En 828D Complete Service v43

SINUMERIK 828D
Service Documentation
Sinumerik 828D
Edition 2011.1
Training Manual
This document was produced for training purposes.

Siemens assumes no responsibility for its contents.
SINUMERIK 828D
Service Manual for

Turning and Milling machines
Valid for:
Sinumerik 828D Software 4.3

Start
Contents
B060
System
Overview
B002
B041
Service & B061
Machine and
Commissioning Menu overview
Setting Data
Tools
B021
Protection
levels
B032
RCS Comman-
der
B045 B044 B025
Network Licensing of Time and Date
configuration Options Settings
B007
Electronic
Logbook
B017
Data
Management
B010 B008
PPU Connec- B051 Profinet Con-
tions and Diag- Line and Motor nections and
nostics Modules Diagnostics
B034
PLC Interface
B026
Creating a PLC
Program
B031 B019
B033
PLC Alarms S7-200 PLC
PLC Functions
and Messages Instructions
B058
PLC Onboard
Diagnostics
B053
Axis and Drive
Diagnostics
B084 B020
B009
Encoder Maintenance
Easy Extend
Adjustments Planner
B018
Easy
Messenger
B011
Easy Screen
Appendix B Appendix A B006

Technology Hardware Electrical
Settings Differences Cabinet Design
End
B060 System Overview
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 given.
Module Objective:
Upon completion of this module you will know the Sinumerik 828D system and the components
which make up the system.
Content:
Sinumerik
System Overview
828D & PPU Information
Machine Control Panels
Drive Components
NX10 Module
Drive-CLiQ Hub & Sensor Modules
PLC Periphery Modules
Hand-held Units
SINUMERIK 828D Page 1 This document was produced for training purposes.
B060
B060
B060 Page 2 SINUMERIK 828D

B060
System overview: Description

System overview:
START
The Sinumerik 828D system is made up of a variety of hard-
ware components. This module gives a graphical overview of
those components and shows where each component is con-
nected.
A brief description of the hardware components is given. System Over-
view
828D & PPU

Information
Machine
Control Pa-
nels
Drive Compo-
nents
NX10 Module
Drive-CLiQ
Hub & Sensor
Modules
PLC Periphe-
ry Modules
Hand-held
Units
System overview:
END
Notes :
SINUMERIK 828D Page 3 B060

B060
System Overview 828D S120 Book size
PP72/48 PN PLC I/O
To other 828D
MCP310 PN
PN/PN
Coupler
MCP483 PN
GSM/GPRS
Modem
PN1 &
PN2
Profinet
+24V DC Supply Mini
Interfaces
X1 PN2 PN1 RS232 HHU
Interface
Compact Flash Front-
X140 Connection
ports
}
X145 X122 Sinamics kit
USB 2.0 Sinumerik X132 Digital I/O
X125
X127
X127-Service
828D & PPU X242
X252 } NCK
Digital I/O
X143
Ethernet Digital I/O NC
X100 X101 X102 X130
Hand-wheels
X130-Factory Ethernet
DMC20
X100 to X102 DriveCLiQ Interface DriveCLiQ
Hub
Teleservice
Modem
Filter NX10 S120

Sinamics S120
Booksize
DMS
Scales/encoders
via SMx & DMC
modules
Reactor
Notes :

B060
System Overview 828D Combi
PP72/48 PN PLC I/O
To other 828D
MCP310 PN
PN/PN
Coupler
MCP483 PN
GSM/
GPRS
Modem
PN1 & PN2
+24V DC Supply Profinet
Interfaces Mini
RS232
X1 PN2 PN1 HHU
Interface
Compact Flash Front-
X140 Connection
ports
}
X145 X122 Sinamics kit
USB 2.0 Sinumerik X132 Digital I/O
X125
X127
X127-Service
828D & PPU X242
X252 } NCK
Digital I/O
X143
Ethernet Digital I/O NC
X100 X101 X102 X130
Hand-wheels
X130-Factory Ethernet
X100 to X102 DriveCLiQ Interfaces
DMC20
DriveCLiQ
Teleservice Hub
Modem
Sinamics
Filter Combi Two additional
DMS-TTL 5V Module axes-S120
Direct to Combi (3/4 axes) single/double
compact
modules
DMS
Scales/encoders
via SMx & DMC
Max 5 circuits
Reactor
Notes :

B060
828D controller with integrated PPU (Panel Processing General Information

Unit) The PPU model number gives information about the control-
ler:-
PPU2xx.1
PPU260/280 0 - Vertical
Vertical variant 1 - Horizontal
10.4” TFT Colour
Screen. 4 -Basic
6 - Standard
8 - Performance
PPU Horizontal layout:
6FC5370-3AT20-0AA0
PPU241.2 Turning version without system software
6FC5370-3AM20-0AA0
PPU241.2 Milling version without system software
PPU261/281 6FC5370-5AA20-0AA0
Horizontal PPU261.2 Standard version without system software
variant
10.4” TFT 6FC5370-7AA20-0AA0
Colour PPU281.2 Performance version without system software
Screen.
PPU Vertical layout:
6FC5370-4AT20-0AA0
PPU240.2 Turning version without system software
PPU240
Horizontal 6FC5370-4AM20-0AA0
variant PPU240.2 Milling version without system software
8.4” TFT
Colour 6FC5370-6AA20-0AA0
Screen. PPU260.2 Standard version without system software
6FC5370-8AA20-0AA0
PPU280.2 Performance version without system software
PPU241 Software- (Current system software delivered on CF

Vertical variant card):
8.4” TFT Colour
Screen. Milling
6FC5832-2GY00-0YA0 Basic for PPU240/PPU251

6FC5831-2GY00-0YA0 Standard for PPU260/PPU261
6FC5830-2GY00-0YA0 Performance for PPU280/PPU281
Turning
6FC5832-1GY00-0YA0 Basic for PPU PPU240/PPU241

6FC5831-1GY00-0YA0 Standard for PPU260/PPU261
6FC5830-1GY00-0YA0 Performance for PPU280/PPU281
Blank Compact Flash Card 1GB:
6FC5313-5AG00-0AA0
Notes :

B060
Specifications PPU interfaces and status LEDs (Rear):
Input voltage- 24V DC +20% /-15% X1-24V DC supply

Power Consumption 60W
Protection –Front operator panel IP65 X100 to X102 -Drive Cliq interface
Rear of PPU IP20
X130-Ethernet factory network-Configurable to receive an IP
Operational temperature 0-45 °C address automatically or a manually assigned fixed address
Operational Relative humidity 5 to 90 % @ 25°C (No can be used.
condensation) Do not use addresses in the following ranges:
192.168.214.xxx and 192.168.215.xxx. These are reserved
Horizontal model Vertical model for the system.
Width 310mm (12.2 in) 483mm (19 in)
Height 380mm (15 in) 220mm (8.66 in) X135-USB interface
Depth 105mm (4.13 in) 105mm (4.13 in)
X140-RS232 interface
General information X122 & X132-Digital I/O for Sinamics
The controller is available in vertical or horizontal formats. X242 & X252-Digital I/O for NCK
The functionality of the two variants is identical.
The PPU includes “Qwerty” and numerical keyboard inputs X143-Hand-wheels x 2
and shortcut keys to specific machine areas.
The 828D encompasses the HMI, NC, PLC and CU logical PN1 & PN2 - Profinet interfaces. (Only PN1 available for
components. PPU240/PPU241)
PPU interfaces and status LEDs (Front): LED Indicators:

X125 USB interface
X127 Ethernet service port-DHCP server (IP address Name Colour Description
192.168.215.1) Issues addresses up to 192.168.215.31. FAULT Red Fault present
X145 Compact Flash (CF) interface SYNC Green Synchronisation OK
LED indicators: Rx/Tx Yellow Network activity (1 each for PN1,

PN2 & X130 interfaces)
Name Colour Description Link Green Network connected (1 each for

PN1, PN2 & X130 interfaces)
RDY Green System ready
NC Orange NC ready (Flashes at approximately
1Hz)
CF Yellow CF card activity
Notes :

B060
The following tables highlight the technical specifications of the 828D controller.
Key:-
 In preparation
 Delivered as standard
 Option
- Not available
PPU240/241 PPU260/261 PPU280/281
Turning Milling Turning Milling Turning Milling
System Performance
Number of axes with standard configuration 3 4 3 4 3 4
Maximum number axes/spindles/positioning axes 5 5 6 6 8 6
Each additional axis/spindle      
Each additional positioning axis      
Maximum number of interpolating axes 4 4 4 4 4 4
Maximum number of machining channels 1 1 1 1 1 1
Minimum block cycle time 9ms 3ms 6ms 2ms 6ms 1ms
CNC user memory (buffered) 1MB 1MB 3MB 3MB 5MB 5MB
CNC Functions
Tool management with tool life monitoring and workpiece
     
count
Replacement tools      
Maximum number of tools/cutting edges 80/160 80/160 128/256 128/256 256/512 256/512
Number of settable zero offsets 50 50 100 100 100 100
Safety Integrated (Safe Torque Off, Safe Brake Control)      
Asynchronous subroutines (ASUP)      
Synchronised actions and high speed auxiliary function out-
     
put
Acceleration with jerk limitation      
Look Ahead (Number of blocks) 1 50 1 100 1 150
Compressor for 3-axis machining -  -  - 
Advanced surface -  -  - 
A, B, C spline interpolation      
TRANSMIT and peripheral surface transformation      
Travel to fixed stop      
Travel to fixed stop with Force Control      
Inclined axis for no orthogonal Y axis - - - -  -
Synchronous spindle function for sub-spindle
- - - -  -
(CP Static)
Synchronous spindle function for sub-spindle
 -  -  -
(CP Basic)
Pair of synchronised gantry axes -  -  - 
Temperature compensation      
Bidirectional lead-screw error compensation      
Multi-dimensional sag compensation - -    
Master/slave for drives - -  -  -
Analysis of internal drive values - -  -  -
Notes :

B060
PPU240.1/241.1 PPU260/261 PPU280/281

Turning Milling Turning Milling Turning Milling
CNC Programming and Operation
Programming language (DIN66025 and high level
     
language expansion)
Online ISO dialect interpreter      
Technology cycles for drilling and milling      
Technology cycles for turning  -  -  -
Residual material detection and machining      
Programming support for technology cycles (Program
     
GUIDE)
ShopMill/ShopTurn machining step programming      
Measuring cycles      
Simulation in plane display      
Simulation in 3-D display - -    
Simultaneous recording (Real-time simulation of current
     
machining operation)
Extended operator functions for complex turning and
- -    
milling tasks.
Contour hand-wheel      
Network drive management      
Remote diagnosis function RCS host      
PLC Functions
Integrated PLC based on SIMATIC S7-200      
PLC periphery modules PP72/48D, PP72/48D 2/2A PN      
Ladder viewer and on board add-on editor      
PLC cycle 9ms 9ms 6ms 6ms 6ms 6ms
Maximum number of PLC ladder steps 12,000 12,000 24,000 24,000 24,000 24,000
Servo synchronous High Speed PLC Task      
Reaction time to process events (Terminal to terminal) <9ms <9ms <6ms <6ms <3ms <3ms
Maximum number of digital inputs/outputs 216/144 216/144 288/192 288/192 360/240 360/240
Maximum number of analogue inputs/outputs 6/6 6/6 8/8 8/8 10/10 10/10
PN/PN coupler      
Commissioning and Service Functions
Easy Screen-easy creation of user screens (OA Run-
     
time licence for over 5 user screens)
Service Planner for maintenance tasks      
Easy Extend management of machine components      
Easy Archive data archiving      
Notes :

B060
Machine Control Panels Interfaces:-

X10 24V DC supply
Machine Control Panel MCP310C PN X20 Ethernet port 1
X21 Ethernet port 1
The MCP310 is recommended for use with the vertical style X30 Feed override switch input
PPU. 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 Panel MCP483C PN
The MCP483 is recommended for use with the horizontal

style PPU.
Hardware information
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
Hardware information
 6 x Pre-drilled holes for hard wired user buttons
 Connections for 9 user Inputs & 6 outputs Part Number:-
 Connection via Profinet 6FC5303-0AF22-0AA1
Features:-
 50 mechanical keys with LED indicators (17 user
Consumable items: assignable)
 Spindle & feed override control.
6FC5247-0AF13-1AA0-Feed override rotary switch incl. cap,
 Key switch
button, pointer & dials
 Emergency stop button
6FC5247-0AF12-1AA0-Spindle  2 x Pre-drilled holes for hard wired user buttons
override rotary switch incl. cap, button, pointer & dials  Connection via Ethernet
 2 x Hand-wheel connections
 Connections for 9 user Inputs & 6 outputs
 Connection via Profinet
Consumable items:
6FC5247-0AF13-1AA0-Feed override, rotary switch incl. cap,

button, pointer & dials
6FC5247-0AF12-1AA0-Spindle override rotary switch incl.

