual value shows overshoot
as it comes into position.
In this case the

must be increased


active

actual value shows no over-
shoot as it comes into posi-
tion.
In this case the

was correct at 0.002

Section 6
Notes
Now Jerk limited acceleration can be optimized: Jerk is used to smooth the accel-
eration response by applying a time for the change in acceleration. Jerk is defined
in units/sec3, i.e. (acceleration [units/sec2 / time [sec]). The time it takes for the
acceleration change to take place, [sec] = acceleration [units/s2] / jerk [units/s3].
Axes do not have to have the same Jerk value.
The result of jerk-limited acceleration is rounded corners at the start and end of
the acceleration phase of the velocity profile and smoothed motion.
Jerk limiting is active when ―SOFT‖ is programmed and de-activated when
―BRISK‖ is programmed. ―SOFT‖ mode is set as the default reset state via chan-
nel MD 20150[20] = 2. It is recommended to use ―SOFT‖ as the default reset
value.
If channel MD 20150[20] = 1, "BRISK" mode is active as a default on power up,

(acceleration without jerk limit).
If channel MD 20150[20] = 2, "SOFT" mode is active as a default on power up,
(acceleration with jerk limit).
The positioning response of the axis can be checked using the servo trace tool
and a commanded position step via part program at different feedrates. In cases
where a direct scale is used, the actual slide response can easily be viewed. In
cases where the motor encoder is used to close the position loop, (indirect feed-
back), the actual response of the slide is not visible to the closed loop or the servo
trace tool. On machines with 828D in general jerk values will be between 20 and
100
The test part program should traverse the axis a sufficient distance that allows the
programmed velocity to be reached, e.g. 50 mm. A dwell time should be used
after the velocity is reached and then after the setpoint position is reached, e.g.
0.5 second. The initial programmed velocity can be approximately ½ of the maxi-
mum axis velocity and the response should be checked at all of the feedrate over-
ride increments as well as the maximum speed.
The previous part program can be used as a basis and the servo trace settings
are the same.
Positioning without
position controller Kv =
0
Resolution 0.005mm/
div.
Without the position

controller the axis po-
sitions with no over-
shoot. The remaining
positioning error exists
because the position
controller is switched
off and the axis is
moving with just feed
forward signals. The
overshoot when com-
ing into position comes
MD 32200 POSCTRL_GAIN = 0 from the mechanics
MD 32610 VELO_FFW_WEIGHT = 1.0 and can be eliminated
MD 32620 FFW_MODE = 3 using jerk limitation.

Section 6
The positioning step without the position controller is now dependant upon the Notes
speed controller and setpoints (Acceleration, JERK - profile).
The response of the feed forward driven axis should show no overshoot or vibra-
tion.
Positioning without
position controller
and jerk too high.
Resolution
0.005mm/div.
This diagram
shows how the jerk
is increased until
there is an over-
shoot in the re-
sponse of the me-
chanics.
Remove the over-

shoot
By decreasing the
MAX_AX_JERK
MD 32200 POSCTRL_GAIN = 0
Positioning with
feed forward and
position controller
active
Resolution
0.005mm/div.
Good positioning
without overshoot
when feed forward
and jerk are cor-
rectly optimized
MD 32200 POSCTRL_GAIN = 4.5

MD 20150[23] =2 Feed Forward can then be enabled as a

default.
MD 36012 STOP_LIMIT_FACTOR = original value

MD 36400 CONTOUR_TOL = original value

Section 7
Acceleration
Notes
7.1 Maximum axis acceleration: Axis MD 32300 defines the maximum axis ac-
celeration. The default value is, [1 m/sec2 (metric), 39.37 in/sec2 (inch) and 2.77
rev/sec2 (rotary)]. Each axis can have a different acceleration setting.
Important! Machine mechanics limit the maximum axis acceleration. The machine
builder must define the required setting value! If not defined, the default value
should be used unless the machine builder authorizes an increase.
Checking the maximum axis acceleration:

The torque utilization under worst-case load and velocity conditions should be
checked after the KV factor and Feed Forward have been optimized to be sure
that the torque limit is not reached.
The "Servo trace" start up tool is used to measure the velocity actual value of the
relevant active measuring system and the torque utilization percentage via the
―Utilization (m_set/m_set_limit)‖ trace signal. When the ―Utilization (m_set/
m_set_limit)‖ trace signal =100%, the drive is on current limit!
If allowed by the machine builder, MD 32300 can be set so that the torque utiliza-
tion during the acceleration phase of the worst case load and velocity lies between
80% and 90% of the limit depending on how much safety factor is desired.
A test part program should traverse the axis a sufficient distance that allows the
programmed rapid velocity to be reached, e.g. 300 mm.
Change the trace measuring parameters to view the load torque utilization and
change the part program as shown.
SOFT
LAB:
G0 X10
X310
GOTOB LAB
M30
Change the trace

measuring parame-
ters to view ―Velocity
act value meas sys-
tem 1‖, ―Utilization
(m_set/m_set_limit)‖
and ―Torque-prod
curr. Act. val i(q)‖

Section 7
Acceleration
Notes
Select the part program in Automatic mode so that it is ready to be processed
when ―Cycle Start‖ is pressed
Select
―Measurement‖
and then Select
―Start to start the
servo trace.
Then Press
―Cycle Start‖ on
the machine con-
trol panel to start
the part program
The maximum
velocity of 48 m/
min is reached
with a utilization of
36%.
The ―Utilization (m_set/m_set_limit)‖ signal selection displays the utilized percentage

of the active current limit.
The active current limit is:

P 0640 = [RMS amps].
P 0640 is limited to whichever is the lower of P0323 Maximum Motor Current/ Mot I
Max [RMS amps] or r0209 Power Unit Maximum Current/ PU I Max [RMS amps]
In this example P640 was 35A
Therefore utilization is 35A x 36.28/100 = 12.7A

Section 8
Circularity Test
Notes
8.1 The “built-in” circularity test is used to check the interpolation of axes that will
work together. The tool measures a circle with reference to the motor or direct meas-
uring system. Machine mechanical alignment is not considered in the result. This
gives the commissioning engineer the ability to clearly separate controller optimiza-
tion issues from mechanical issues.
Axis MD32200,MD32400,MD32402,MD32410,MD32490,MD32500,MD32510,
MD32520, MD32540 MD32620, MD32640, MD32810, MD32900, MD32910,
MD32930, MD32940 and drive P1421 to P1426. P1400, P1433, P1434 are checked
via this procedure.
The following positional error compensations should be switched off when this proce-
dure is carried out. Backlash Comp MD32450, Encoder Comp MD32700, CEC Comp
MD32710, Temperature Comp MD32750, Friction Comp MD32500.
Note:- Backlash MD 32450 must be adjusted using an external device e.g ballbar or
dial gauge
The best overall contouring results are achieved when the circle test results in the
correct actual size, shape and minimum p/p deviation between combinations of inter-
polating axis, (X-Y, X-Z, Y-Z).
A circle test part program and the circularity test start up tool can be used to measure
and evaluate these results. The ―worst case‖ test circle radius and path feedrate
must result in a realistic radial acceleration that the machine is capable of. Machine
builders typically have specifications for test circle radius and feedrate.
Standard machine builder circle tests typically use a radius of 100 mm or 150 mm at
feedrates determined by the machine builder. The machine builder defines the ac-
ceptable result specifications.
High speed cutting requirements are usually more stringent and test circles for high
speed cutting machines might be in the range of 10 to 25mm radius at feedrates of 5
m/min to 10 m/min. For high speed cutting machines, the results are normally ac-
ceptable when the p/p deviation </= 0.010 mm, and the actual size is equal to the
programmed radius at the worst case path feedrate.
Example of an X-Y circle part program –

Position, feedrate and active plane must be adapted to the machine!
FFWON
SOFT
G90 G01 F3000 X400 Y200 Z500
LAB:
G91 G64 G02 X0 Y0 I10
GOTOB LAB
M30
Select ―Optimiz/test‖

Circularity Test
Section 8
Notes
Select ―Circular.
Test‖
Select
―Measurement‖
and enter the
relevant parame-
ters. The pa-
rameters shown
are for a 10mm
radius in X-Y
plane at a
feedrate of 3m/
Setting the ―Circularity test‖ parameters:

> From the start up tool page, press the ―Circularity test‖ softkey.
After this keystroke sequence, the control is in Circularity test start up tool.
> Set the desired measuring parameters to match the programmed circle:
- Measurement, select the relevant axis and the ―active‖ measuring system.
- Parameter, enter the programmed radius and feedrate. The multiplier should
remain at 1.
- Resolution, set the resolution as desired, e.g. 0.010 mm/grad
- Representation, select ―Mean radius‖.