cap, button, pointer & dials
Notes :

B060
General information
Interfaces:-
X10 24V DC supply
Line modules are responsible for generating the DC link sup-
X20 Ethernet port 1
ply for the drive system.
X21 Ethernet port 2
They require 3-phase AC for the DC link and +24V DC for the
X30 Feed override switch input
electronic supply.
X31 Spindle override switch input
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
LED Indicators:-
network.
H1 LED POWER OK LED
Modules of 16 Kw and above do connect to the DriveCliq.
H2 LED BUSSYNC (Bus ok & synchronised)
H3 LED BUSFAULT (Bus fault)
Active Line Modules (ALM)
S1 Hand-wheel type selection switch
These modules are capable of mains regeneration and the
S2 IP address selection switch
DC link is stabilised.
All ALM modules are connected to the DriveCliq network.
Drive Components
Line Modules
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
Smart Line Module Active Line Module
Notes :
SINUMERIK 828D Page 11

B060
Line Modules-continued The motor modules convert the DC link voltage into a vari-
able AC voltage which is then output to the servo
Motors.
Part Numbers-SLM
Motor Modules are supplied with 24V DC via the ALM/SLM
6SL3130-6AE15-0AB0 5Kw Internal cooling
All motor modules are connected to the DriveCliq network.
6SL3130-6AE21-0AB0 10Kw “ “
They are available in one or two axis variants and can be
6SL3130-6TE21-6AA3 16Kw “ “
internally or externally cooled.
6SL3130-6TE23-6AA3 36Kw “ “
6SL3131-6AE15-0AA0 5Kw External cooling
6SL3131-6AE21-0AA0 10Kw “ “
Interfaces:-
Part Numbers-ALM
Single MM
6SL3130-7TE21-6AA3 16Kw Internal cooling
X1-Output to Motor.
6SL3130-7TE23-6AA3 36Kw “ “
X21-Enable & temperature sensor input
6SL3130-7TE25-5AA3 55Kw “ “
6SL3130-7TE28-0AA3 80Kw “ “
6SL3130-7TE31-2AA3 120Kw “ “
Double MM
6SL3131-7TE21-6AA3 16Kw External cooling
X1 & X2-Output to Motors
6SL3131-7TE23-6AA3 36Kw “ “
X21-Enable & temperature sensor input (Motor 1)
6SL3131-7TE25-5AA3 55Kw “ “
6SL3131-7TE28-0AA3 80Kw “ “
X200, X201, X202, X203-DriveCliq connections
6SL3131-7TE31-2AA3 120Kw “ “
Motor Modules (MM)
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 “ “
Single MM Double MM 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 “ “
Notes :

B060
Motor Modules (MM) S120 Book-sized Compact Combi Drive (Combined Line and Motor Modules)
The S120 book sized motor modules are use to expand the The Combi drive unit consists of a Line Module and either 3 or
number of drives the Sinamics Combi drive system to the 4 Motor Modules, the first of which is dedicated to the Spindle.
maximum of 6. The modules are only available with internal They must always be connected to the DriveCLiQ network via
cooling. controller interface X100.
The number of axes can be increased by adding Sinamics
Interfaces:- S120 Booksized Compact Motor Modules up to the maximum
Single MM allowed by the system.
X1-Output to Motor.
X21-Enable & temperature sensor input .
X200, X201, X202-DriveCliq connections.
Double MM
X1 & X2-Output to Motors.
X200, X201, X202, X203-DriveCliq connections.
Part Numbers:-
3 Axes Modules:
6SL3111-3VE21-6FA0 16Kw
Part Numbers:- (Spindle -18 amps, all axes 5 amps)
6SL3111-3VE21-6EA0 36Kw
Single Modules (Spindle -24 amps, all axes 9 amps)
6SL3420-1TE13-0AA0 3/9 Amps 6SL3111-3VE22-0HA0 55Kw
6SL3420-1TE15-0AA0 5/15 Amps (Spindle -30 amps, all axes 9 amps)
6SL3420-1TE21-0AA0 9/27 Amps
6SL3420-1TE21-8AA0 18/54 Amps
4 Axes Modules:
Double Modules 6SL3111-4VE21-6FA0 16Kw
6SL3420-2TE11-0AA0 2 x 1.7/5.1 Amps (Spindle -18 amps, axis1-9 amps, axes 2&3-5 amps)
6SL3420-2TE13-0AA0 2 x 3/9 Amps 6SL3111-4VE21-6EA0 36Kw
6SL3420-2TE15-0AA0 2 x 5/15 Amps (Spindle -24 amps, all axes 9 amps)
6SL3111-4VE22-0HA0 55Kw
(Spindle -30 amps, axis1-12 amps, axes 2&3-9 amps)
Notes :

B060
Braking Modules & Resistors Part Numbers-

6SL3100-1AE31-0AB0 Braking Module 1.5Kw rated power
6SN1113-1AA00-0DA0 Braking Resistor 0.3Kw rated power
If the regenerative capability of the line module is inadequate it
6SL3100-1BE31-0AA0 Braking Resistor 1.5Kw rated power
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 resis-
tors require good ventilation and ideally need to be mounted
externally. Control Supply Modules
Braking modules and resistors can also facilitate the controlled

The Control Supply Module is a 24V/20A DC Power Supply
shut down of the drives in the event of a power failure.
Unit.
It is used to maintain the 24V DC in the event of a power
Another feature is the fast discharge of the DC link. This fea-
failure.
ture is used to quickly discharge the capacitors so that mainte-
nance tasks can be carried without having to await natural
The initial power to the module is taken from the line supply,
discharge times. Fast discharging should only be carried out 1
when a power failure occurs power is taken from the residual
to 2 times per week to avoid damaging the capacitors.
voltage of the DC link.
The braking module is connected to the DC link and 24V DC
Part Number:-6SL3100-1DE22-0AA0
bus systems.
Connector X21 on the braking module is used for enable/fault/

ready signals.
Connector X1 is for connecting the external resistor.
Braking resistor
Control Supply
Module
Braking Module
Notes :

B060
NX10 Module Drive-CLiQ Hub & Sensor Modules
NX10 Module (Numerical Control Extension) DMC20 Drive-CLiQ Hub
General information
General information
The requirement for additional Drive-CLiQ ports is catered for
Since the integrated control unit (CU) can control only 6
by the DMC20.
axes, an NX10 module is required to achieve the maximum
There are 6 Drive-CLiQ ports, 5 of these are available for
number of 8 axes allowed by the system.
additional devices such as direct measuring systems.
The modules are of the same design as the Sinamics S120
The remaining port is used for connecting to the PPU/Drive-
drives and fit neatly into the drive rack.
CLiQ network.
All modules have to be connected to the DriveCliQ
network.
Part Number:-
6SL3055-0AA00-6AA0
The drive enable connections are not required to be physi-
cally connected, these signals are mirrored with the CU Interfaces:-
connections:-  X500 - Drive-CLiQ, Connects to PPU/Drive-CLiQ network
X122.1 = OFF1
X122.2 = OFF3
 X501 to X505 - Drive-CLiQ, additional devices
 X524 - 24V DC supply
Part Number:-  RDY - LED indicator
6SL3040-0NC00-0AA0
Interfaces:-
 X100 to X103 DriveCliQ
 X122 4 x digital inputs & outputs
 X124 24V DC supply
NX10
Notes :

B060
Sensor Modules (SMC & SME) Sensor Modules (SMC & SME)-continued
SMC30
General information
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:-
SMC30
For the evaluation of the following measuring systems:-
Incremental with TTL/HTL signals
SSI with incremental TTL/HTL signals
SSI without incremental signals
SMC10/SMC20 (Temperature evaluation-KTY84-130 can also be used)
SMC10 Interfaces:-
For the evaluation of 2-pole resolvers & Multi-pole resolvers,
including motor temperature evaluation (KTY84-130)  X500 DriveCliq
 X520 TTL measuring system input (25 pin D-type con-
Interfaces:- nector)
 X500 DriveCliq  X521 HTL/TTL measuring system input (Screw type
 X520 Measuring system input (25 pin D-type connector) connector)
 X524 24V DC supply  X531 “ measuring system input (Screw type
connector)
 Status LED’s
 Status LED’s
Part Number:-  X524 24V DC supply
6SL3055-0AA00-5AA0 Note-The extra measuring system interfaces offer more flexibil-
ity for connecting the encoder, The device however can only
SMC20 handle a single encoder.
Incremental sin/cos 1v pp Part Number:-
Absolute EnDat encoders 6SL3055-0AA00-5CA1
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)
 X524 24V DC supply
 Status LED’s
Part Number:-
6SL3055-0AA00-5BA1
Notes :

B060
Sensor Modules (SMC & SME)-continued PLC Periphery Modules
SME20/SME25 PP72/48D PN Modules (Combined I/O module)

Incremental sin/cos 1v pp with C and D tracks 5V supply-
S1
SME20
Absolute EnDat encoders 5V supply-SME25
Absolute SSI with incremental signals 5V supply Sin/Cos 1V
pp-SME25 X111
Interfaces:-
 DriveCliq-also supplies 24V DC
 Measuring system input
Part Number:-
6SL3055-0AA00-5EA0-SME20 X222
6SL3055-0AA00-5HA0-SME25
X2 X2
Port Port X333
2 1
X1
SME20/SME25
PP72/48D PN modules are a compact component which
connect to the Profinet network (Ports PN1 or PN2 of the
SME120/SME125 NCU). A 24V DC supply is required.
Incremental sin/cos 1v pp with C and D tracks 5V supply- There are two variants, one of which is all digital while the
SME120 second offers both digital and analogue functionality (only for
Absolute EnDat encoders 5V supply-SME125 PLC).
(Temperature evaluation-KTY84-130 can also be used)
24 digital inputs and 16 digital outputs are available on each
Interfaces:- of the 3 ribbon connectors giving a total of 72 inputs and 48
 DriveCliq-Also supplies 24V DC outputs for each module.
 Measuring system input
 Hall effect sensor input A maximum of 3 PP72/48 modules with the PPU240/PPU241
controllers.
 Temperature sensor input A maximum of 4 PP72/48 modules with the PPU260/PPU261
controllers.
Part Number:- A maximum of 5 PP72/48 modules with the PPU280/PPU281
6SL3055-0AA00-5JA0-SME120 controllers.
6SL3055-0AA00-5KA0-SME125
Part numbers:-
6FC5311-0AA00-0AA0 Digital only (PP72/48D PN)
6FC5311-0AA00-1AA0 Digital/analogue (PP72/48 2/2A PN)
Interfaces:-
S1-Adressing switch-Default setting of 9
X1-24V DC Supply
X2-Profinet network ports 1 & 2
SME120/SME125
X111 digital inputs/outputs-ribbon connector
X222 digital inputs/outputs-ribbon connector (first byte has
fast gating hardware)
X333 digital inputs/outputs- ribbon connector
Notes :

B060
PN/PN Coupler Hand-held Units
Hand Held Unit (HHU)
Hand held units allow the operator to manually control the

machine remotely from the main operator panel.
HHU with coiled cable, connector and mounting device:-
PN/PN Coupler
The PN/PN coupler is used to link two Profinet networks so

that data can be exchanged between them.
The HHU offers manual axis movement via hand wheel or jog
The coupler requires a +24V DC supply. buttons.
A rotary switch is used to select the required axis, it is only
One coupler is allowed per controller. possible to select one axis at a time from the maximum of five
axes.
Part number:- Safety is provided via a 2 channel emergency stop button and
-6ES7158-3AD00-0AX0 a 3 position “Dead mans” enable button.
The casing has magnets which are useful to attach the unit to
Interfaces:- any suitable metallic surface, alternatively a holder can be
X1 Port 1 & 2 Profinet 1 Network purchased for this purpose.
X2 Port 1 & 2 Profinet 2 Network A terminating connector is available to facilitate the (Cold)
PS1 & PS2 +24V DC supply removal of the HHU without affecting the machine operation.
In addition to the +/- & Rapid jog buttons there are three user
LED’s assignable buttons.
SF1 Group fault for Profinet 1 network (Red)
SF2 Group fault for Profinet 2 network (Red) The signals from the HHU are split into three categories.
BF1 Bus fault for Profinet 1 network (Red) 1. The emergency and enabling buttons should be used
BF2 Bus fault for Profinet 2 network (Red) in the safety/enabling circuit of the machine.
MT1 Maintenance display Profinet 1 network (Yellow) 2. The jog and axis selection should be done via the user
MT2 Maintenance display Profinet 2 network (Yellow) PLC program
ON Power supply +24V DC (Green) 3. The hand-wheel signals need to be taken to X143 of
LINK Connection on (Green) One per Profinet connection the PPU
RX/TX Data Exchange (Yellow) One per Profinet connection
A connection kit that must be ordered separately is required
for connection of the mini HHU.
Notes :