Section 8
Circularity Test
Notes
> The example program should first be modified to fit

the machine positions, feedrates and plane if neces-
sary. The example program uses circular interpolation
and runs the programmed circle continuously. Follow
the specific machine procedures to run the test part
program.
Important: The circularity test must be activated manu-

ally by pressing the "Start" softkey after the test pro-
gram is started.
> After the measurement is complete, press the

―Display‖ softkey to view the results.
Parameter:
Radius = Entered radius (e.g. 10 mm)
Feedrate = Entered feedrate (e.g. 3000 mm/min)
Measuring time = Calculated time for the measurement
Representation:
Resolution = units per graduation (e.g. 0.010 mm/div)
Represent = Type of display, (e.g. mean)
Radius = Actual radius
Delta R = p/p deviation

Circularity Test
Section 8
Notes
As a general rule with feed forward optimized the actual

value radius is too large. This can be corrected using a
time constant MD32410 AX_JERK_TIME. If necessary
enable the time constant in all axes.
The circle above shows the results after feed forward has
been optimized however the mean radius is .0017 too
large.
32200 POSCTRL_GAIN 4.500 4.500

P1460 SPEEDCTRL_GAIN1 2.0 2.0
P1462 SPEEDCTRL_INTEGRATOR_TIME_1 4.0 4.0
P1433 SPEEDCTRL_REF_MODEL_FREQ 220.0 220.0
P1440 NUM_SPEED_FILTERS 0 0
32610 VELO_FFW_WEIGHT 1.0 1.0
32620 FFW_MODE 3 3
32810 EQUIV_SPEEDCTRL_TIME 0.002 0.002
32400 AX_JERK_ENABLE 0 0
The circle size is now corrected using AX_JERK_TIME
32200 POSCTRL_GAIN 4.500 4.500

32620 FFW_MODE 3 3
32402 AX_JERK_MODE 2 2
32410 AX_JERK_TIME 0.013 0.013

Section 8
Circularity Test
Notes
This circle shows the effect of AX_JERK_TIME being different, there-

fore it is also possible to use AX_JERK_TIME to correct this type of
error
32200 POSCTRL_GAIN 4.500 4.500

32620 FFW_MODE 3 3
32410 AX_JERK_TIME 0.012 0.014
32200 POSCTRL_GAIN 4.500 4.500

32620 FFW_MODE 3 3
32410 AX_JERK_TIME 0.015 0.011

Spindle Optimization
Section 9
Check Preset MD as below also any relevant parameter for spindle/axis in- Notes
terpolation
Example is for 8000 rpm Spindle Motor with no mechanical gear ranges
The following parameters can be pre-set to the suggested values in the

charts below. The values will vary depending upon the application.
Machine Machine Data Name Value

Data
MD 30300 IS_ROT_AX 1 Rotary axis/spindle
MD 30310 ROT_IS_MODULO 1 Modulo conversion for rotary axis/spindle
MD 30320 DISPLAY_IS_MODULO 1 Modulo 360 degree display for rotary axis/
spindle
MD 32000 MAX_AX_VELO[0] 8000 Max axis velocity
MD 32010 JOG_VELO_RAPID 60 Traverse rate in rapid jog
MD 32020 JOG_VELO 10 Traverse rate in jog
MD 32040 JOG_REV_VELO_RAPID 60 Rotary traverse rate in rapid jog
MD 32050 JOG_REV_VELO 10 Rotary traverse rate in jog
MD 32200 POSCTRL_GAIN[0] x To be optimized
MD 32200 POSCTRL_GAIN[1] x To be optimized
MD 32620 FFW_MODE 3 3 for Velocity Feed Forward
MD 32640 STIFFNESS_CONTROL_ENABLE 1 Dynamic Stiffness Control
MD 32810 EQUIV_SPEEDCTRL_TIME[0] x As per axis that interpolates with spindle.
MD 32810 EQUIV_SPEEDCTRL_TIME[1] x As per axis that interpolates with spindle.
MD 34000 REFP_CAM_IS_ACTIVE 0 If no bero switch
MD 34020 REFP_VELO_SEARCH_CAM 30 Reference point approach velocity

MD 34040 REFP_VELO_SEARCH_MARKER[0] 30 Creep velocity
MD 34040 REFP_VELO_SEARCH_MARKER[1] 30
MD 34060 REFP_MAX_MARKER_DIST[0] 370 Maximum distance to reference mark
MD 34060 REFP_MAX_MARKER_DIST[1] 370
MD 33000 FIPO_TYPE 3 Type of interpolator
MD 35000 SPIND_ASSIGN_TO_MACHAX 1 Assignment of spindle to machine axis
MD 35100 SPIN_VELO_LIMIT 8800 Maximum spindle speed
MD 35110 GEAR_STEP_MAX_VELO[0] 8000 Maximum spindle speed for gear change
MD 35110 GEAR_STEP_MAX_VELO[1] 8000
MD 35130 GEAR_STEP_MAX_VELO_LIMIT[0] 8000 Maximum spindle speed for gear stage
MD 35130 GEAR_STEP_MAX_VELO_LIMIT[1] 8000
MD 35200 GEAR_STEP_SPEEDCTRL_ACCEL X Acceleration in speed control mode
[0] To be optimized
MD 35200 GEAR_STEP_SPEEDCTRL_ACCEL X
[1]
MD 35210 GEAR_STEP_POSCTRL_ACCEL[0] X Acceleration in position control mode
To be optimized
MD 35210 GEAR_STEP_POSCTRL_ACCEL[1] X
MD 35500 SPIND_ON_SPEED_AT_IPO_START 2 Feedrate enable for spindle in the set range
MD 35550 DRILL_VELO_LIMIT[0] 4000 Maximum spindle speed for tapping
MD 35550 DRILL_VELO_LIMIT[1] 4000
MD 36000 STOP_LIMIT_COARSE 0.4 In position course limit
MD 36010 STOP_LIMIT_FINE 0.1 In position fine limit
MD 36030 STANDSTILL_POS_TOL 5 Standstill tolerance
MD 36040 STANDSTILL_DELAY_TIME 1 Delay for standstill monitoring
MD 36050 CLAMP_POS_TOL 1 Clamping tolerance
MD 36060 STANDSTILL_VELO_TOL 2 Tolerance for ―Axis/spindle‖ stopped
MD 36200 AX_VELO_LIMIT[0] 8800 Threshold for velocity monitoring
MD 36200 AX_VELO_LIMIT[1] 8800
MD 36300 ENC_FREQ_LIMIT[0] 100000 Encoder limit frequency
0
MD 36300 ENC_FREQ_LIMIT[1] 100000
0
MD 36400 CONTOUR_TOL[ 30 Tolerance band for contour monitoring
P 1433 SPEED_CONTROLLER_REFERENC x Same as the axis which interpolates with

E_MODEL_NATURAL_FREQUENCY The spindle e.g.Z

Section 9
Notes
Field and Current Controllers:
The field controller gain, (Kp, P 1590[0], and Tn, P 1592[0]), and current controller
gain, (Kp, P 1715[0] and Tn, P 1717[0]), settings are automatically calculated and
entered into the relevant parameters at the time of start-up based on the motor
data and power module current rating. These settings match the motor to the
drive and do not require further optimization.
Speed controller gain settings:

The speed controller gain settings, (P 1460 through P 1465) are automatically cal-
culated and entered into the relevant parameters at the time of start-up. The de-
fault values are based on the motor data and power module current rating.
7.1 Carry out a frequency response measurement on the speed controller
Select ―Startup‖ then

―Optimiz./test‖.
Select ―Axis +‖ until

the Main Spindle is
reached.
Then Select ―Speed

contr. Loop‖
and then Type of
Measurement ―Refer
frequency response
(after speed setpoint
filter)‖

Section 9
Notes
Enter the measur-

ing parameters as
shown.
Select
―Measurement‖
and then Select
―Start‖
You will then get a

message saying
Press NC Start.
Press ―Cycle
Start‖ on the Ma-
chine Control
Panel
When the meas-

urement I finished
Select ―Display‖ to
view the results.
Here it can be
seen that the Pro-
portional Gain of
the speed control-
ler can be in-
creased.

Section 9
Notes
Select ―Drive MD‖ and

search for P1460.
This value can now

be increased and the
frequency response
measurement can be
repeated.
After increasing
P1460 it can be seen
that we have a reso-
nance at 660 Hz and
so we can build in a
current setpoint filter.
NOTE :- If a low resolution spindle encoder is being used and only noise can be
seen at higher frequencies (e.g. above 800Hz) then a value can be used in
P 1441[0] ACTUAL_SPEED_SMOOTHING_TIME. Values between 0.3—0.5 are
useful
Select the 2nd filter

and make it a Band
Stop filter.
Then enter in the rele-

vant parameters

Section 9
Notes
P 1460 can now be

increased to keep
the amplitude re-
sponse at 0db to as
high a frequency as
possible
7.2 Speed Controller Gain Adaption :-For main spindle applications with en-
coder feedback the speed controller gain adaption function is enabled by default.
The function allows different proportional and integral gains to be active at low and
high speeds. The result is dynamic performance for tapping, threading and orien-
tation without having oscillation at high speeds.
The speed control-

ler adaption func-
tion is switched on
by default with
P1400 bit 5
P1460-P Gain lower

adaption range
P1461-Kp Gain adaption
speed upper scaling
P1462-I Gain lower adap-
tion range
P1463-Tn adaption speed
upper scaling
P1464-Lower adaption
speed
P1465-Upper adaption
speed
Example: P1460 = 8, P1461 =20%, Kp upper adaption = 8 x 20% = 1.6 Nms/rad

P1462 = 10, P1463 = 600%, Tn upper adaption = 10 x 600% = 60 ms
P1464 = 850, P1465 = 3400.

Section 9
Notes 9.3 The position controller should now be optimized using a ―Ref frequency re-
sponse‖ measurement. For this measurement Feed Forward should be switched off
therefore MD 32620 FFW_MODE = 0.
Because the spindle will interpolate with the Z axis during tapping/threading it is best
to try to keep the same values in MD 32810 EQUIV_SPEEDCTRL_TIME, MD 32200
POSCTRL_GAIN (check parameter sets) and
P1433SPEED_CONTROLLER_REFERENCE_MODEL_FREQ.
Select ―Position contr

loop‖
and then Type of
measurement ―Ref
frequency respo‖
Select ―Measuring pa-

rameters‖ and then
enter tha values
shown.
Bandwidth 166 Hz for

Position controller cy-
cle 3ms, 333 Hz for
Position controller cy-
cle 1.5ms

Spindle Optimization Section 9
Notes
Select
―Measurement‖
and then Select
―Start‖
You will then get a

message saying
Press NC Start.
Press ―Cycle
Start‖ on the Ma-
chine Control
Panel
When the meas-

urement is fin-
ished select
―Display to view
the results.
It can be seen
here that MD
32200 can be in-
creased but the
amplitude should
not come above
0db
Select ―Axis MD‖

and search for
32200.
The value can

then be increased

Section 9
Notes
The result here

shows that MD
32200 was in-
creased to bring the
amplitude closer to
0db but it should not
rise above the 0db
line
Feed Forward should now be switched back on.

9.4 A part program should now be created to check the spindle positioning
without overshoot, and the servo trace function should be used to view the results.
LAB:
SPOS=0
G4 F1
SPOS=130
G4 F0.2
GOTOB LAB
M30

from the ―Startup‖,
―Optimiz./test‖ menu

Section 9
Notes
Enter the Trace

selections as
shown.
The part program

should be selected
in Automatic Mode
and then ―Cycle
Start‖ on the ma-
chine control panel
should be pressed.
Once the program

is running Select
―Start‖ .
Once the trace

function has fin-
ished Select
―Display‖ to view
the results.
There should be no
overshoot as the
spindle comes in to
position.
MD 35210[0]
GEAR_STEP_POS
CTRL_ACCEL can
now also be in-
creased but no
overshoot should
be seen.
In some cases it
may be necessary
to switch drive pa-
rameter sets in or-
der to optimize per-
formance in differ-
ent gear ranges

Section 9
Notes
9.5 A check should now be made of the speed control acceleration. Firstly iden-
tify the acceleration time without any influence by the NC.
Set MD 35200[1] $MA_GEAR_STEP_SPEEDCTRL_ACCEL to a maximum e.g.

9999 rev/s2 ( t=V/a t=9000/60s/9999 t=15ms therefore no influence)
Now look at the motor data sheet
E.g. 1PH7101-2QF02-08J3 asynchronous motor

Section 9
Notes
Acceleration/deceleration with the original motor data equates to the S1 curve
P640 Current limit 14,97 A

(P305 rated motor current x1,5)
P1121 Ramp function generator ramp-down(ori10s) 0s
P1520 Torque limit upper/motoring 23,55 Nm
P1521 Torque limit lower/regenerative -23,55 Nm
P1530 Power limit motoring 3,70 KW
P1531 Power limit regenerating -3,7 KW
P326 motor stall torque correction factor 78 %
Select ―Servo
trace‖ from the
―Startup‖, ―Optimiz./
test‖ menu
Enter the Trace

selections as
shown.
Select
then ―Start‖
Once spindle ac-

tual speed is above
5 rpm the trace will
start.

Section 9
Notes
Enter a program in MDA.
S9000 M03
G04 F3
M30
Then press ―Cycle Start‖ on the machine control panel.
Once the trace func-

tion has finished Se-
lect ―Display‖ to view
the results.
The trace shows the acceleration taking 2.8 seconds from 0 to 9000 rpm and the
torque and power values relate to the motor S1 curve
Acceleration/deceleration with modified motor data equates to the S6 curve

Enter the values from the S6 curve as below.

P1520 Torque limit upper/motoring 40 Nm
P1521 Torque limit lower/regenerative -40 Nm
P326 motor stall torque correction factor (original 78 %

value)
Now repeat the servo trace test with the MDA program

Section 9
Notes
The trace now shows the acceleration taking 2.3 seconds from 0 to 9000 rpm and
the torque and power values relate to the motor S6 curve
9.6 Acceleration/deceleration with modified stall torque correction factor.
The motor stall torque correction factor P326 can be modified to further improve
the acceleration.
This value is write protected when P300 = 107 ( 1PH7 induction motor)
First change P10 = 3 ( Motor commissioning)

Then P300 = 1 ( Induction motor)
Now P326 can now be adjusted
P10 should be returned to 0
P326 =100 %
Acceleration now
1.77 seconds

Section 7
Notes
P326 =120 %
Acceleration now
1.58 seconds,
however under-
shoot can be
seen in the ac-
tual current trace
when decelerat-
ing and so P326
= 120 is too big.
P326 =105 %
Acceleration now
1.75 seconds,
this appears to
be the optimum
setting

P1520 Torque limit upper/motoring 40 Nm
P1521 Torque limit lower/regenerative -40 Nm
P326 motor stall torque correction factor 105 %
Adjust MD 35200[1] $MA_GEAR_STEP_SPEEDCTRL_ACCEL to give the machine

tool builders requirement for spindle acceleration

Section 7
Notes
9.7 Circularity test to check Solid Tapping:

When tapping the NC system automatically switches the Z axis and Spindle into
the relevant parameter sets. If the Spindle has no gear ranges then both the Spin-
dle and the Z axis are switched into parameter set 2 i.e. [1].
The NC system also always switches into Feed Forward during tapping and there-
fore it is important that Feed Forward has been commissioned on the Z axis and
also that speed controller adaption has been used on the Spindle (see relevant
sections). It is also important that all of the time constants are similar between Z
and Spindle. (Equiv_Speedctrl_Time, Speedctrl_Ref_Model_Freq etc)
In order to see any error between Z and Spindle it is best to run a circularity test
program with the X and Z axes and then to use the Coupled axis feature to link the
Spindle with the X axis. You can then to view a circularity test between the Z axis
and the Spindle. Any errors in the circle between Z and Spindle can then be seen.
Circularity test:
A circle test part program and the circularity test start up tool can be used to
measure the actual size and shape of a given test circle.
Example of an X-Z circle part program with Spindle coupled to X axis
FFWON
SOFT
TRAILON(SP1,X,1)
G90 G01 F3000 X400 Z400
LAB:
G91 G64 G02 X0 Z0 I10
GOTOB LAB
M30
Select ―Circularity
test‖

Section 9
Notes
Enter the values as

shown.
Then select the part

program in Automatic
mode and press
―Cycle Start‖ on the
machine control
panel.
Once the program is

running select ―Start‖
Once the circularity

test is finished select
―Display to see the
result.
NOTE spindle resolu-

tion is in fractions of a
degree.

Section 10
Advanced Surface
Notes
10.1 Use the following Technology G groups
 DYNNORM ( Standard Setting )

 DYNPOS ( Standard Setting )
 DYNROUGH ( AS - Setting )
 DYNSEMIFIN ( AS - Setting )
 DYNFINISH ( AS - Setting )
With the Technology G Groups a defined parameter state exists for each setting.
Because of this no machine data is ever overwritten and therefore at any time the
parameters are in a clearly defined state.
The following machine data are effective in the Technology Group
MD 32300 MAX_AX_ACCEL [0..4]

MD 20600 MAX_PATH_JERK [0..4]
MD 32431 MAX_AX_JERK [0..4]
MD 32432 PATH_TRANS_JERK_LIM [0..4]
MD 32310 MAX_ACCEL_OVL_FACTOR [0..4]
MD 20602 CURV_EFFECT_ON_PATH_ACCEL [0..4]
MD 20603 CURV_EFFECT_ON_PATH_JERK [0..4]
MD 32433 SOFT_ACCEL_FACTOR [0..4]
NOTE : - Check that there are no existing subroutines or cycles that over-
write these machine data. Also consider Cycle 832 and Cycle 832T. When
the Technology G Groups are used there is no longer a reason to over-
write machine data via cycles etc
!!!!!! Simplify the handling of the parameters as much as possible !!!!!