B060
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 termi-

nator.
6FX2006-1BG13 Non assembled connection kit without

terminator.
6FX2006-1BG20 Pre assembled connection kit with termi-

nator.
6FX2006-1BG25 Pre assembled connection kit without ter-

minator.
6FX2006-1BG70 Holding cradle
Notes :

B060
Connection method
A separately ordered connection kit is used with the Mini HHU which allows the three sets of
signals to be separated according to their functionality.
Flange Socket
Flange socket
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12
1 2 3 4 5 6 7 8 9 10 PPU X143 Hand-wheel connections
Emergency Stop and safety circuits
X51 X52 X55
1 2 3 4 1 2 3 4 1 2 3 4
MCP X51, X52, X55 DU box connectors for axis selection

and jog signals
Standard addresses for X51, X52 & X55

Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
Axis selection switch
F2 button F1 button Rapid Jog minus Jog plus (Binary)
IB122
X55.2 X55.1 X52.3 X52.2 X52.1
X51.3 X51.2 X51.1
F3 button
IB123
X55.3
Notes :

Hand-held Units
B060
Mini Hand Held Unit Colour Codes
Emergency Stop Enabling Button Axis Selection Function/jog/rapid Keys Hand-wheel bk - Black
br - Brown
rd - Red
ye - Yellow
gn - Green
bu - Blue
vt - Violet
gy - Grey
wh - White
pk - Pink
wh bn gn ye gy pk bu rd bl vt ye/ gy/ rd/ wh/ bn/ wh/ wh/ gy/ wh/ pk/ wh/ bn/ wh/
bn pk bu gn gn ye gy bn pk bn bu bu rd
1 2 3 4 5 6 7 8 9 10 16 11 12 13 14 15 17 24 18 19 20 21 22 23 HHU plug/flange socket
Page 21
Connection kit
wh br gn ye gy pk bu wh br vt rd bu pk gy ye gn bk br wh bu pk ye gn
1 2 3 4 5 6 7 1 2 3 4 1 2 3 1 2 3 2 1 6 5 4 3
X51 X52 X55 X143
Connector block MCP310/483PN PPU

B060: END
Notes :
B060
SINUMERIK 828D
B060 END

B002 Service and Commissioning Tools
Module Description:
In order to integrate the Sinumerik 828D CNC to a machine tool, software tools are required. The
tools enable the machine tool builder to create the PLC program for the machine and also assist in
the drive configuration.
These tools, including service tools are supplied on a DVD, the DVD is called the Toolbox DVD
and is included in the scope of delivery.
Software included in the toolbox:
 PLC828 Programming Tool (PLC user program)

 Start-up Tool (configuration of drives)
 Configuration Data (rescue card image, examples e.g. for Easy Extend)
RCS Commander is not included in the toolbox but is required for certain commissioning/service
procedures.
Module Objective:
Upon completion of this module the course participant will be able to do the following:
 Install the software tools from the toolbox DVD.

 Install the RCS Commander software tool.
 Connect to the controller with each of the software packages.
Content:
Sinumerik
Theory and Objective.
ToolboxInstallation.
RCS Commander Installation.
Network Settings
Online Connection-RCS Commander
Online Connection-PLC828 Programming Tool
Online Connection-Start-up Tool
B002
B002

B002
Service and Commissioning Tools: Description Service and

Commissioning
Tools:
START
Toolbox Installation:
Each controller is delivered with a DVD which contains the

software tools required for service and commissioning work.
Toolbox
The tools are automatically installed by running a the
Installation
“setup.exe” file found on the root of the DVD
The following software will be installed:
PLC828 Programming Tool - Creating, editing and diagnos- RCS

ing the PLC user program. Commander
Installation
Start-up Tool - Configuration of drives during the commis-
sioning stage.
Configuration Data - A rescue card image, which used in the

event of a system card failure, is installed in the following Network
path: C:\Program Files\Siemens\Toolbox 828D\V02063200. Settings
(V02063200 represents the version of toolbox)
The DVD also contains example files of PLC user projects,

Easy Extend and Tool Management.
Online
Connection:
RCS Commander:
RCS
Commander
The RCS Commander software tool is not delivered as part of
the toolbox and has to be obtained separately. Installation is
achieved by running a “Setup.exe” file.
Online
The software is used for service, commissioning and remote Connection: PLC
access. These functions are explained in detail in other Programming
Modules Tool
Network Connection:
Online
The software tools communicate to the controller via Connection:
Ethernet. Start-up
The external PC needs to be set to allow communication to Tool
take place,
When the Toolbox installation is complete a connection to the
controller will be made with the PLC828 Programming Tool, Service and
Start-up Tool and RCS Commander Commissioning
The external PC needs to be set to allow communication to Tools:
take place,
END
Notes :

B002
Toolbox Installation Software licence agreement:-
Toolbox content:
- Configuration Data:- image for replacement card.
- Programming Tool PLC828:- For Creating/Loading/Editing
the PLC user program.
- Start-up Tool:- For the configuring of the drives.
Installation Process
Installation is started with “setup.exe” on the Toolbox DVD.
Double click the “Setup.exe” Software to be installed is dependant upon the required task.
file to start the toolbox installa-
tion.
Note:-
The default installation path is “C:\Program

Files\Siemens\Toolbox 828D.
It is good practice to avoid installing to the C drive of the com-
puter. This drive typically contains the operating system
installation folders.
Use the “Browse” button to select another more suitable drive.
Notes :

B002
Toolbox Installation RCS Commander Installation
Note:- Start-up Tool Installation RCS Commander allows a remote operation between the
828D controller and a computer.
The 828D controller operates with the Sinamics drive system, Data such as part programs etc can be transferred between
therefore the “Solution Line” variant should be selected. the remote computer and the controller.
This can be changed later using the NCU connection wizard if A viewer is included which is used to view and change the
it is necessary to work also on the Powerline system. controller settings remotely (Dependant upon access rights).
The software can also be used to write images to compact
flash cards for service and commissioning tasks.
The RCS commander software is not part of the toolbox DVD.
Installation:
To install the RCS Commander software, locate the

“Setup.exe” file in the root of the RCS Commander DVD. Start
the installation by double clicking the file.
Acknowledge any further dialogue boxes and allow the

installation to fully complete. Double click the Setup.exe” file
to start the installation.
Allow the installation to complete.
Notes :

B002
Network Settings: Ethernet port X127 of the controller is a DHCP server and
issues IP addresses. The computer has to be set to obtain an
X127 is a DHCP server with a fixed IP address of IP address automatically.
92.168.215.1.
Addresses 192.168.215.2 to 192.168.215.31 are automatically
issued to any PC connected to X127.
The network adapter name has to be known.

This can be found in the “Network connections” area of the
computer:
Click “Internet
Protocol (TCP/IP)”
from the list and
then select
“Properties”.
Ensure that
“Obtain an IP
address
automatically” is
selected.
Confirm the
changes with the
OK key.
In the following example the network adapter is a:-
“Marvell Yukon 88E8055 PCI-E Gigabit Ethernet Controller”
The adapter type will vary between computer types.
Notes :

B002
Online Connection-RCS Commander It is necessary to login with a password depending on the ac-
Double click the “RCS Commander” icon which is found on the cess level required:-
PG/PC desktop.
When the program is opened for the first time after the
The access level determines which data can be accessed via
installation it is necessary to assign a password for encryption
RCS Commander. The “Manufacturer” login grants the most
purposes. As a suggestion use “SUNRISE”
access, the “User” login is the most restrictive.
Select the login and enter the password.
Passwords:-
Manufacturer-SUNRISE
A dialogue box appears where the choice of connection is Service-EVENING
made. User-CUSTOMER
A default connection is available, this is specifically for
connecting to X127 of the controller .
IP address 192.168.215.1). After a short delay the data folders of the controller will
appear in the bottom half of the RCS Commander program,
this indicates a successful connection was made.
Notes :

B002
Online Connection - PLC Programming Tool A dialogue box opens giving the opportunity to cancel the
changes. Accept by selecting the “OK” button.
An Ethernet cable is required to connect between X127 of the
controller and the PG/PC.
Start the Programming tool. A shortcut is auto-

matically placed on the desktop during
Installation.
Locate and select the “Communications” option The selected adapter will be shown on the right of the dia-
found in the left “View” column of the program- logue box.
ming tool. The IP address of the controller should be entered in the
“Communication Parameters\Remote Address” section.
The default IP address of X127 is 192.168.215.1.
A communication protocol is not

active. Double click the area
Chosen adapter.
highlighted.
The correct adapter should be selected from the list and con-
firmed with the “OK” button.
Enter the IP address of the
Note:- Adapter types will not controller.
necessarily be the ones shown in this example. X127 - 192.168.215.1
After entering the IP address, double click the “Double click

to Refresh” icon.
Select the cor-

rect network
adapter.
Notes :

B002
Online Connection - PLC Programming Tool continued Online Connection: Start-up Tool
If the connection is successful an icon of the controller will During installation a folder is created on the desktop of the
appear. computer. Within this folder are shortcuts for starting the “NC
Connect Wizard” and the “Start-up Tool and the start-up tool.
The PLC828 Pro-

gramming Tool is
now connected to the
controller.
NC Connect Wizard
Clicking on the at the top right of dialogue box will close it
down. Start the wizard and select the “840D Solutionline” option.
Notes :

B002
Online Connection: Start-up Tool
X127 has a fixed address of 192.168.215.1.
Select the “Engineering Tools (Recommended)” option.
The connection setting can be saved under a suitable name

for future use, do not change any other settings.
Select “Finish” to complete the task.
Connection/cabling information is provided, a crossover or

straight cable can be used depending upon the network
adapter of the PG/PC.
Notes :

B002
Setting the PG/PC Interface
The “Access
It is also necessary to check the PG/PC interface setting to Point of the Appli-
ensure that the software is able to communicate. These cation” needs to
settings are checked in the “Control Panel” area of the PG/ be
PC. selected from the
list.
In the “Control Panel” area, select and open the “Set PG/PC
Interface” program.
Select the
network adapter
which is in use.
Connect an ethernet cable between the computer and port

X127 of the controller. Run the Start-up tool via the “Start-Up
Tool” shortcut.
The software will boot to the following screen:
The Access point and network adapter have to be selected.

The Access Point required is the “Sinumerik_CP” option.
The network adapter is the one identified earlier in the
module on Page 6
To exit the software select the F10 key on the PG/PC

keyboard followed by the “EXIT” soft-key.
B002: END
Notes :

B002 END

B061 Menu Overview
Module Description:
Module Description:
The Sinumerik 828D system is categorised into 6 menu areas. Each menu area is sub-divided to
allow the user easy access to the necessary areas of the system.
Menu Areas:
 Machine
 Parameter
 Program
 Program Manager
 Diagnostics
 Start-up
Module Objective:
Upon completion of this module you will know the menu areas of the Sinumerik 828D system.
Content:
Sinumerik
Menu Select Button

Mode Selection
Menu Selection
Menu Area: Machine (JOG Mode)
Menu Area: Machine (MDA Mode)
Menu Area: Machine (AUTO Mode)
Menu Area: Parameter
Menu Area: Program
Menu Area: Program Manager
Menu Area: Diagnostics
Menu Area: Start-up
B061
B061

B061
Menu Overview: Description Menu

Overview:
START Menu Area:
The Sinumerik 828D system is categorised into 6 menu ar- Program Ma-
eas. Each menu area is sub-divided to nager
allow the user easy access to the necessary areas of the
system.
Menu Select
Menu Areas: Button
Menu Area:
 Machine Diagnostics
 Parameter
 Program Mode
 Program Manager Selection
 Diagnostics
 Start-up Menu Area:
Start-up
Menu
Selection
Menu
Overview:
END
Menu Area:
Machine (JOG
Mode)
Menu Area:
Machine (MDA
Mode)
Menu Area:
Machine
(AUTO Mode)
Menu Area:
Parameter
Menu Area:
Program
Notes :

B061
Menu Select Button
The menu system of the Sinumerik 828D is accessed via the “Menu Select” button.
Location of the Menu Select button of the vertical and horizontal controller variants.
Notes :

B061
Mode Selection
Pressing the Menu Select button reveals 6 horizontal menu soft-keys and 5 vertical soft-keys.
The 5 vertical soft-keys can be used to change between the machine modes: This can also be
achieved via the Machine Control Panel.
Vertical Soft-key Functionality:
Automatic mode (AUTO) is selected.
Manual Data Automatic mode (MDA) is selected.
Jog mode (JOG) is selected.
Reposition mode (REPOS) is selected.
Reference Point (REF POINT) mode is selected.
Notes :

B061
Menu Selection
The 6 horizontal soft-keys are used to select the different menus.