Section 10
Advanced Surface
Notes
10.2 Reduce the axis acceleration in the 5th Technology G Group ( DYN-
FINISH )
Even on very dynamic machines machines an acceleration of 2 m/s2 is rarely

reached ( limited by axial jerk) during finishing operations. Therefore reduc-
ing the acceleration in the 5th Technology Group rarely has an effect on the
processing time of the component, however it has the effect with LOOKA-
HEAD of a smoother path velocity
Recommendation :- MD 32300 MAX_AX_ACCEL = 1…..2 m/s2
10.3 De activate backlash and friction compensation
Under some conditions these compensations can lead to marks on the work
piece surface. If the cutting test has given a positive result and there is still a
requirement for friction compensation then adaptive friction compensation
should be used.
100
90
80
70
Switch Off amplitude in mm/min
60
50
Series1
40
30
20
10
0
0 0.1 0.2 0.3 0.4 0.5
Radial Acceleration in m/s^2
32520 FRICT_COMP_CONST_MAX 5 mm/min
32530 FRIDT_COMP_CONST_MIN 60 mm/min
32550 FRICT_COMP_ACCEL1 0.02 m/s^2

10.4 Monitoring of the AS function during operation using a Synchro-
nous Action
Using a synchronous action the variable $AC_IPO_STATE can be read and

this variable shows the state of the AS function
IDS=1 WHENEVER TRUE DO $R0=$AC_IPO_STATE
In the R parameter R0 the state of the AS function can now be observed.
Bit 0 = 0 Normal state

Bit 0 = 1 Advanced surface
Bit 1 = 0 COMPOF
Bit 1 = 1 COMPCAD
When finishing or when AS is required then Bit 0 = 1 and Bit 1 = 1

Section 10
Advanced Surface
Notes
10.5 The following G-Codes must be active during AS processing
For 3 Axis operation
SOFT
COMPCAD
G642 for SW stands <= 72.05
G645 for SW stands >= 72.06
FIFOCTRL
FFWON
DYNROUGH, DYNSEMIFIN or DYNFINISH
10.6 Set $MA_MAX_ACCEL_OVL_FACTOR[4] to 1.01 for all axes for

operation with DYNFINISH

Section 10
Advanced Surface
Notes 828D SL MACHINE DATA ADVANCED SURFACE
MD DESCRIPTION AS
10200 $MN_INT_INCR_PER_MM 100000 Manufact
10210 $MN_INT_INCR_PER_DEG 100000 Manufact
11400 $MN_TRACE_SELECT 0 System
11411 $MN_ENABLE_ALARM_MASK System
18360 $MN_MM_EXT_PROG_BUFFER_SIZE 500 Manufact
20150[3] $MC_GCODE_RESET_VALUES 3 FIFOCTRL Manufact

20150[44] $MC_GCODE_RESET_VALUES 2 UPATH Manufact
20170 $MC_COMPRESS_BLOCK_PATH_LIMIT 20 Manufact
20442[0] $MC_LOOKAH_SYSTEM_PARAM 0 System

20443[0] $MC_LOOKAH_FFORM 0 DYNNORM Manufact
20443[1] $MC_LOOKAH_FFORM 0 DYNPOS Manufact
20443[2] $MC_LOOKAH_FFORM 0 DYNROUGH Manufact
20443[3] $MC_LOOKAH_FFORM 1 DYNSEMIFIN Manufact
20443[4] $MC_LOOKAH_FFORM 1 DYNFINISH Manufact
20490 $MC_IGNORE_OVL_FACTOR_FOR_ADIS 1 Manufact
20550 $MC_EXACT_POS_MODE 3 Manufact
20600[0] $MC_MAX_PATH_JERK 10000 DYNNORM Manufact
20600[1] $MC_MAX_PATH_JERK 10000 DYNPOS Manufact
20600[2] $MC_MAX_PATH_JERK 10000 DYNROUGH Manufact
20600[3] $MC_MAX_PATH_JERK 10000 DYNSEMIFIN Manufact
20600[4] $MC_MAX_PATH_JERK 10000 DYNFINISH Manufact
20602[0] $MC_CURV_EFFECT_ON_PATH_ACCEL 0 Manufact
20603[0] $MC_CURV_EFFECT_ON_PATH_JERK 0 Manufact

Section 10
Advanced Surface
20603[1] $MC_CURV_EFFECT_ON_PATH_JERK 0 Manufact Notes
20605[0] $MC_PREDYN_SMOOTHING_FACTOR 1 Manufact
20606[0] $MC_PREDYN_SMOOTHING_ON 0 DYNNORM Manufact
20606[1] $MC_PREDYN_SMOOTHING_ON 0 DYNPOS Manufact
20606[2] $MC_PREDYN_SMOOTHING_ON 0 DYNROUGH Manufact
20606[3] $MC_PREDYN_SMOOTHING_ON 1 DYNSEMIFIN Manufact
20606[4] $MC_PREDYN_SMOOTHING_ON 1 DYNFINISH Manufact
20607[0] $MC_PREDYN_MAX_FILT_LENGTH_GEO 2 Manufact
20608[0] $MC_PREDYN_MAX_FILT_LENGTH_RD 5 Manufact

20482 $MC_COMPRESSOR_MODE 100 Manufact
20484 $MC_COMPRESSOR_PERFORMANCE 9 System
28060 $MC_MM_IPO_BUFFER_SIZE 150 Manufact
28070 $MC_MM_NUM_BLOCKS_IN_PREP 80 Manufact
28302[0] $MC_MM_PROTOC_NUM_ETP_STD_TYP 28 System
28530 $MC_MM_PATH_VELO_SEGMENTS 5 Manufact
28533 $MC_MM_LOOKAH_FFORM_UNITS 18 Manufact
28540 $MC_MM_ARCLENGTH_SEGMENTS 10 Manufact
28610 $MC_MM_PREPDYN_BLOCKS 10 Manufact
29000 $OC_LOOKAH_NUM_CHECKED_BLOCKS 150 Manufact
32310[0] $MA_MAX_ACCEL_OVL_FACTOR 1,20 Manufact

32431[0] $MA_MAX_AX_JERK Standard DYNNORM Manufact
32431[1] $MA_MAX_AX_JERK Standard DYNPOS Manufact
32431[2] $MA_MAX_AX_JERK Standard DYNROUGH Manufact

32431[3] $MA_MAX_AX_JERK 20,00 DYNSEMIFIN Manufact
32431[4] $MA_MAX_AX_JERK 20,00 DYNFINISH Manufact
32432[0] $MA_PATH_TRANS_JERK_LIM Standard DYNNORM Manufact
32432[1] $MA_PATH_TRANS_JERK_LIM Standard DYNPOS Manufact
32432[2] $MA_PATH_TRANS_JERK_LIM Standard DYNROUGH Manufact
32432[3] $MA_PATH_TRANS_JERK_LIM 20,00 DYNSEMIFIN Manufact

Section 10
Advanced Surface
Notes 32432[4] $MA_PATH_TRANS_JERK_LIM 20,00 DYNFINISH Manufact
32620 $MA_FFW_MODE 3 Manufact
42471 $SC_MIN_CURV_RADIUS 1 Manufact

B051 Line and Motor Modules
1 Brief description
Module Objective:
Upon completion of this module you will know how the drive components of the Sinumerik 828D sys-
tem are integrated and how the power to these components should be applied and re-
moved.
Module Description:
The Sinumerik 828D operates with Sinamics drive components, these components must be powered
on/off in a certain sequence. This module shows how these components are connected to the system
and the required power on/off enabling sequence.
Sinumerik 828D
B051
Line and Motor Modules B051
Section 2 Section 2
Page 3
Smart Line Module (SLM)
Section 3 Section 3
Active Line Module (SLM) Page 10
Section 4 Section 4
Motor Module (MM) Page 13
Section 5 Section 5
Supply and Enabling Examples Page 17

Smart Line Module (SLM) Section 2
General Information Notes
The SLM is responsible for rectifying the AC mains supply into the DC link voltage
which is then utilised by the Motor Modules.
This DC link voltage is non-stabilised.
The SLM is also responsible for handling regenerative current caused by the
braking of motors.
The regenerative current is fed back into the mains network. This eliminates the
need for braking resistors and complex measures for heat dissipation can be
omitted.
The SLM is available in 5, 10, 16 & 36Kw variants with internal or external cooling
capability.
Due to the non-stabilised DC link voltage, the SLM would be used on low dynamic
machinery where the axis/spindle acceleration/deceleration rates are not severe.
2.1 Smart Line Module. (5Kw & 10Kw)

The 5 & 10Kw SLM’s are not for use on the DriveCliq network.
Example:-An internally cooled 10Kw SLM module with terminal locations etc.
X21/X22:
Enables etc.
Electronics/DC link
X24:Electronics bus bars. (below flip
supply. down cover).
LED status
Indicators
(See page 6)
X1: Mains supply

Protective earth (3-Phase AC)
connections.
Terminal descriptions.
X1-Mains power connector.
Terminals:- U1, V1, W1

Supply:- 380V to 480V 3 phase AC +10% (-15% < 1 min)

Section 2 Smart Line Module (SLM)
Notes X24-Electronics supply 24V DC (All SLM variants)
Terminal + = Nominal +24V DC (20.4V to 28.8V)
Terminal M = Electronics ground
The electronics supply not only supplies the SLM module but also supplies the
remaining drive modules via a bus-bar system which is found below the flip down
covers on the front of the drive modules.
Location of the electronics supply and DC link bus bars.
24V DC Electronics supply (X24) Bridging device for

continuity of the bus
between drive
modules.
+24V DC Bus-bar
0V DC Bus-bar
+ DC Link Bus-bar
- DC Link Bus-bar
LM MM1 MM2
Location of SLM connectors X21 & X22.
X21: X22:
Enable, ready and Regeneration and
fault signals. fault reset signals.
X24:
24V DC Electronics
supply
SLM

Description of connector X21 (SLM 5 & 10 Kw models only). Notes
Terminal Function Description

1 Ready Signal Switches high (+24V DC) when the
(Output) following conditions are true:-
 Electronics supply present (X24).
 DC Link is pre-charged.
 Pulses enabled (X21.3 & X21.4)
 No over-temperature
 No over-current
It is recommended that the signal is connected directly

to the 828D controller via connector X20 pin 1. This is
the OFF1 enable signal.
2 Pre-warning Switches low (0V DC) when any of the following
(Output) conditions arise:-
 Over-temperature threshold reached.
 I²t threshold reached.
 Mains fault making regenerative
feedback impossible (If feedback is
deactivated (X22.2 = +24V DC) this
warning will not be active.
This signal is for use by the machine tool builder to set

a user alarm and alert the operator to a problem.
3 Enable Pulses Applying +24V DC will cause the pulses to be
(Input) enabled. (Current consumption:10mA)
This signal must be removed at least 10ms prior to the

3-phase mains supply being removed.
Failure to do this can lead to damaged drive modules.
This is especially important when the axes/spindles
are decelerating and causing regenerative currents. if
the mains circuit is opened these regenerative
currents remain within the drive system causing
damage to the modules.
It is recommended that this terminal is connected via

an early break contact on the machine isolator switch
and the line contactor (If used).
If the terminal is used by the manufacturer it must be
ensured that it is controlled in the suggested manner.
When used in this way the transistors will be switched

off and mains regeneration halted, the motors will then
coast to a halt. This is not suitable for an emergency
stop situation.
4 Enable Pulses Must be connected to the 0V of the enable pulses
(Ground) supply.

Notes Description of connector X22 (5Kw & 10Kw models only)

1 +24V DC +24 V DC Supply for use with the functions of X22.2 &
(Output) 3 described below.
2 Disable Applying +24V DC will cause the regeneration func-

Regeneration tion to be disabled.
(Input)
Usage:-In some case. it may be necessary to stop the
regeneration of current caused by braking motors.
Example:- Poor quality mains Networks not able to
handle regeneration.
Note:-The fitting of resistor modules to dissipate
excess energy will be required should this function be
used.
3 Fault Reset Applying +24V DC will cause the resetting of any drive
(Input) faults.
Usage:-A fault occurring on the drives system will be

latched, this can be reset with this function providing
the cause of the original fault is no longer present.
4 0V DC Must be connected to the 0V of the electronics supply

(Ground) (X24).
LED Status Display-Smart Line Modules 5 & 10 KW

LED Colour Status Explanation
Green On Module is healthy and operational.

Yellow On Pre charging of DC link active; Bypass relay
READY dropped out.
(Top)
Red On Over temperature/current fault or electronics power
supply outside permitted range.
Off Electronics power supply outside permitted range.
DC LINK Yellow On DC link voltage within tolerance.

(Bottom)
Red On DC link voltage outside tolerance.

SLM modules 16Kw and above Notes
These models are equipped with DriveCLiQ drive bus technology.
The function of certain terminals are therefore different from the non-DriveCLiQ SLM
modules.
Smart Line Modules (16Kw & 36Kw)

The 16 & 36Kw SLM’s are always connected to the DriveCliq network.
Below:-An internally cooled 36Kw SLM showing terminal locations etc.
X200/X201/X202:
X21: DriveCLiQ
Pulse enable connectors
X24:Electronics
supply.
Electronics/DC
link bus bars.
(below flip down
cover).
LED status
Indicators.
(See page 9)
Protective earth
terminals.
X1: Mains supply
(3-Phase AC)
Terminal description.
X1-Mains power connector.


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

M Terminal:-Electronics ground 0V
The electronics supply not only supplies the SLM module but also supplies
the remaining MM modules via a bus-bar system which is found below the flip
down covers on the front of the drive modules.
24V DC Electronics supply (X24) Linking device for

continuity of the
electronics bus
between drive units.
+24V DC Bus-bar
0V DC Bus-bar
+ DC Link Bus-bar
- DC Link Bus-bar
LM MM1 MM2
Location of SLM connectors X21, X22, X200, X201 & X202.
X21:
Pulse enable.
X202:
DriveCLiQ connector.
X201:
X200:
X24:
24V DC Electronics
supply.

Description of connector X21. (SLM 16 & 36Kw models only). Notes

1 Not used Not used
2 Not used Not used
3 Enable Pulses Applying +24V DC will cause the pulses to be
(Input) enabled. (Current consumption:10mA)
This signal must be removed at least 10ms prior to the

3-phase mains supply being removed.
This is especially important when the axes/spindles are
decelerating and causing regenerative currents. if the
mains circuit is opened these regenerative
It is recommended that this terminal is connected via

an early break contact on the machine isolator switch
and the line contactor (If used).
If the terminal is used by the manufacturer it must be
ensured that it is controlled in the suggested manner.
When used in this way the transistors will be switched

off and mains regeneration halted, the motors will then
coast to a halt. This is not suitable for an emergency
stop situation.
4 Enable Pulses Must be connected to the 0V of the enable pulses
(Ground) supply.
LED Indicators SLM 16Kw and above.

Green On Module configured and ready, DriveCLiQ commu-
nication is active.
Orange On DriveCLiQ communication is being established/
module not configured.
READY Red On At least one fault is present.
(Top)
Green/ Flashing Firmware download procedure is running.
Red 2Hz
Green/ Flashing Component recognition is active (p0124 = 1)
Orange 2 Hz
or Red/
Orange
DC LINK Orange On DC link voltage within tolerance-Only if unit is con-

(Bottom) figured and ready.
Red On DC link voltage outside tolerance-Only if unit is
configured and ready.

Section 3 Active Line Module (ALM)
Notes The ALM is responsible for the rectification of the AC mains supply into the DC link
voltage which is then utilised by the Motor Modules.
This DC link voltage is also stabilised unlike the SLM.
The ALM is also responsible for handling regenerative current caused by the braking
of motors.
The regenerative current is fed back into the mains network. This eliminates the need
for braking resistors and complex measures for heat dissipation can be omitted.
The ALM is available in 16, 36, 55, 80 & 120Kw variants with internal or
external cooling capability.
The ALM is always connected to the DriveCLiQ bus and has four
connections.
The stabilised DC link makes the ALM suitable for high dynamic machinery where the
acceleration and positioning of axes/spindles is critical.
Below:-ALM terminal locations etc.
X21:
Pulse enable, X200/X201/X202:
temperature DriveCLiQ
sensor. connectors
X24:Electronics
supply.
Electronics/DC link
bus bars. (Below
flip down cover).
LED status
Indicators.
(See page 12)
Protective earth X1:

3-Phase AC
Mains supply
Terminal description.


Active Line Module (ALM) Section 3
Location and Identification of the electronics supply bus bar. Notes
+ Terminal = Nominal +24V DC (20.4V to 28.8V)

M Terminal = Electronics ground
The electronics supply not only supplies the ALM module but also supplies the
remaining drive modules via a bus-bar system which is found below the flip down
covers on the front of the drive modules.

between drive
modules.
Top bus-bar: +24VDC
Bottom bus-bar: 0V
LM MM1 MM2
Location of ALM connectors X21, X22, X200, X201 & X202
X21:
Enable and
Temperature sensor
Connections.
X203:
X202:
X201:
X200:
X24:
24V DC Electronics
supply.

Section 3 Active Line Module (ALM)
Notes Description of connector X21
1 + Temp Temperature sensor input from Active Interface

(Input) Module (Observe the polarity)
2 - Temp Temperature sensor input from Active Interface
(Input) Module (Observe the polarity)
3 Enable Applying +24V DC will cause the pulses to be
Pulses enabled. (Current consumption:10mA)
(Input)
This signal must be removed at least 10ms prior to the 3-
phase mains supply being removed.
This is especially important when the axes/spindles are
decelerating and causing regenerative currents. if the
mains circuit is opened these regenerative
It is recommended that this terminal is connected via an

early break contact on the machine isolator switch and
the line contactor (If used).
If the terminal is used by the manufacturer it must be en-
sured that it is controlled in the suggested manner.
When used in this way the transistors will be switched off

and mains regeneration halted, the motors will then coast
to a halt. This is not suitable for an emergency stop
situation.
4 Enable Must be connected to the 0V of the enable pulses supply.
Pulses
(Ground)
LED Status Indicators-ALM Modules.

Green On Module configured and ready, DriveCLiQ
communication is active.
Orange On DriveCLiQ communication is being established/
module not configured.
READY Red On At least one fault is present.
(Top)
Red 2Hz
Orange 2 Hz
or Red/
Orange
Orange On DC link voltage within tolerance-Only if unit is
DC LINK configured and ready.
(Bottom)

Motor Module (MM) Section 4
The Motor Modules are responsible for converting the DC link voltage into a variable Notes
AC voltage in order to drive the motors.
The modules have to be connected to the DriveCLiQ bus.
The modules are available in single or double axis versions.
The double axis modules are equipped with four DriveCLiQ connectors, one more
than the single axis modules.
Single Axis MM.