It is also possible to select the menus via the integrated keyboard of the PPU.
Menu Soft-keys: Brief Description
The Machine menu displays information such as the axis

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

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

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

Include password entry, machine data modifications, creating archives, creating
alarm files, PLC diagnostics, time/date settings, network set-up, licensing/option
selection, system data management, servo optimisation etc.
Reboot HMI
A further soft-key is available which is used for rebooting the HMI only. This is found via the
Menu extension key.
The Reboot HMI soft-key is used when only the HMI requires re-booting. This
function will not have any effect on the NC/PLC/Drives.
Notes :

Menu Area: Machine (JOG Mode)
B061
Page 7
Notes :
B061
SINUMERIK 828D
Menu Area: Machine (MDA Mode)
SINUMERIK 828D
B061
Page 8
Notes :
B061
Menu Area: Machine (AUTO Mode)
B061
Page 9
Notes :
B061
SINUMERIK 828D
Menu Area: Parameter
B061
Notes :

B061
Menu Area: Program
Notes :

Menu Area: Program Manager
SINUMERIK 828D
B061
Page 12
Notes :
B061
B061
Menu Area: Diagnostics
Notes :

Menu Area: Start-up
SINUMERIK 828D
B061
Page 14
B061: END
Notes :
B061
B041 Machine and Setting Data
Module Description:
Machine and Setting data's are used in many ways to influence the operation of a machine.
During commissioning some of the machine data is automatically set while other machine data has
to be changed.
Over time, as the machine mechanically wears it may be necessary to edit certain machine data
such as compensation data's.
This module shows the different machine data areas and other criteria such as how to activate the
machine data.
Module Objective:
Upon completion of this module you will be able to locate the different Machine/Setting data areas
and be able to carry out adjustments if required.
Content:
Sinumerik
Machine & Setting Data Overview
Data Classes
Editing Machine & Setting Data
User Views
B041
B041

B041
Machine and Setting Data: Description

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

B041
Machine & Setting Data Overview Menu „Machine data“
General assignment 1 2 3 4 5
The machine data are sub-divided into the following ranges:
Range Description
9000 - 9999 Display machine data
10000 - 19999 General machine data
20000 - 29999 Channel-specific machine data
30000 - 39999 Axis-specific machine data
41000 - 41999 General setting data
42000 - 42999 Channel-specific setting data
43000 - 43999 Axis-specific setting data
51000 - 51999 General cycle machine data
52000 - 52999 Channel-specific cycle machine data 1 Number of the machine data
53000 - 53999 Axis-specific cycle machine data
54000 - 54999 General cycle setting data 2 Denomination of the machine data
55000 - 55999 Channel-specific cycle setting data

Value and physical unit of the machine data
56000 - 56999 Axis-specific cycle setting data 3
m/s**2 m/s2 (Meter/second-squared): Accel-
For every one of these ranges an own listing exists, in which eration
machine data can be displayed and altered. U/s**3 U/s3 (Revolutions/second power 3):
rate of change of acceleration
for rotating axis
The following data ranges are used for the machine data:
kg/m**2 kgm2 (Kilogram-meter-squared): Mo-
$MM_ Display machine data ment of inertia
$MN_ General machine data mH mH (Milli-Henry): Inductivity
$MC_ Channel-specific machine data Nm Nm (Newton-Meter): Turning mo-
$MA_ Axis-specific machine data ment
us µs (Micro-seconds): Time
$MNS_ General cycle machine data
uA µA (Micro-Ampere): Electrical cur-
$MCS_ Channel-specific cycle machine data rent
$MAS_ Axis-specific cycle machine data uVs µVs (Micro-Volt-second): Magnetic
flux
Which mean: userdef User definition: The unit to be deter-
$ System variable mined by user.
M Machine data
4 Activation of the machine data:
M, N, C, A, S Part range (second/thierd letter) im = Active on selection of the “Input” key (immediate).
cf = Active on selection of “Set MD active (cf)” soft key.
The following data ranges are used for the setting data: re = Active on selection of the “Reset” key.
$SN_ General setting data po = Active on control power off/on or “Reset (po)” soft
$SC_ Channel-specific setting data key.
$SA_ Axis-specific setting data
5 Data class of the machine data:
$SNS_ General cycle setting data
S = System
$SCS_ Channel-specific cycle setting data
M = Manufacturer
$SAS_ Axis-specific cycle setting data I = Individual
U = User
Which mean:
$ System variable In case of machine data without a unit the units-column is empty. If
D Setting data the value terminates with an „H“, the value is in hexadecimal format.
N, C, A, S Part range (second/thierd letter)
Notes :

B041
Data Classes Editing Machine & Setting Data
The 828D controller uses machine data which is divided into To locate the machine data screens first ensure that the rele-
data classes. vant access level is active (Module B021 Protection Levels)
Data classes can be used to create archives which contain then use the following key sequence:-
only specific data's of the controller, data according to it´s
classification. Upgrades etc. can therefore be carried out
while leaving any existing unrelated data of the controller
intact.
Types of Data Classes:-

The display should now show the machine data area with soft-
The Data Classes are split into four categories:- keys available to switch between the different machine data
areas.
System (S) - This data belongs to the system and cannot be
edited. The values are determined by the controller type and
standard data. Data belonging to this class is not saved in
any archive type.
Manufacturer (M) - The manufacturer data is common

throughout a particular machine series. No individual or user
data is included.
Individual (I) - The individual data is machine specific

(Compensations, reference points etc.). An archive of the
Individual type could typically be made prior to a software
update.
User (U) - The user 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 or in the case of a software update. The machine data which are available for viewing is limited on
the activated display filters.
Data Classes for Machine and Setting Data
When looking at the machine data area of the controller it is

possible to see which machine data belongs to which Data
Class.
Example:-Axis specific machine data screen showing data

class identifiers:
Note:-
Machine Data is often referred to as “MD”.
Setting Data is often referred to as “SD”.
Data Class Identifier
Notes :

B041
Editing Machine & Setting Data continued The correct machine data should first be located. This is
done by either using the page/cursor keys or the search
The Machine & Setting Data is separated into different groups. 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
General MD and general Cycle MD.
name in text format.
Channel-specific MD and channel-specific Cycle MD.
Axis-specific MD and axis-specific Cycle MD.
User Views- Allows the user to create list of specific

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

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

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

changes immediately (see below).
General SD and general Cycle SD.
Channel-specific SD and channel-specific Cycle SD.
Axis-specific SD and axis-specific Cycle SD.
Display MD.
Notes :

B041
Editing Machine & Setting Data continued
Insert new data in machine data list.
REMEMBER:- Create a data backup.
Editing of any type of data should only be undertaken by ex-

perienced personnel and in conjunction with the machine
manufacturer.
For a detailed description of each machine/setting data refer
to the “Function description” manual found on “DOConCD”
User Views
User views allows a customised list of machine data to

be made.
The machine data list will be stored on the System CF card.
Select machine data list.

The location of the machine data list is:
Edit existing machine data list or create new System CF card/user/templates
machine data list.
Create new machine data list.
The machine data list will be displayed in the machine data

area. Additional it will be displayed in the Parameter/Setting
data area.
B041: END
Notes :

B041 END

B021 Protection levels
Module Description:
The data of 828D controller is protected by seven protection levels. Four of which are set via a key-
switch and three by password.
This module explains the different protection levels, how to set these levels and how to protect
individual files.
Module Objective:
Upon completion of this module you will be able to set the different protection levels using a pass-
word or key switch.
You will also be able to change the protection levels of individual NC programmes.
Content:
Sinumerik
Password and key-switch information
Setting and Deleting the Password
Protection of files
Version 04.03
B021
B021

B021
Protection Levels: Description Protection

Levels:
START
The data of 828D controller is protected by seven protection
levels. Four of which are set via a keyswitch and three by
password.
Password
This module explains the different protection levels, how to
and
set these levels and how to protect individual files.
key-switch
information
Setting and
Deleting the
Password
Protection of
files
Protection
Levels:
END
Notes :

B021
Password and key-switch information Setting and Deleting the Password
The following table shows the password/key-switch positions

Setting the password:-
and associated protection levels/users.
The screen for entering the password is reached via the fol-
Protection lowing key presses
Intended user:- Protected via:-
level
1 Manufacturer Password: SUNRISE
2 Service Password: EVENING

A dialogue box is opened, this box shows the current access
3 User Password: CUSTOMER
level and allows a password to be entered using the key-
board.
4 Programmer, Setter Key-switch position 3
5 Qualified operator Key-switch position 2
6 Trained operator Key-switch position 1
7 Untrained operator Key-switch position 0

After typing the password it is confirmed by pressing the “OK”
The key switch is located to the bottom right of the MCP and soft key.
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. The dialogue box disappears and the current access level is
displayed above the left hand horizontal soft-keys.
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 pro-
tection level 4 (Key position 3) or higher is released.
Notes :

B021
Setting and Deleting the Password continued Protection of files

Certain files such as important cycles, programmes etc can be
Deleting the password: individually protected against accidental editing, deletion or
execution. They can also be hidden from view.
Before deleting a password the next highest password level
or higher should be set. Navigate to the screen where the The desired file has to be located before the properties can be
password is entered, and select the “Delete password” soft edited. In this example, the part programme “828.MPF” is to
key have it’s properties changed.
The “Part program” directory is located by selecting the
“Program manager” key.
A dialogue box is opened, this box shows the current access
level and asks if you really want to delete the current pass-
word, if yes select the “OK” softkey to delete the password.
By highlighting the correct directory and opening it with the

“Input” key we can see the program “828D.MPF”. Ensure this
is highlighted.
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.
Changing the password:-

It may be necessary to change the password from the default.
To change a password the same level of access or higher
should be set. E.G to change the “Service” password, levels 2
or 1 must be active.
It should be noted that the highest level password (Level 0) is
not available for general use. This means that if the
“Manufacturer” password is changed and then forgotten, the
only way to gain access to level 1 is to re-commission the
controller and return the passwords to 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 Manu- The properties of the file are found by paging right and select-
facturer, Service & User passwords to be changed. Naviga- ing the properties Soft-key.
tion of the dialogue box is achieved via the cursor and select
keys, confirmation is via the “OK” 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”
In this example the “Manufacturer” password is active, this password or higher is active
allows the Manufacturer, Service & User passwords to be
changed.  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
Notes :

B021 END
Protection of files continued
When the correct settings have been entered the “OK” soft
key has to be selected.
B021: END
Notes :

B032 RCS Commander
Module Description:
It may be a requirement for service personnel to remotely diagnose problems with the controller or
machine.
This is achieved by using the RCS Commander software package installed on a PG/PC.
When connected, a viewer function is available so that the user can see and changes the control-
ler data.
This module shows the installation of the RCS Commander software and how to make an online
connection using both the available ethernet ports X127 and X130.
Module Objective:
Upon completion of this module you will be able to connect remotely to the system using the Re-
mote Diagnosis function and the RCS Commander software tool.
Content:
Sinumerik
Network Settings
RCS Commander Online Connection
External Viewer
B032
B032

B032
RCS Commander: Description

RCS
It may be a requirement for service personnel to remotely Commander:
diagnose problems with the controller or machine. START
This is achieved by using the RCS Commander software

package installed on a PG/PC.
When connected, a viewer function is available so that the Network
user can see and changes the controller data. Settings
This module shows the installation of the RCS Commander

software and how to make an online connection using both
the available ethernet ports X127 and X130. RCS
Commander
Online
Connection
External
Viewer
RCS
Commander:
END
Notes :

B032
Network Settings The settings can now be changed to suit the network that the
controller is to be connected to.. Use the cursor and select
Network Settings keys to change the selections
RCS Commander can be connected to the controller via Address Type:-DHCP-To obtain IP address automatically.
Ethernet port X127 (Front) or X130 (Rear). Connection to Manual-To enter a defined IP address.
X127 (DHCP server) is straight forward and is tested during
the software installation Module B002. When the settings have been chosen select the “OK” soft-
key” and perform power off/on of the controller.
Ethernet port X130 is configurable, the port can be assigned a
fixed IP address or be set to automatically acquire an IP ad-
dress.
Port X130 is for connecting to the factory network. When con-
figuring for connection to a factory network, certain information
from the factory network administrator is required. Any existing
X130 settings should be recorded before attempting any
changes.
Configuring Port X130

IP address restrictions– Do not use IP addresses
192.168.215.xxx &192.168.214.xxx. These are reserved by
the system.
Locate the “TCP/IP diagnostics” screen with the following key

selection:-
In the following example the IP address of 192.168.100.1

and a sub-net mask of 255.255.255.0. have been manually
Basic Informa- assigned.
tion about the
two network
ports is
displayed.
X130 is not
configured.
X127 shows
the fixed IP
address of
192.168.215.1
To edit the settings select the “Details” and “Change” soft-

keys.
Notes :

B032
Network Settings continued RCS Commander Online Connection

Connection via X130
To activate the new setting the controller needs to be
powered off/on. A default connection is available in RCS Commander for con-
necting to X127. If ethernet port X130 is to be used a new
The TCP/IP diagnostics screen now will show the IP address connection will have to be created.
of port X130.
Enter the IP address for X130 (192.168.100.1) also enter a

connection name and choose a login level (Manufacturer, Ser-
vice, User) and the correct password for the selected login.
Computer Network Settings

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

address of 192.168.100.2 and subnet mask of 255.255.255.0.
The subnet mask must match the one entered on the
controller. Set the transmission
mode to LAN
To make the connection select the “Connect” icon on the RCS

Commander toolbar.
From the drop down menu select the connection to be used

then press the “Connect” button.
Notes :

B032
RCS Commander Online Connection continued
After a short delay the data folders of the controller will appear
in the bottom half of the RCS Commander program.
Viewing Rights-HMI
Rights for remote access - Selected in HMI
Do not allow remote access-Prevents remote connections.
The RCS Commander program can be used for copying and Allow remote monitoring-The remote computer can monitor
pasting files between the controller to the external computer. the controller.
Files resident on the controller can be opened directly for edit- Allow remote operation-The remote computer can access the
ing. various screens of the controller and changes can be per-
In many cases it is easy to create files offline and then copy formed.
them to the controller using RCS.
Viewing Rights-PLC
The function for writing images to CF cards is described in Rights for remote access, Specified by PLC (Not settable on
Module B017. screen)
The access can be restricted/blocked via the user PLC with

interface signals. These signals have priority over the
“Selected in HMI” settings.
External Viewer
Behaviour for remote access
External Viewer Confirmation dialog display time-When a connection attempt
The external viewer duplicates the controller display on the is made a dialogue box will appear which requires acknowl-
external computer including menu and soft-key functionality. edgement, this determined how long the
When the viewer connects, access can be restricted on the dialogue box stays on the screen.
HMI or by the PLC interface. Afterwards remote access is allowed automatically-If this is
To configure the HMI use the following soft-key sequence: 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.
To change the settings select the “Change” soft key. Use the Connection via modem
cursor and select keys modify the settings: It is possible to connect to the controller using a Teleservice
adapter and modem. In this case the “Allow modem” soft-key
is used to permit the connection.
Notes :

B032
External Viewer continued The following keys are used to navigate the controller from
the remote PG/PC:
Connecting the Remote Viewer
To start this function select the following icon from the RCS Keys Description
Commander tool bar, Alternatively select “Start” from the
Remote control” drop down menu. F1 to F8 Horizontal soft-keys
Shift & F1 to Vertical soft-keys
F8
F9 Page Back/Up
F10 Menu Select
Shift & F9 Page right
When the viewer attempts to connect, providing that the re-
mote viewer has not been blocked, the screen of the control- F12 Help function
ler will be displayed. If acknowledgement is required, the con- Escape Alarm Cancel
troller “OK” soft-key will require selecting within the time limit
specified on the RCS set-up screen. Select Space Bar
Programs, machine data etc can be directly changed from the

remote computer, archives can also be created.
When the connection is successful the viewer will display the

same screen as the controller.
B032: END
Notes :

B032 END

B025 Time and Date Settings
Module Description:
It is important that the system date and time are correct.
This is necessary for checking when an alarm occurred or when a file (Part program, archive etc)
was created or edited.
If at the time of installation the time and date is not set correctly, the Guarantee period of the con-
troller could be effected.
Before the date and time displays can be edited, the password for the “User” or higher must be
entered.
Module Objective:
Upon completion of this module you will be able to set the time and date for the system.
Content:
Sinumerik
Setting the Date and Time
B025
B025

B025
Time and Date Setting: Description

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

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

B025 END
Setting the Date and Time
Before the date and time displays can be edited, the password
for the “User” or higher must be entered.
The Date/Time screen is reached with the following soft key
sequence:-
The time and date can now be checked and corrected if nec-
essary.
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 con-

firmed using the “Input” key.
Once the time & date are correct press the “OK”
soft key.
B025: END
Notes :

B044 Licensing of Options
Module Description:
When a controller with options is purchased a software licence key is issued. The licence key is
unique to the CF card supplied with the controller.
This module explains the licensing procedure and how to activate options.
Module Objective:
Upon completion of this module you will be able to check the control for the correct licence and
activate options.
Content:
Sinumerik
Entering and Checking Licences
Assigning Licences
B044
B044

B044
Licensing of Options: Description

Licensing of
Options:
START
When a controller with options is purchased a software li-
cence key is issued. The licence key is unique to the CF card
supplied with the controller.
This module explains the licensing procedure and how to Entering and
activate options. Checking
Licences
Assigning
Licences
Licensing of
Options:
END
Notes :

B044
Entering and Checking Licences
To check the licence number, use the following key com-

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

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

licence 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. This is described on page 6.
The licence key should now be displayed. A full report can
If the licence key is lost it is usually possible to retrieve it via be sent to an email address if desired.
the internet, the serial number of the internal CF card will be
needed to recover the licence key.
The licensing page can be found at::

www.siemens.com/automation/license
Notes :

B044
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.
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.

Restoring the licence number:-
Select the “Read in licence key” soft-key.
Highlight the licence key file and press the “OK” soft-key.
Create a new directory if required.
The licence key should now appear in the licence key box.
The new folder appears . Select “OK” to save the licence key
file to this folder.
Notes :

B044
Entering and Checking Licences continued Assigning Licences
The “All options” soft-key can be selected to view all set and If a licence key is insufficient for a required option, it is possible
licensed options. to assign a new licence key that includes the missing option.
The assignment of a new licence key is done via the internet.
Each option is issued a Licence Certificate. The certificates are

delivered with the controller along with information about the
licence dispatch note numbers.
These are required for the Web Licence Manager.
Example: A licence certificate
To select an option use the cursor keys to highlight the de-

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

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

hardware type from the licensing manager screen.
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 licences”

soft-key.
Notes :

B044
Call up the “Web Licence Manager“ on a PC with Internet ac- Progress message box Step 2 of 5 - Identify Product:
cess: Enter the hardware serial number and select the product.
http://www.siemens.com/automation/licence
Progress message box Step 3 of 5 - Select licences:

The licences which have not yet been assigned on the dispatch
note selected are displayed here. You can assign additional
licences to the hardware here.
Select “Direct Access“ of “Web Licence Manager“.
Progress message box Step 1 of 5 - Login:

Enter the licence number resp. dispatch note number.
Progress message box Step 4 of 5 - Assign licence:

Overview of licences selected.
Notes :

B044
Assigning Licences continued
You assign the licences to the hardware specified by clicking

the “Assign“ button.
When you click “OK“, the licences are assigned to the hardware
specified.
Progress message box Step 5 of 5 - Generate Licence Key:

The Licence Key includes all options assigned for the hardware
specified.
The alarm caused by the unlicensed options is no longer dis-

played after assigning the Licence Key.
You can check whether the Licence Key has been entered
successfully by pressing the “All options“ softkey. The option
should now be available in the “Licensed“ column.
Download the Licence Key by clicking the following link.
Change to the licensing screen and enter the Licence Key by

pressing the “Read in licence key“ softkey.
Notes :

B044
Setting the Options According to the Licence Key:
It is possible to set all the options allowed by the current li-
cence key by selecting the “Set option acc. Lic” soft-key.
All options should now be set according to the licence key:
B044: END
Notes :

B044 END

B045 Network configuration
Module Description:
The 828D controller is equipped with a configurable ethernet interface (X130). This interface can
be used for service/commissioning work.
A soft-key can also be configured to facilitate the easy handling of data e.g. remote storage of part
programs.
This module shows how the ethernet connection is configured and the activation of a soft-key in
the program manager area.
Module Objective:
Upon completion of this module you will be able to configure ethernet connections on the control-
ler/external PC, create a shared folder on the PC and add a soft-key in the Program manager area.
Content:
Sinumerik
Activating the Network Option
Network Settings
Creating a Shared Folder
Configuring a Network Drive Soft-key
B045
B045

B045
Network Configuration: Description

Network
Configuration:
The 828D controller is equipped with a configurable ethernet START
interface (X130). This interface can be used for service/
commissioning work.
A soft-key can also be configured to facilitate the easy han-
dling of data e.g. remote storage of part programs. Activating
the Network
Option
This module shows how the ethernet connection is configured
and the activation of a soft-key in the program manager area.
Network
Settings
Creating a
Shared
Folder
Configuring a
Network Drive
Soft-key
Network
Configuration:
END
Notes :

B045
Activating the Network Option Configuring Port X130
A series of step are required to initialise and set up the net- IP address restrictions– Do not use IP addresses
work connection: 192.168.215.xxx & 192.168.214.xxx. These are reserved
by the system.
 Activation of the network drive option
Locate the “TCP/IP diagnostics” screen with the following
 Configuring the network drive on the controller key selection:
 Configuring the external PC
 Adding the soft-key in the Program Manager area
Activation of the Network Drive Option:
Use the following soft-key sequence to set access the licens-

ing/options screen.
Basic Information about the two network ports is displayed.

X130 is not configured.
X127 shows the fixed IP address of 192.168.215.1
Network drive management is enabled
To edit the settings select the “TCP/IP config” and “Change”

Network Settings soft-keys.
RCS Commander can connect to the controller via Ethernet

ports X127 (Front) or X130 (Rear).
Connection to X127 (DHCP server) is straight forward and is
tested during the software installation Module B002.
Ethernet port X130 is configurable, the port can be assigned a

fixed IP address or be set to automatically acquire an IP ad-
dress.
Port X130 is for connecting to the factory network.

When configuring for connection to a factory network, certain
information from the factory network administrators is required.
Any existing X130 settings should be recorded before attempt-
ing any changes.
Notes :

B045
The settings can now be changed. Use the cursor and select
keys to change the selections
Address Type:-DHCP- To obtain IP address automatically.