Available in the following rated current output sizes:-
3, 5, 9, 18, 30, 45, 60, 85, 132 & 200A.
Example:-A single axis MM showing connector locations etc.
X21:
Enables etc. X200/X201/X202:
DriveCLiQ
Connectors.
Electronics/DC link
bus bars. (below flip
down cover).
LED Status
Indicators.
(See page 16)
X11: Brake output

for MM of 45A and
above.
X1: Output to
Motor, including
Protective earth the brake output for
terminals. MM less than 45A.
Motor connector. (MM less than 45A).
Screw terminals. Not on Metal connector

Fixing screw housing, also used for
Crimped cable types.
cable shield.
Brake: Negative Brake: Positive

Connection Connection
Locating key- Locating key-

Changeable Changeable
Motor: Phase U Motor: Phase V Motor: Phase W

Section 4 Motor Module (MM)
Notes Motor connector. (MM 45A and above).
For MM modules of 45A and above, the brake is supplied by a separate connector
(X11)
Further information can be found in the “Sinamics S120” Equipment Manual.
The brake control circuit is isolated therefore it is not permissible to connect the –ve
brake connector to the 0 volt common of the machine.
Double Axis MM.

Available in the following rated current output sizes:-3, 5, 9 & 18A
Example:-A double axis MM showing connector locations.

These units will have two identical Motor/Brake connectors (X1 & X2) and two
identical enable connectors (X21 & X22)
X21:Motor 1 X22:Motor 2
Enables etc. Enables etc.
X200/X201/X202/
X203: Electronics/DC link
DriveCLiQ bus bars. (below flip
connectors down cover).
LED Status
Indicators.
(See page 16)
X1 & X2 Output to
Motor,
including the brake
output for MM less
than 45A
X11: Brake output

Protective earth
for MM of 45A and
connections.
above.
DC link bus-bar and +24V DC bus bar location.

Both bus bar systems originate from the SLM/ALM modules.

between drive
modules.
+24V DC Bus-bar
0V DC Bus-bar
+ DC Link Bus-bar
- DC Link-Bus-bar
SLM MM1 MM2

Motor Module (MM) Section 4
Terminal descriptions-All variants. Notes
X21: Pulse
Enable etc.
X22: Pulse
X21: Pulse
Enable etc.
Enable etc.
X203:
DriveCLiQ
X202:
DriveCLiQ.
X202:
X201: DriveCLiQ
DriveCLiQ.
X201:
DriveCLiQ
X200:
DriveCLiQ.
X200:
DriveCLiQ
Single axis Double axis

Module. Module.
Connector X21 & X22 (X22 only for double axis

modules)
1 + Temp Positive temperature sensor input from non-DriveCLiQ

(Input) temperature sensor.
Type:- KTY84-1C130/PTC
2 - Temp Negative temperature sensor input from non DriveCLiQ
(Input) temperature sensor.
Type:- KTY84-1C130/PTC
3 Enable Applying +24V DC will cause the pulses of the individual
Pulses axis to be enabled.
(Input) When the signal is low, “Safe pulse suppression” is
activated.
(Current consumption:10mA)
Note:-No electrical isolation is made between the Motor
module and the motor.
This enable signal is only operational if the Safety
Integrated function “Safe Standstill (SH)” is enabled.
This is a dual channel monitoring system of the Control
Unit and Motor Module. The status of the Enable Pulses
input is cross checked against the corresponding CU
input, an error is reported if they do not match.
4 Enable Must be connected to the 0V of the enable pulses
Pulses supply.
(Ground)

Section 4 Motor Module (MM)
Notes
Off Electronics power supply outside permitted
range.
Green On Module configured and ready, DriveCLiQ commu-
nication is active.
Orange On DriveCLiQ communication is being
READY established/module not configured.
(Top) Red On At least one fault is present.
Red 2Hz
Orange 2 Hz
or Red/
Orange
Off Electronics power supply outside permitted
range.
DC LINK Orange On DC link voltage within tolerance-Only if unit is
(Bottom) configured and ready.

Supply and Enabling Examples-SLM 10 & 16Kw Section 5
For trouble free operation it is essential that the drives are powered on/off and Notes
enabled correctly.
If the mains supply switch/contactor is opened while the drive pulses are
enabled and the drive is in regeneration mode, the regenerative current which is
normally fed back into the mains will have no where to go, except that is into the
motor and line modules, this can result in damage to these modules.
The solution is to use an auxiliary contact fitted to the mains switch and drive line
contactor.
This auxiliary contact must open at least 10ms before the main contacts open.
The contact is wired to the Pulse Enable terminal of the SLM/ALM module.
If the Main switch or contactor is operated while the drive is in operation the pulses
will be disabled and the motors will free wheel to a standstill. (Except when the Safety
Integrated function “Safe Stop” is enabled)
Any potentially harmful current will be unable to enter the drive modules as the
transistors are now switched off.
Below is the recommended timing diagram for the enabling of drives via the controller
and using a line Contactor.
Mains supply
E Stop active
DB2700.DBX0.1
Input to ALM/SLM Minimum 10mS
Enable Pulses
ALM/SLM X21.3
Minimum 10ms
Energise Line Con-

tactor-From 828D
X132.10
Input to 828D
ALM/SLM enabled.
From user or SLM
X21. 1 to 828D
X122.1 (Off1)
Input to 828D
Enable OFF3 from
user to 828D
X122.2
SLM X21.1 Ready (Output from SLM)

X21.2 I2t warning (Output from SLM)
X21.3 Enable pulses 24V (Input to SLM)
X21.4 Enable pulses 0V (Input to SLM)
828D X122.1 Line Module Ready OFF1 signal (Input to 828D)

X122.2 Drive Enable OFF3 (Input from E stop circuit)

Mains Supply and Enabling Examples.
Section 2
B051
SLM 5 & 10Kw, no line contactor, user controlled enable.
Notes
X122
I2t alarm
From SLM
Main to user
supply
Main Early break

Switch contact X132
X21
Optional:-
Pulse enable via
user PLC
+24V 24V DC 0V
Page 18
PSU
Supply to other
equipment
Drive enable
From user to
828D
Filter Reactor
SINUMERIK 828D
Mains Supply and Enabling Examples-
SLM 5 & 10Kw . User controlled line contactor (Early break contact) and 828D controlled enables.
Section 2
Notes
SINUMERIK 828D
X122
I2t alarm
From SLM
Mains to user
supply
Drive ready-SLM to 828D
Main Early break

Switch contact X132
X21
Supply to other
equipment
Optional:-
Pulse enable via
Page 19
user PLC
0V 24V Drive enable

From user to
828D
Line Early break
Contactor contact
Energise
+24V 24V DC 0V Line
Line
PSU contactor
contactor
energised.
From user
To user PLC
PLC
Filter Reactor
B051
Mains Supply and Enabling Examples.
Section 2
B051
ALM and SLM (16 & 36Kw)-no line contactor, user controlled enables.
Notes
X122
Main
supply
X100
Main Early break

DriveCliq
Switch contact X132
X21
Optional:-
Pulse enable via
user PLC
X200
+24V 24V DC 0V
Page 20
PSU
Supply to other
equipment
ALM/SLM Drive enable

enable From user to
From user to 828D
828D (OFF3)
Filter Reactor
SINUMERIK 828D
Mains Supply and Enabling Examples-
ALM and SLM 16 & 36Kw. User controlled line contactor (Early break contact) and 828D controlled enables.
Section 2
Notes
SINUMERIK 828D
X122
Mains
supply
X100
Main Early break DriveCliq

Switch contact X132
X21
Supply to other
equipment
X200
Optional:-
Pulse enable via
Page 21
user PLC
0V 24V
ALM/SLM Drive enable

Line enable From user to
Early break
Contactor From user to 828D
contact
(OFF3)
+24V 24V DC 0V
PSU Energise
Line
Line
contactor
contactor-
Filter Reactor energised-
From user
To user PLC
PLC
B051
Mains Supply and Enabling Examples- Section 2
B051
ALM & SLM 16 & 36Kw . 828D controlled line contactor (Early break contact) and enables.
Notes
X122
Mains
supply
X100
Main Early break DriveCliq

Switch contact X132
X21
Supply to other
equipment
Line Energise
X200 contactor Line
Optional:- energised- contactor-
Page 22
Pulse enable via To 828D From 828D
user PLC or
828D X122/X132
0V 24V
Drive enable
From user to
828D
Line Early break (OFF3)
Contactor contact
+24V 24V DC 0V
PSU
Filter Reactor
ALM/SLM
enable
From user to
828D
SINUMERIK 828D
B006 Electrical Cabinet Design
1 Brief description
Module objective:
Upon completion of this module you will understand the requirements to design an electrical cabinet.
Module description:
Technological advances have resulted in the reduction in size of electronic equipment. The down
side of this is that the equipment is more prone to heat, dust and moisture damage.
By calculating the power loss of the components and therefore ensuring the correct cooling
requirements of a particular cabinet, it is possible to reduce the failure rate of these and other compo-
nents.
It is also essential that the cabinets are designed to prevent/minimise the ingress of contaminants.
This module explains what is required to produce an acceptable electrical cabinet and what “Sins” to
avoid.
Sinumerik 828D
B006
Contents:- B006
Section2
Seven Deadly Sins Page 3
Section2
Choice of cabinet Page 4
Section 3
Arrhenius’ Law Page 5
Section 4
Cabinet Cooling Page 6
Section 5
Equipment Mounting Page 10
Section 6
Plugs, Sockets and Cabling Page 12
Section 7
Cabinet Sealing. Page 14
Section 8
Miscellaneous. Page 15

Deadly Sins
Section 2
The key to building a good electrical cabinet is avoiding certain “Sins” which will cause Notes
premature equipment failure and sporadic faults.
Sin 1 Cooling units must be able to deal with the heat generated by the electrical
equipment.
Sin 2 Air circulation must be controlled in a manner which will prevent condensation
forming and must make use of the natural convection of warm air.
Sin 3 Shielding of cables should be done with purposely made clamps and not with a
wire tail.
Sin 4 Cabinets should be fully sealed including unused cable entries.
Sin 5 Electrical equipment must be installed in such a way that the air can flow freely,
recommended air gaps around the equipment must be adhered to.
Sin 6 Electrical cables must be routed so that sensitive signal cables are kept
separate from the power cables.
Sin 7 DC link bus-bar connections must be tightened to the recommended torque.