Manual- To enter a defined IP address.
When the settings have been chosen select the “OK” soft-
key” and perform power off/on of the controller.
In the following example the IP address of 192.168.100.1 and

a sub-net mask of 255.255.255.0. have been manually
assigned.
Select “Control
Panel”
Locate and double click the

Network Connections icon.
To activate the new setting the controller needs to be
powered off/on.
The TCP/IP diagnostics screen now will show the IP address

of port X130
Double click the Local Area Connection icon
Computer Network Settings
The IP address and subnet mask of the computer will also

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

address of 192.215.100.2 and subnet mask of 255.255.255.0.
The subnet mask must match the one entered on the
controller.
Locate the “Control Panel” on the “Start” menu of the PC:
Notes :

B045
Network Settings continued Creating a Shared Folder
Select “Properties” A shared folder is required on the PC for storage of files etc.
The path to the folder and a soft-key are created in the next
section.
It should be first ensured that the “Simple file sharing” option

is deactivated on the computer to be connected to the con-
troller. This allows full access to the shared folder options.
Deselecting the “Simple file sharing” option:
Cursor to “Internet
Protocol (TCP/IP) and
select “Properties”
Select the „Use the following IP address” option and enter a

unique IP address. The subnet mask should match the subnet
mask set on the controller
Notes :

B045
On the PC select a suitable place for the shared folder. The

following example will show how to create a folder on the D Select the “Sharing” tab
drive.
Use explorer and select the D drive, right click with the
mouse in the right hand Window and select New/Folder. Select “Share this folder”
Select “Permissions”
Enter a suitable name for the new folder.
Select all options in the

Right click on the folder and select “Properties”. “Allow” column.
The folder should now have a Hand Symbol:
Sharing the folder makes it visible on the network. Networking

can be a problematic subject. In this example the security
settings are relaxed, security feature can be introduced once
a successful connection is made.
Problem with connecting can be caused by anti virus and
firewall setting.
Notes :

B045 END
Configuring a Network Drive Soft-key The new soft-key should now be available in the Program
area:
To give the operator access to the remote folder a soft-key is
added to the Program Manager screen. The configuration
screen is found by using the following soft-key sequence.
The USB port is configured as default, this should be left un- Files can be copied to/from the controller using the Copy/
touched. The next available free area is position 2. Use the cursor Paste soft-keys.
and select keys to navigate the screen.
The new folder is also available in the “System data” area.
This provides a convenient method of saving files such a s
archives to a safe storage location.
The information of the external PC has been entered in the

following example.
Information such as IP address, shared folder name, log on
details etc. are required.
Ensure that a suitable network cable is connected and select
the “Activate drive” soft-key.
A message will be displayed briefly above the horizontal soft-

keys to show a connection was made. To continue press the
“OK” soft-key.
B045: END
Notes :

B007 Electronic Logbook
Module Description:
The electronic logbook function of the 828D controller is used to enter data such as manufacturer
(OEM), dealer and user information, 1st and 2nd commissioning dates as well as records of service
visits.
This data is then saved to a log file. The log file has to be uploaded into the EUNA database via the
upload website.
The function is not only necessary for warranty issues but also for service personnel (Records of new
and previous service visits) and also for quality control measures.
The warranty period of the controller can only be activated through EUNA.
Module Objective:
Upon completion of this module the course participant will be able to do the following:
 Import/Enter EUNA data

 Make logbook entries
 Save and load the log file using the EUNA upload website.
Content:
Sinumerik
Logbook information
Importing/Entering EUNA Data
1st Commissioning-Start-up Complete.
2nd Commissioning-Machine Installed.
Recording a Service Visit.
Saving the Logbook Data-identSNAPSHOT.
Uploading to the EUNA Website.
Siemens assumes no responsibility for its contents. B007
B007

B007
Electronic Logbook: Discription
Electronic Logbook:
The electronic logbook function of the 828D controller is used START
to enter data such as manufacturer (OEM), dealer and user
information, 1st and 2nd commissioning dates as well as
records of service visits.
This data is then saved to a log file. The log file has to be
uploaded into the EUNA database via the upload website. Logbook
The function is not only necessary for warranty issues but also information
for service personnel (Records of new and previous service
visits) and also for quality control measures.
The warranty period of the controller can only be activated
through EUNA.
Importing/
Entering
EUNA Data
1st Commis-
sioning-
Start-up
Complete
2nd Commis-
sioning-
Machine
Installed
Recording a
Service Visit
Saving the
Logbook Data-
IdentSNAP-
SHOT
Uploading to
the Online
Registration
Website
Electronic Logbook:
END
Notes :

B007
Logbook Information Importing/Entering the Logbook Data
In the past, the validity of warranty claims was difficult to man- The OEM and Dealer information can be imported to the con-
age and was the cause of delayed service response times. troller in three ways:
System/hardware faults were logged in paper logbooks which
were then usually left on the machine and often became dam-  Import the XML file via the “Import” soft-key.
aged or lost. (Preferred method)
By using EUNA and the Electronic Logbook system, the war-

ranty will automatically start, a record of the machine details
 Copy/paste the XML file in the “System data” area.
(If the “Import” soft-key is not available)
and breakdowns will also be available on the controller.
The time and date of each entry is recorded; it is impor-  Type the information directly on the controller.
tant that the time and date settings of the controller are (When the files are not available)
correct. Incorrect time and date settings can lead to early
expiry of the warranty.
The preferred method is to obtain the correct xml files from
It is necessary to make entries at certain stages during the life your Siemens contact partner. These are pre-populated files
of the machine: containing the relevant OEM/machine information etc. Using
this method guarantees the consistency between the data
- Manufacturer information at OEM stored in EUNA and the data stored on the machine.
- Dealer information at delivery and installation of machine
- End user information at delivery and installation of machine The following files can be imported:
- 1st Commissioning - End of start-up at Manufacturer
- 2nd Commissioning Machine installed - End of start-up at
end user File Function
- All service visits
oem.xml Manufacturer information
oemsubs.xml Manufacturer subsidiary information
Note: If the procedures are not followed the warranty will
not be valid. dealer.xml Dealer information
user.xml End user information
identSNAPSHOT
ma_types.xml List of available machine types
When the “save” procedure is carried out, an xml file is cre-
ated. The files are imported using the “Import” soft-key, failing this,
This is known as the “identSNAPSHOT” function and is a the copy and paste option can be used.
snapshot of the system including version data, cycle data, If the files are not available they can be created directly on the
hardware components etc controller or offline on a computer.
Each time an entry is made, the log file should saved and up-
loaded to the EUNA database via the Online Registration
Website.
The file name is made from a combination of the machine Machine Identity File (identity.xml)
name and system CF card serial number.
When the information has been imported the “identity.xml” file
is automatically created which contains all the information
from the imported xml files.
If at any data is already present in the logbook area and needs

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

Data 17400.
Notes :

B007
Concept for Electronic Logbook Data Import and Upload:
identSNAPSHOT-Controller
Offline preparation (identity.xml, MD17400) File upload & RSV activation
OEM Data OEM Data (identity.xml)
oem.xml/oemsubs.xml: *Customer number*

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

Export & upload
dealer.xml: *Customer number*
Load via “Import” soft-key. Online
Or *Country* Registration
OEM.xml:
No “Import” soft-key? *Dealers name* Activation of RSV warranty
Load via “Copy/paste” function.
Or *Town* Configuration data:
OEM.xml: components, machine identity,
File not available? licence requirements,
Input data via controller keyboard. version information,
logbook entries etc.
User Data User Data (identity.xml)
No XML file available? Not usually available

Input data via controller keyboard. until point of sale.
Logbook entries
1st Commissioning
2nd Commissioning
Service visits
If the controller has existing machine identity data or a mistake is made when entering data manually, it is necessary to de-
lete the “identity.xml” file.
The location of the “identity.xml” file:
System CF card\user\sinumerik\hmi\data\version\identity.xml
Notes :

B007
Data Import function (Preferred method)
The Electronic Logbook is located in the Diagnostics area of the

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

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

B007
Machine type Copy and Paste Option
The machine type can be manually typed at the same time as If the “Import” soft-key is not available it is possible to copy the
the name/number is entered. Alternatively a list of machine files from USB/networked PC via the “system data” area using
types can be viewed if the “ma_types.xml” has been imported. the copy and paste functions.
Example of an “ma_types.xml” file that has been edited to in-

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

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

B007
Subsidiary files Select the branch/subsidiary name; in this case “ABC SUB”
Subsidiary files are used to define the details of manufacturer

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

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

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

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

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

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

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

B007
The templates can be used if the files cannot be obtained from Or Or
the Siemens partner. They should be copied and edited to
leave the original templates intact.
Example template for dealer.xml. Example: Manually entered “End user” data.
The file contains various

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

can be imported using the method described earlier.
A summary of the information can be seen.
Manually Entering Machine Identity Data
If an xml file is not available the data can be typed directly into
the controller.
Select which data is to be entered; Manufacturer, Dealer, End

user.
Notes :

B007
1st Commissioning-Start-up Complete
When the machine has been commissioned at the manufac-

To confirm that 2nd Commissioning is complete.
turer the “Start-up Complete” soft-key is selected. This auto-
matically logs the current time and date.
The information is now added to the main logbook page .
!!This is the point when the warranty period begins, the

file must be saved then uploaded to the EUNA database!!
To confirm that 1st Commissioning is complete.
The information will appear on the main logbook page. Recording a Service Visit
Whenever an engineer visits the machine to carry out mainte-

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

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

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

B007
The details of the service visit are now shown on the Logbook The file is given a default name using details from the machine
page. information page. This can be changed. A comment can also
be added.
Two files are created by default, Version data and Configura-
tion data.
The “Version data (.TXT)” file is a text file and contains details
regarding the versions of the controller, drives etc.
The “Configuration data (XML)” file is an xml file and contains
more information about the whole system including the log-
book entries. It is this file which needs to be uploaded to the
database via the internet.
Saving the Logbook data
The following procedure shows how to save the newly entered

data to a file.
The file contains all information about the system (Controller, The information will now be saved.
drives, software and hardware etc) as well as the information
entered on the logbook pages.
The save procedure should be carried out after each data

entry in the logbook.
To save the data to a file first locate and select the “Save”
soft-key.
In this example, the files are saved in the “version” folder.
The file should be saved to the default “Version data” folder as System CF card\user\sinumerik\hmi\data\version
a standard procedure to ensure that a copy is locally available .
The file is to be uploaded via an external PC, therefore it
should also be saved to an external USB/CF device.
Notes :

B007
Uploading to the Online Registration Website The file is closed with the following soft-key selection.
The file can be opened for viewing in the “System data” area:
Use the copy/paste function to transfer the xml file to a
computer in preparation for uploading to the Online Registration
Website.
New Log Files

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

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

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

now stored in the xml file.
Service visits are found at the end of the file:
Language selection.
Notes :

B007
Entering the email address and enabling the “enable email

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

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

B007: END
Problems with uploading the XML files
After a short delay an information box will indicate a successful
upload operation.
In the event of an error during the upload process will be

necessary to email the xml file to:
service.euna.industry@siemens.com
The uploaded file will be seen in the “Assigned files list”
The “Action Bar” of the assigned files list is used for various
functions.
Refresh the page
Upload an XML file
View the file
Delete the file
B007: END
Notes :

B017 Data Management
Module Description:
It is necessary to have procedures in place for saving and restoring the customers data stored in
the CNC.
The following cases have to be taken into consideration:

 Series machine production
 Individuality of machines
 Manufacturer changes to prototype machine
 Damage to the PPU
 Damage to the system CF card
Module Objective:
Upon completion of this module the course participant will know how to:
 Create and restore archives using the data class system of the 828D
 Create and restore a system image.
Content:
Sinumerik
Data Management Concept
Data Classes
Easy Archive
Save Data Function
System Software Backup and Restore
Creating Archive With Shortcut Key
System CF Card Replacement
B017
B017

B017
Data Management: Description
Data Management:
START
The 828D uses a data system in which data is separated into
Classes (data class structure).
Data classes allow backups to be created which contain only
the data which is belonging to the Manufacturer, individual Data
machine or end customer. Management
This enables upgrades etc. to be carried out while leaving Concept
other non-related data in the controller untouched.
The operating system of the 828D controller is stored on an

internal compact flash (CF) card, an image of this card can be
created for use in the event of a failure of this CF card. Data
Classes
It is necessary to have procedures in place for saving and re-
storing the customers data stored in the CNC.
The following cases have to be taken into consideration:

 Series machine production Easy
 Individuality of machines Archive
 Manufacturer changes to prototype machine
 Damage to the PPU
 Damage to the system CF card
Save Data
Function
System
Software
Backup and
Restore
Creating
Archive With
Shortcut Key
System
CF Card
Replacement
Data Management:
END
Notes :

Data Management Concept
B017
B017
Page 4
Notes :
SINUMERIK 828D
B017
Data Classes
The 828D controller uses machine data which is divided into

data classes.
Data classes can be used to create archives which contain
only specific data's of the controller, data according to it´s clas-
sification. Upgrades etc. can therefore be carried out while
leaving any existing unrelated data of the controller intact.
Types of Data Classes:-
The Data Classes are split into four categories:-
System - This data belongs to the system and cannot be ed-

ited. The values are determined by the controller type and
standard data. Data belonging to this class is not saved in any
archive type.
Manufacturer - The manufacturer data is common throughout

a particular machine series. No individual or user data is in- Data Class Identifier
cluded.
Individual - The individual data is machine specific Data Classes for PLC Data Blocks
(Compensations, reference points etc.). An archive of the Indi-
vidual type could typically be made prior to a software update. 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
User - The user data is user specific (Part programs, tool data, properties box is displayed.
zero points etc.). An archive of the user type could be used to The Data Class can be changed via the drop down menu. If
transfer data to an identical machine the Data Block already exists, the properties can be viewed by
cutting the same component or in the case of a software up- right clicking on the Data Block and selecting properties.
date.
Data Classes for Machine Data
When looking at the machine data area of the controller it is

possible to see which machine data belongs to which Data
Class.
Example:-Axis specific machine data screen showing data
class identifiers:
Selection of the required

Data Class.
Notes :

B017
Easy Archive Control Components:-
Creating Data Class Archives NC data:- The NC data consists of:-

To create a Series Start-up Archive locate the correct area by All machine and Setting data (except for drive machine data)
using the following key sequence. Tool data
Offsets
R parameters
Part Programs
Ensure that the option “Create series start-up” is selected and PLC data:- This will create an archive suited to restoring the
select “OK”. PLC user program in the event of a problem.
Drive data:- This will create an archive containing data for the
Sinamics drives.
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
HMI data:- This saves data that is stored on the HMI.

The list comprises of:-
Cycle storage
Texts
Templates
Applications
Configurations
Help
Version data
Logs
User views
Dictionaries
The example below shows the “All” option selected with the
Creating Data Class Archives including all data four control components also selected. This would create a full
backup of the controller.
A number of choices are available regarding what to include in
the archive you are about to create.
The “All” option takes into account the Data Classes and
includes all data.
Individual control components can be selected to make a full
backup of that particular control component.
Notes :

B017
Easy Archive continued
Comments about the archive can be entered.
A dialogue box indicates that the archive was successfully

created.
Select the “Generate archive” soft-key.
The destination of the archive is selected next. this can be on

the controller itself in the “Archive” directory or externally to a
USB or CF device.
A new directory can be created if necessary.
Creating Data Class Archives
Data Class archives are created under the “Execute” option.
A name for the archive needs to be entered.
The archive is now created and stored in the destination

specified.
The archives are created with a default extension of ”.ard”.
Notes :

B017
A choice of MANUFACTURER, INDIVIDUAL or USER can be

A suitable name for the archive should be entered.
made.
MANUFACTURER:-This will create an archive containing all

manufacturer relevant data of the machine. This will not contain
any individual or user data.
INDIVIDUAL :-This archive will save only machine specific ma-

chine data such as ball-screw compensations, reference point
offsets etc.
USER :-This archive will save user specific data such as part
programs, tool and zero offsets.
The files are created with a default extension ”.ard”.
The example below shows the selections which would create a

User Data Class archive containing data from the NC only.
Note that the Drive data option is not available for selection,
Drive data always belongs to the “Manufacturer” Data Class.
The archive is now created and stored in the destination speci-
fied earlier.
The archives are created with a default extension of “.ard”.
A dialogue box indicates that the archive was successfully

created.
The destination of the archive is selected next. this can be on

the controller itself in the “Archive” directory or externally to a
USB or CF device. A new directory can be created if desired.
Notes :

B017
Easy Archive continued The advanced “Start-up” menu will be displayed.
The menu contains many options.
Reading in Archives The type of archive to be loaded will determine which option
should to be selected.
In the event of a hardware/software change it could be Example 1:-If a complete NCK archive is to be loaded, the
necessary to read in archive files. “NCK default data” option would be selected.
Loading Standard Data Example 2:-If a complete NCK, PLC, Drives & HMI archive is to
be loaded, the “Factory settings” option would be chosen.
Before reading in an archive it is recommended that the
controller is loaded with default data.
Restart the controller, within 3 seconds of the following screen
appearing, press the “select” key.
Press SELECT key to enter setup menu
The basic “Start-up” menu will be displayed, to display the

advanced “Start-up” menu select the keys indicated below in Cursor to the required option and press the “Input” key.
the numerical order shown.
1 2 3
Notes :

B017
Depending upon which option has been selected, a series of

dialogue boxes may appear, acknowledge these as required.
Allow the control to 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, alarm
120402 will be present if the default drive data was loaded)
These alarms can be ignored.
Set the password to “service” or higher.
Selecting the archive to be read in
Use the following key combination to reach the area for read- The reading in of the archive will begin, this is indicated by a
series of information boxes.
ing in archives:-
Cursor to the “Read in series start-up” option and press “OK”.
When the archive has been successfully read-in the following

message box is displayed.
Select the archive to be read-in.
When the process is complete the functionality of the machine

can be tested.
It is important that the operator checks tool data, offsets,

Information about the archive is displayed. It is possible to read programs etc. as the archive could contain old data.
in all or part of the archive, depending upon the archive con-
tents.
Notes :

B017
Save data function
The “Save Data” function is used to automatically save the NC

data stored in the static ram memory (SRAM) of the 828D con-
troller to the system CF card.
The “Save data” function stores an image of the data to the
internal CF card of the controller (the image is not accessible
via HMI explorer).
Only one copy of the image is stored, the previous image is The data is now stored on the system CF card.
overwritten each time the save data function is performed.
Restoring the data saved with the Save Data function
The saved data can be used in one of two ways:-
The data saved previously can be restored by one of two meth-
 Creation of series machines. Series machines are pro- ods.
duced by creating an image of the system CF card of
the prototype machine. When the image is Creation of series machines:
created it will include the “Save data” image which will When a system CF card, created using an image of the proto-
automatically be restored during 1st power on of the type machine, is inserted into a new controller for the first time,
series machine. the saved data will be automatically reloaded. This produces a
clone of the prototype machine.
 Creation of backups during commissioning. The saved
data can be manually reloaded from the Start-up menu. Manually reloading the saved data:
If the function has never been carried out, the controller The saved data can also be manually loaded. This is done
will be loaded with standard data. from the start-up menu. Message “4062 Backup data loaded”
will be displayed to warn the operator that the data was re-
Data saved by the “Save data” function:- loaded.
All machine and setting data (Except for drive machine data)
Tool data The start-up menu is selected during the start-up of the
Offsets controller:-
R parameters
Part Programs Reboot the controller, within 3 seconds of the following screen
appearing, press the “select” key.
Performing the Save Data Function:
Notes :

B017
Save data function continued Allow the procedure to continue, this could take about five
minutes.
The Start-up menu will appear, cursor to the “Reload saved
user data” option and press the “Input” key. When the process is complete a message is displayed warn-
ing 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 pos-
sibly be old data and may contain incorrect tool data etc.
The operator should be warned of this fact and be prepared
to check program data, offsets, tools etc. before operating the
machine.
Cursor to the “Yes” button and press the “Input” key.
Notes :

B017
System Software Backup Creating a system image
When the prototype of a particular machine is complete, series Before commencing it is necessary to perform the “Save data”
production can begin. In order to do this a clone of the data of function described in Section 5.
the prototype machine is required.
Insert a FAT formatted CF card or USB stick of at least 1024MB
The 828D controller uses an internal system CF card. This into the front of the controller (X125-USB, X145-CF card).
card contains the system software from which the controller
operates. The card also contains other important data which is Restart the controller, within 3 seconds of the following screen
essential for the machine to function. appearing, press the “select” key.
The following procedure shows how to create an image of the

card. The image is of the type ”.tgz” and is saved to an exter-
nal USB or CF storage device.
Start-up of series machines is achieved quickly using USB/CF

cards:
Completed prototype
machine
Empty storage device Storage device containing

(CF card/USB stick) system image (TGZ)
1 2 3
Notes :

B017
System Software Backup continued Enter a suitable name for the file, the “tgz” extension must
remain.
The advanced menu will be shown, select the option “Create
software update/backup”.
Press the input key to continue.
The file will now be created, as the process continues the file
size, indicated in the brackets, will increase.
When the image has been created a confirmation message is

displayed. Remove the USB/CF storage device and power off/
on the controller.
The image should be stored in a safe place for future use.
Continue with the “Input” key.
Notes :

B017
System Software Backup continued The following procedure will flash the backup image
saved earlier to the new system CF card.
Restoring a System Image
The controller should be started and the advanced
The previously created system image (TGZ file) is used for the “Start-up menu” selected.
starting up of series machines.
Cursor to the “Install software update/backup” option
A licensed system CF card should be inserted into the rear CF
card slot of the Controller. and press the “Input” key.
Location of rear CF card slot, insert the system CF in here:
Insert the USB/CF device which contains the backup

image and select “Yes” followed by the “Input” key.
Notes :

B017
System Software Backup continued When the controller reboots, the alarm “4062 Back-up data
loaded” will be displayed, this data is the data saved in the
Select the backup image and press the “Input” key. It is possi- “Save data” procedure. Clear with the “Reset” key
ble that more than one image is present on the card/USB stick,
ensure that the correct one is chosen.
The machine functionality should now be checked. The opera-

tor should ensure that tool data, offsets etc are correct.
If alarm alarms numbers 4060 & 400006, 120402 are present,

this indicates that the “Save data” procedure was not carried
out before the system image was created.
In this case an archive will need to be loaded to get the
machine to an operational condition.
Time and Date Settings
The 828D controller uses the EUNA system for registering the
machine
The registration is very important with respect to the start of
the 2 year warranty
Period (2nd commissioning at End user).
The data backup is now written to the internal card. Allow the
For this reason it is essential that the time and date be set
process to finish
correctly.
When the procedure is finished the controller needs to be

powered off to allow the USB/CF device to be removed.
Notes :

B017
Creating Archive with Shortcut keys System CF Card Replacement
The screen of the 828D controller is integrated into the PPU In the event of the internal CF card becoming damaged it is
and cannot be changed. In the event of a screen failure it is possible to write a previously saved system image to a new CF
not possible to create an archive in the usual card.
manner prior to replacing the controller. It is necessary to obtain a replacement blank CF card from
For this reason it is possible to create a complete archive by Siemens. Part number for replacement 1GB card: 6FC5313-
simultaneously pressing three keys together. 5AG00-0AA0.
The keys to be pressed are “CTRL” + “ALT” + “S”
This procedure will automatically create an archive to an exter- The card will need to be licensed, this can only be done via the
nal USB or CF memory device. Siemens Hotline.
The serial numbers of the faulty and replacement cards are
Select the following keys simultaneously to produce the ar- required by the Hotline before a new licence number can be
chive. issued.
A system image (TGZ file) is a copy of the working system CF

+ + card, creating a system image is described in Section 6 .
The “Save Data” function described in Section 5, should be
performed prior to creating a system image.
Preparing the replacement System CF card:

If the procedure is used on a controller with an operational
screen, several dialogue boxes be will be shown, these will This card needs to be made bootable using the following
clear when the archive has been created. procedure.
If the screen has failed these boxes will obviously not be seen.
The replacement CF card should be inserted into a computer
using a suitable adaptor.
The software package “RCS Commander” is required plus a

recovery file called “minsys.img”. This file is installed as part of
the toolbox and is found within the folder named “Recoverysys”
in the toolbox directory.
Start the “RCS Commander” software:
The controller should be allowed plenty of time to create the

archive, a guide would be to allow 5 minutes.
A file with the .arc extension will be created and given a de-
fault name which includes time and date information.
It should be checked that the file exists on the USB/CF device
before commencing work. If there are any doubts it may be
better to do the procedure twice and compare the file sizes.
A connection to the controller is not necessary, cancel any
Example: dialogue boxes.
Notes :

B017
System CF Card Replacement continued Start the write procedure with the “Write” button.
From the “View” menu select the “Expert view” option.
When the procedure is complete a confirmation box is dis-

played.
From the “NC commissioning” list, select the option “Creating

SINUMERIK 828D boot system”.
Browse for the CF card:

Writing the Image to the Replacement CF Card
The “Minsys” recovery file to the CF card makes the card boot-
able. The card needs to placed in the rear CF card slot of the
controller in place of the “damaged” card.
The following procedure will flash the backup image saved
earlier to the new system CF card.
Insert the replacement bootable system CF card in the rear

slot of the controller.
Highlight the drive letter of the CF card. Example “K:\” Switch the controller on and allow to startup, the following dia-
logue box will be displayed, select the “Input” key to continue.
Notes :

B017
System CF Card Replacement continued When the procedure is finished the controller needs to be pow-
ered off to allow the USB/CF device to be removed.
Insert the USB/CF device which contains the backup image
and select “Yes”.
Switch off the controller, remove the front CF card/USB stick

and then switch the controller on.
When the controller reboots, the alarm “4062 Back-up data
loaded” will be displayed, this data is the data saved in the
“Save data” procedure. Clear with the “Reset” key.
Select the backup image and press the “Input” key. It is possi-
ble that more than one image is present on the card/USB stick,
ensure that the correct one is chosen.
If alarm alarms numbers 4060 & 400006, 120402 are present,

this indicates that the “Save data” procedure was not carried
out before the system image was created.
In this case an archive will need to be loaded to return the
machine to a running condition.
Licensing
The licence key number is matched to the System CF card

serial number, using a new CF card means that the numbers
do not now correspond.
Alarm number 8081 is generated because of this. The number
of options not licensed will differ between machines.
The data backup is now written to the internal card. Allow the
process to finish.
The new licence number obtained from the Siemens Hotline

will need entering, this is described in Module B044.
The data that was reloaded will need to be checked, tool data,
offsets etc will probably have changed since the image was
created.
The operator should verify this data before running the ma-
chine.
B017: END
Notes :