Section 2 Choice of cabinet.
Notes Most of the heat within an electrical control cabinet is produced by the drive
components.
Sinamics drives are available in internally or externally cooled variants.

The internally cooled drive types dissipate heat within the cabinet and will usually
require a cooling unit to remove this heat.
The externally cooled drive types dissipate heat to the outside of the cabinet and may
not require cooling units.
It may be preferable to always use cooler units as this allows the cabinet to be sealed
which is the best option for stopping the entry of contaminants. Within the cabinets it
may also be necessary to install fans to ensure the air is circulated and prevent “Hot
spots” from forming.
The technical specifications of the individual hardware component will provide details
of the power loss measured in Watts.
Calculations are made to see if the cabinet can dissipate the heat naturally.
The cabinet manufacturer can supply details of the heat-loss of the cabinet.
Natural heat dissipation occurs through the cabinet walls providing the wall is in free
air and not against a wall for example.
A general rule is that the energy dissipated is approximately 50Watts/m² of free
cabinet wall assuming a 10° temperature difference between the cabinet and the
outside air.
Example 1:- A cabinet with a width of 3 m, a height of 2 m and a depth of 1 m

arranged with its back to a wall has an effective surface area of approximately 13 m².
2m x 3m = 6m² (Front)
2m x 1m = 2m² (left side)
2m x 1m = 2m² (Right side)
3m x 1m = 3m² (Top)
Total = 13m²
Therefore this cabinet is able to dissipate approximately 650 W. (50W x 13m²)

If the actual losses of the cabinet equipment are higher than this, other cooling
measures have to be implemented.
Example 2:-
Internally cooled 36Kw Active Line Module-Power loss = 630 W
Internally cooled 18A Single Motor Module-Power loss = 165 W
Internally cooled 30A Single Motor Module-Power loss = 630 W
These few items alone add up to 1425 W which would require extra cooling if fitted
into the cabinet described in example 1.
The ideal ambient temperature for the cabinet is 35°C. The cooling unit should be set
to achieve this temperature. If the temperature is allowed to get too high the lifetime of
the components will be reduced. If the temperature is set too low there is a risk of
condensation forming on the electronic components which can also be detrimental to
the equipment.

Section 3
Arrhenius’ Law
The following graph demonstrates Arrhenius Law and shows the effects that increased Notes
temperature has on the lifetime of electronic components.
It can be seen that an increase in temperature by 10 will result a 50% increase in the
failure rate (50% reduction in life time)
Expected
Life Defect
Time Rate
120% — 9.00
— 8.00
100%
— 7.00
80% — 6.00
— 5.00
60%
— 4.00
40% — 3.00
— 2.00
20%
— 1.00
0% — 0.00
-10K -5K 0K 5K 10K 15K 20K 25K 30K

Temperature Change

Section 4 Cabinet Cooling.
Notes Cabinet cooling is usually accomplished using fans and filters or cooling units.
The fans and filter option would normally be used on low power installations or where
the drive units are of the externally cooled type.
A drawback of this method is that the fans pull air from outside the cabinet via filters.
Even if the filters are serviced regularly it is impossible to keep all contaminants out
of the cabinet.
Cooling units allow the cabinets to be air-tight as the air within the cabinet is
re-circulated through the cooling unit.
A thermostat should be employed to regulate the temperature to the recommended
35°C
If a higher temperature is unavoidable (Max 50°C) the drive units have to be
de-regulated
It is important to position the cabinet and cooling devices to ensure correct operation.
A cabinet placed in such a position where it restricts the ventilation inlet/outlet can
prevent the cabinet from being cooled correctly or result in the cooling unit becoming
damaged due to excessive work cycles.
The cooling device should also be positioned to ensure the cool air is reaching the
desired areas and that the warm air is extracted and not allowed to cause hot spots
within the cabinet.
The inlets and outlets of the cooling units must have a clearance of at least 200mm.
See below
≥ 200mm
Roof mounted
cooling units
m
0m Outlet
20
≥
≥ 200mm
t
t
le
le
In
In
Potential
obstruction
Electrical cabinet Electrical cabinet
The use of baffles is recommended to prevent ventilation short circuits where the
exhaust air is taken directly into the cooling units.

Section 4
Cabinet Cooling.
Correct installation of cooling units. Notes
The cool air should be directed to the bottom of the drive. The internal drive fans and
natural convection will draw the air through the drives.
The cool air from the cooling unit should not be directed straight onto/into the drives, it
should be allowed to mix with the warmer air already in the cabinet, This will minimise
the risk of condensation forming.
Cabinet top mounted cooling units require a method of directing the cool air from the
cooling unit to the bottom of the drives.
In the case of a door mounted unit it may be necessary to direct the cool air with the
use of a baffle.
Below:-Examples of cabinet cooling with cooling units and internally cooled drives
Outlet Cooling
unit
Inlet
Ducting
Outlet
Drive ≥ 200mm Cooling

equipment unit
Drive
equipment
Baffle
Temperature Temp.
Measuring point Meas.
point Inlet
Cabinet top mounted cooling unit. Cabinet door mounted cooling unit.
It is advisable that the cooling units are switched off automatically when the cabinet
door is opened.
Large differences between the outside air temperature and the cabinet temperature
can lead to condensation forming when the cabinet doors are opened. This should be
taken into consideration when the cabinet thermostat is set.
A by-product of cooling units is water. For obvious reasons it must be ensured that this
water is not allowed to enter the electrical cabinet . This is particularly important for
roof mounted cooling units as any leaking water could drip directly onto the drive
equipment..
The outside of the cooling unit must be protected from any possible contamination
such as coolant, machine waste etc.

Section 4
Cabinet Cooling.
Notes Cabinet cooling sins
Outlet Cooling
unit
Inlet Air short circuit/
contamination due to
cabinet sealing
problems
Air short circuit due

to lack of ducting
≥ 200mm
Drive
equipment
Drive
equipment
Baffle
Temp.
Meas.
point
Air short circuit/

Cabinet top mounted cooling unit contamination due to
without ducting cabinet sealing
problems
Air intake restricted due

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

onto drive equipment Warm air intake at the
will cause condensation bottom of the cooling
problems. unit.
Incorrectly installed cooling unit Wrong type of cooling unit used.

Section 4
Cabinet Cooling
For cabinets with externally cooled drive units it is possible that the cooling can be Notes
achieved with fans drawing air from the outside via a filter.
Natural convection causes the warm air to exit via a filter.
The fact that air is being drawn directly from the outside means that this system can
never be airtight.
Having a fan for the inlet side only ensures that the cabinet is positively pressurised
which helps keep contaminants from entering.
It is extremely important that the filters are service regularly to avoid ingress of
contaminants and to maintain the efficiency of the cooling process.
Outlet
via filter
Drive
equipment
Temperature
Measuring points
Inlet via
Fan &
filter unit
Fan & filter type cooling sys-
Example:- Externally cooled drive Example:- Externally cooled drive

module heat-sinks protruding from modules with heat-sink cover and fan & filter.
the rear of a cabinet with a cut-out The fan takes air in at the bottom and the
ready to accept another module. cover creates a chimney effect to give a good
cooling effect.

Section 5
Equipment Mounting
Notes The correct mounting of equipment is important with respect to the cooling process
and for Electromagnetic compatibility measures.
Air flow to drive units:-
It is essential that the air flow to the drive units is unrestricted. Other electrical
equipment, including cable ducting and cables, must be mounted a suitable distance
away from the top and bottom sides of the drive units. The minimum distance for
Sinamics S120 drives is 80mm.
Cable
ducting
≥ 80mm
Drive
equipment
≥ 80mm
Cable
ducting
Diagram showing minimum Photograph of correctly installed drive

distance between drive units units. Cables and ducting are not
and other cabinet components. causing restrictions to the air flow
Electromagnetic Compatibility (EMC):-
To cut down on the interference effects caused by the high frequency drive equipment
certain measures can be taken. One of these includes the positioning of the
equipment within the cabinet. By positioning the line module, reactor and filter in close
proximity to each other, cables lengths can be kept to a minimum thus cutting down on
emissions.
Further reductions in emissions can be achieved by screening the cables.
The mounting plate for the equipment should be one of bare metal, this acts as a
central earth point and also improves the EMC.
Left:-A bare metal backplane

ready for the drive modules
to be mounted, note the earth
bonding cables, one for each
drive module.

Section 5
Equipment Mounting
Below:-A typical cabinet layout demonstrating the close proximity of the filter, reactor Notes
and line module in order to reduce the interference effects of the high frequency drive
current.
The use of shielded cables is also necessary to further eliminate this Interference.
Shielding plates offer the best method for grounding the shields.
The power cables and the signal cables should also be run separately from each other
throughout the machine and not just in the electrical cabinet.
It is not permissible to connect any other equipment between the line module and the
filter and reactor.
Remaining
Filter Equipment
Shielded Power Cables. Shielded DriveCliq

Cables.
Main
Line Module Motor Modules
Switch
Filter Reactor
Protection
≥ 100mm
Shielded Power Cables.

Shielded Motor Cables.
Shield plates for
grounding the shields.
Right:-Example of a filter, reactor and line

module installation
Below:-Example of how shielded cable can
be grounded.
Filter
Reactor
Line Module

Section 6
Plugs, Sockets and Cabling
Notes Shielded power cables are recommended between the Sinamics line filter, reactor and
line module. If the cable length is 1m or less the cables can be twisted and not
shielded.
Signal cables and power cables should be kept separate by a distance of at least
0.2m.
Cables should be kept as close as possible to objects with a ground potential, this
reduces crosstalk between cables.
Where the cable shield is grounded it should be done with the use of grounding plates,
this allows a large surface area of the shield to be connected. The use of a wire to
connect the shield to ground is not permitted as the wire then becomes an aerial
which can introduce problems.
Failure to observe all of the above can lead to intermittent faults.
Above:-A correct shielding method Above:-An incorrect shielding method
The shielding of cables has a downside in that it causes additional losses in the line
filter, reactor, in-feed and motor modules. This becomes worse the longer the cable
length and can cause overheating of the drive components.
A maximum of 50m is allowed for each motor module and a maximum of 150m for
each drive system.
Shielding that is connected via a plug & socket housing must use a metallic housing
with a continuous metallic contact.
Metalized housings are not permitted, over a period of time the metalized coating
becomes worn and fails to be conductive to the levels required.
To maintain the airtight properties of the cabinet, cable outlets should use methods
which form a seal and any unused openings blanked off.
Above:-Examples of cabinet cable entries

Section 5
Plugs, Sockets and Cabling
Cabling Sins Notes
Above:-Encoder and power cables in close proximity.
Above:-Encoder and motor cables in close proximity.

Section 7
Cabinet Sealing
Notes A cabinet that isn’t sealed correctly can lead to a multiple of problems. Poor Sealing
can be caused by cable entries, poorly fitting doors, etc.
A poorly sealed cabinet can:-
 Influence the air circulation and cause overheating due to hotspots forming and
air short circuits.
 Lead to a high moisture content which can in turn lead to component failure.
 Emit electrical interference, causing problems with other nearby equipment.
 Allow harmful, conductive contaminants to enter causing component failure.
The cabinet door should always be closed and locked during normal running
operation, access should only be with a key or tool and by authorised personnel.
Below:-An example of a poorly fitting cabinet door
Top Bottom

Section 8
Miscellaneous
Electromagnetic compatibility can also affect other cabinet mounted components. To Notes
deal with this suppressing devices can be used on any item with a coil.
AC components use RC networks for suppression while DC components use diodes.
Below:-Example of 3 phase AC suppressors
AC Suppressor

B099 Tips and Ticks
1 Brief description
Module objective:-
This Module is intended for advanced users and is not part of the standard
commissioning course.
Module description:
Sinumerik 828D
B099
Contents:- B006
Firmware Update of Profinet Section2

Periphery Components. Page 3

Section 2
Firmware Update of Profinet Periphery Components.
Notes
It is essential that the hardware is up to date with the current software release. This is
done by updating the firmware of the hardware.
To carry out the updates a PG/PC with Ethernet adapter is required, also required is a
crossed ethernet cable, although a straight cable can be used if the PG/PC adapter is
auto-switching.
The latest firmware package should also be available locally on the PG/PC.
To prepare the PG/PC for connection to the hardware the TCP/IP protocol needs to be
setup.
To do this the properties of the “TCP/IP” internet protocol need to be changed for the
Ethernet adapter to be used, this adapter will differ between PG/PC.
If any entries already exist these should be noted down.
Select the option “Use the following IP address” and enter an IP address of
192.168.214.15, the subnet mask should be 255.255.255.0
The device to be updated needs to be setup. Each has a set of switches for this
Purpose. The IP address of the device is to be set as 192.168.214.0. This is achieved
by setting switch 4 and 9 to the on position, all other switches should be set to off.
Before making changes make a note of the original settings and set back these when
the update is finished.
Left:-Switch S1, a ten-position switch used for addressing the P72/47PN

periphery I/O board.
The MCP variants also have the same type of switch but are labelled as
S2.

Section 2 Firmware Update of Profinet Periphery Components.
Notes Apply power to the device to be updated, the PG/PC should automatically connect to
the device, this may be indicated by a message on the taskbar of the PG/PC
The update procedure uses the Dos command box, to check that the connection is
valid in the Dos area open up a Dos command box from the Start/Run menu of the
PG/PC.
Type the letters “CMD” (Short for Command) and select “OK”.
A Dos box will open up, type the following:- “ping 192.168.214.8” and press the return
key.
A successful connection is indicated by the text:-
“Reply from 192.168.214.8: bytes = 32 TTL = 64”
This line will be displayed four times.
The update can now be carried out. The path to the folder where the update file was
extracted to needs to be typed in the Dos box.
In this example the files were extracted to C:\MCP_update.

In the Dos box type:- “cd mcp_update” and press enter.

Section 2
Notes
The existing version of the device can be checked using the “MCPb_version_8.bat”
file.
Type this in to the Dos box at the command prompt and press enter.
The system firmware is the firmware version
The image version shown to the left is

the version that the device will be
updated to.
The online version shows the current

version of the device. The system
firmware version can be ignored.
To update the firmware the file called “MCPb_fw-update_8.bat” must be run from the
command prompt.

Section 2
Notes To cancel the procedure press the “Ctrl” & “C” keys together, press any other key to
continue. The update will now take place, when the message “ok—all done have fun”
is displayed the process is complete. To finalise the procedure the power needs
removing and reapplying to the updated device.
After reapplying power to the device the version can be checked.
The update and online firmware

versions have been updated.
The switch settings must now be returned to their original state.

Sinumerik - 828D - Machine Commissioning - 2009 PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Sinumerik - 828D - Machine Commissioning - 2009 PDF

Uploaded by

Copyright:

Available Formats

SINUMERIK 828D

This document was produced for training purposes.

B060 System overview.

Machine Control Section 4

PLC Periphery Section 8

B060 Page 2 SINUMERIK 828D

SINUMERIK 828D Page 3 B060

A choice of horizontal or vertical mounting is available:-

B060 Page 4 SINUMERIK 828D

PPU Horizontal layout:-

PPU Vertical layout:-

Software (Current system software delivered on CF card):-

Milling (Max 6 axes)

Input voltage- 24V DC +20% /-15%

Operational temperature 0-45 °C

Horizontal model Vertical model

SINUMERIK 828D Page 5 B060

MCP 310C PN(12.2”)

B060 Page 6 SINUMERIK 828D

MCP 310 PN(12.2”)

SINUMERIK 828D Page 7 B060

MCP 483C PN (19”)

B060 Page 8 SINUMERIK 828D

MCP 483C PN (19”)

SINUMERIK 828D Page 9 B060

Smart Line Module Active Line Module

Smart Line Modules (SLM)

Active Line Modules (ALM)

B060 Page 10 SINUMERIK 828D

Motor Modules (MM)

The motor modules convert the DC link

SINUMERIK 828D Page 11 B060

Part Numbers-single modules

Part Numbers-double modules

Braking Modules & Resistors.

B060 Page 12 SINUMERIK 828D

Control Supply Modules.

The Control Supply Module is a 24V/20A DC

The initial power to the module is taken from the

SINUMERIK 828D Page 13 B060

Since the integrated control unit (CU) can control

All modules have to be connected to the

Digital input & output functionality is available.

A separate 24V DC supply is required in order for

B060 Page 14 SINUMERIK 828D

Sensor modules are required to convert non-DriveCliq encoder signals into

SINUMERIK 828D Page 15 B060

For the evaluation of the following measuring systems:-

B060 Page 16 SINUMERIK 828D

SINUMERIK 828D Page 17 B060

A 24V DC supply is required.

Part number:- 6FC5311-0AA00-0AA0 Digital only (PP72/48D PN)

A maximum of 4 PP72/48 modules with the PPU260 and PPU261 variants.

B060 Page 18 SINUMERIK 828D

Machine Data Index IP address Switch S1

PP72/48 No.1 Input range 0 to 8, output range 0 to 5 Switch 1 & 4 on

Below:-Example of machine data 12986 set to enable the PP72/48 modules

The machine data is activated with an NCK power off.

SINUMERIK 828D Page 19 B060

B060 Page 20 SINUMERIK 828D

Pin Signal Pin Signal Pin Signal

SINUMERIK 828D Page 21 B060

Below:-HHU with coiled cable, connector and mounting device.