B017: END
Notes :
B017 Page 20 SINUMERIK

B010 PPU Connections and Diagnostics
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 hardware has to be correctly connected, the location and
functionality of these interfaces is described in this module.
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 all the hardware connections and know their functionality.
Content:
Sinumerik
PPU Status LED’s and Interfaces (Front)
PPU Status LED’s and Interfaces (Rear)
Digital Input/Output Terminal Description
B010
B010

B010
PPU Connections and Diagnostics : PPU Connections

Description And
Diagnostics:
START
The 828D PPU can be diagnosed using status LED’s. The
status can be quickly assessed prior to using more detailed
diagnostic tools. PPU Status
For the controller to function correctly the hardware has to be LED’s and
correctly connected, the location and functionality of these Interfaces
interfaces is described in this module. (Front)
PPU Status
LED’s and
Interfaces
(Rear)
Digital Input/
Output
Terminal
Description
PPU Connections
And
Diagnostics:
END
Notes :

B010
PPU Status LED’s and Interfaces (Front) PPU Status LED’s and Interfaces (Rear)
The interfaces are found on the front and the rear of the PPU. Interface locations:-
The front interfaces are found beneath a hinged cover to the
left of the screen. Rear view of PPU showing interfaces.
Internal (System) CF card location.
Fault
X100 Sync PN
X101 Fault PN
Sync
Rx/Tx X130
X102 Link
X140 X135
X122
Ethernet DHCP server port. X132
Default address-192.168.215.1
X127 Issues addresses up to X242
192.168.215.9. X252
RDY X143
LED status indicators, see table
NC X1
below. M T1 T2 T3
CF
X125 USB port for keyboard and
memory devices.
Interfaces for 828D S120 Book-size Drive Modules:
Compact Flash port for cus- X1 +24V DC supply

X145 tomer data storage and service/ X100 DriveCliq interface for line/motor modules
commissioning tasks. X101 DriveCliq interface for DMC module
X102 DriveCliq interface for NX10 module
X130 Ethernet-Factory network
X135 USB interface
X140 RS232 interface
X143 Interface for two Hand-wheels
Red/ X122 Digital I/O for Sinamics
LED Green Orange Red X132 Digital I/O for Sinamics
Orange
X242 Digital I/O for NC
NC Ready X252 Digital I/O for NC
PLC in stop NC in stop Power-up
RDY and PLC in
mode mode (Alternating) PN Profinet interface
run mode
PN Profinet interface (Not on 828D Basic M/T)
NC operation T0 Analogue output measuring socket
NC T1 Analogue output measuring socket
(Flashes cyclic)
T2 Analogue output measuring socket
Internal/External M Electronic ground for analogue measuring sockets
CF card access
CF
(Flashes ran-
domly)
Note: The CF card should not be removed while the CF LED

is flashing.
Notes :

B010
Interfaces for 828D S120 Combi Drive System: Digital Input/Output Terminal Description
X1 +24V DC supply X122, X132, X242 & X252 Terminal Description

X100 DriveCliq interface for Combi Drive.
X101 DriveCliq interface for S120 Book-sized Compact X122 & X132: BiCo’s are used to assign Sinamics inputs/
Motor Modules outputs to a specific function e.g. Enabling of drives, BERO’s,
X102 DriveCliq interface for TM54 Terminal Module for automatic line contactor control etc
Safety Integrated signals Certain terminals are automatically assigned to a function by
X130 Ethernet-Factory network default, these are the OFF1 and OFF3 drive enable signals
X135 USB interface and the input for probe 1.
X140 RS232 interface The remaining terminals can be assigned to a function via
X143 Interface for two Hand-wheels machine data.
X122 Digital I/O for Sinamics The status of the terminals is transferred to CU parameter
X132 Digital I/O for Sinamics r0722 which is referred to when assigning a function.
PN Profinet interface
PN Profinet interface (Not on 828D Basic M/T) X122-Sinamics I/O
M Electronic ground for analogue measuring sockets
X122 Signal Function/Default Setting
LED Indicators (All variants):
Pin 1 Sinamics DI0 OFF1 (ALM, SLM >=16Kw), Pulses
enabled (SLM <16Kw)
Name Colour Description
Pin 2 Sinamics DI1 OFF3 drive enable-Fast Stop
FAULT Red Fault present (Profinet interface)
Pin 3 Sinamics DI2 Safety Integrated SH/SBC 1 Group 1
SYNC Green Synchronisation OK (Profinet interface) input
Pin 4 Sinamics DI3 Safety Integrated SH/SBC 1 Group 2
Rx/Tx Yellow Network activity (X130 interface)
input
Link Green Network connected (X130 interface) Pin 5 Sinamics DI16 DI 16 Free to assign
Pin 6 Sinamics DI17 DI 17 Free to assign
Pin 7 MEXT2 Ground (M) Ground for pins 1 to 6
Pin 8 P24EXT1+24V DC (P) +24V DC common
Pin 9 Sinamics DI/DO8 Safety Integrated SH/SBC 1 Group 1
output
Pin 10 Sinamics DI/DO9 Safety Integrated SH/SBC 1 Group 2
output
Pin 11 MEXT1 Ground (M) P Ground for pins 9, 10
Pin 12 Sinamics DI/DO10 Bero 1 reference mark input
Pin 13 Sinamics DI/DO11 Probe 1 de-centralised input
Pin 14 MEXT1 Ground (M) Ground for pins 12, 13
Notes :

B010 END
Digital Input/Output Terminal Description continued X252-NCK Digital I/O
X132-Sinamics I/O

X132 Signal Function/Default Setting Pin 1 Not connected Not connected
Pin 1 Sinamics DI4 DI 4 Free to assign Pin 2 Not connected Not connected
Pin 2 Sinamics DI5 DI 5 Free to assign Pin 3 NCK DI9 (IN9) DI $A_IN[9]
Pin 4 Sinamics DI7 Line contactor check back signal input Pin 5 NCK DI11 (IN11) DI $A_IN[11]
Pin 6 Sinamics DI21 DI 21 Free to assign Pin 7 MEXT4 Ground (M) Ground for pins 3 to 6
Pin 7 MEXT2 Ground (M) Ground for pins 1 to 6 Pin 8 P24EXT3 +24V DC (P) +24V DC common
Pin 8 P24EXT1+24V DC (P) +24V DC common Pin 9 NCK DI9 (OUT9) DO $A_OUT[9]
Pin 9 Sinamics DI/DO12 Infeed is ready output Pin 10 NCK DI10 (OUT10) DO $A_OUT[10]
Pin 10 Sinamics DI/DO13 Ready to power up output Pin 11 MEXT3 Ground (M) Ground for pins 9, 10
Pin 11 MEXT1 Ground (M) Ground for pins 9, 10 Pin 12 NCK DI11 (OUT11) DO $A_OUT[11]
Pin 12 Sinamics DI/DO14 Line module contactor control output Pin 13 NCK DI12 (OUT12) DO $A_OUT[12]
Pin 13 Sinamics DI/DO15 Probe 2 de-centralised input Pin 14 MEXT3 Ground (M) Ground for pins 12, 13
X242-NCK Digital I/O X143-Hand-wheel connections

Pin 1 5V DC (P5) +5V DC common
Pin 2 0V DC (M) Ground
Pin 1 Not connected Not Connected
Pin 3 1A Hand-wheel 1 signal A
Pin 2 Not connected Not Connected
Pin 4 –1A Hand-wheel 1 signal –A
Pin 3 NCK DI1 (IN1) DI $A_IN[1]
Pin 5 1B Hand-wheel 1 signal B
Pin 6 –1B Hand-wheel 1 signal –B
Pin 6 NCK DI4 (IN4) DI $A_IN[4] Pin 7 5V DC (P5) +5V DC common
Pin 7 MEXT4 Ground (M) Ground for pins 3 to 6 Pin 8 0V DC (M) Ground
Pin 8 P24EXT3 +24V DC (P) +24V DC common Pin 9 2A Hand-wheel 2 signal A

Pin 9 NCK D01 (OUT1) DO $A_OUT[1] Pin 10 –2A Hand-wheel 2 signal –A
Pin 10 NCK DO2 (OUT2) DO $A_OUT[2] Pin 11 2B Hand-wheel 2 signal B
Pin 11 MEXT3 Ground (M) Ground for pins 9, 10 Pin 12 –2B Hand-wheel 2 signal –B
Pin 12 NCK DO3 (OUT3) DO $A_OUT[3]
Pin 13 NCK DO4 (OUT4) DO $A_OUT[4]
B010: END
Notes :

B051 Line and Motor Modules
Module Description:
The Sinumerik 828D uses Sinamics drive components, these components must be powered on/off
in a certain sequence in order to operate correctly. This module shows how these components are
connected to the system and the required power on/off enabling sequence.
Module Objective:
Upon completion of this module you will know how the drive components of the Sinumerik 828D
system are integrated and how the power to these components should be applied and removed.
Content:
Sinumerik
Topology Drive Object Numbering
General Information
Drive Module power Supply
Smart Line Module (SLM)
Active Line Module (ALM)
Motor Module (MM)
Supply and Enabling Examples
B051
B051

B051
Line and Motor modules: Description Line and Motor

Modules:
START
The Sinumerik 828D uses Sinamics drive components, these
components must be powered on/off in a certain sequence in
order to operate correctly. This module shows how these
components are
connected to the system and the required power on/off ena- Topology Drive
bling sequence. Object
Numbering
General Infor-
mation
Drive Module
power Supply
Smart Line Module

(SLM)
Active Line Module

(ALM)
Motor Module (MM)
Supply and
Enabling Ex-
amples
Line and Motor

Modules:
END
Notes :

B051
Topology: Drive Object and Component Numbering
Example- 5 axis system (Spindle, X, Y, Z, A)
The system assigns the object/component numbers on the Drive-CLiQ Bus in the order they are connected.
CU is always object number 1.
The servo drives are classed as drive objects.
Motors, encoders etc are classed as drive components.
Components Motor, encoder etc. are then assigned in reverse order.
Objects are numbered in red.

Components are numbered in purple.
828D CU
Drive Object 1
X100 X101 X102

• • •
Single Motor Module Double Motor Module Double Motor Module SMC20
Drive Object 2 Drive Objects 3 & 4 Drive Objects 5 & 6 SMC- 7
ENC- 8
•X200 X201• •X200 X201• •X200 X201• •X500
X202 X202 X203 X202 X203

• • • •
•
Sp motor X motor Y motor Z motor A motor

SMI- 21 SMI- 18 SMI- 15 SMI- 12 SMI- 9
ENC- 22 ENC- 19 ENC- 16 ENC- 13 ENC- 10
MOT- 23 MOT- 20 MOT- 17 MOT- 14 MOT- 11
Notes :

B051
Example- 7 axis system with NX10
The NX10 can only be connected to X102. The connected drives/motors are numbered in the same way as the CU.
The DriveCLiQ line module is always
assigned Object number 2.
Equipment connected to X101 is assigned to the CU, the numbering follows on from the last Component connected to X100.
CU Objects are numbered in red.

CU Components are numbered in purple.
NX Objects are numbered in green.
NX Components are numbered in blue.
Double Motor Module

NX10 Drive Objects 2 & 3
Drive Object 1
•X100 X101• •X200 X201•
X202 X203
• •
828D CU
Drive Object 1
Motor 6 Motor 7
SMI- 7 SMI- 4
X100 X101 X102
ENC- 8 ENC- 5
• • •
MOT- 9 MOT- 6
DMC20 25 SMC20
SMC- 26
ENC- 27
•X500 X502• •X500
SLM/ALM Single Motor Module Double Motor Module Double Motor Module SMC20
Drive Object 2 Drive Object 3 Drive Objects 4 & 5 Drive Objects 6 & 7 SMC- 8
ENC- 9
•X200 X201• •X200 X201• •X200 X201• •X200 X201• •X500
X202 X202 X203

X202 X203
• • •
• •
Motor 1 Motor 2 Motor 3 Motor 4 Motor 5

SMI- 22 SMI- 19 SMI- 16 SMI- 13 SMI- 10
ENC- 23 ENC- 20 ENC- 17 ENC- 14 ENC- 11
MOT- 24 MOT- 21 MOT- 18 MOT- 15 MOT- 12
Notes :

B051
Example– 5 axis system with Combi Drive.
The Combi drive can only be connected to X101.

Additional axes are facilitated by the addition of Book-sized Compact Modules. These must always be connected to X101.
X102 is reserved for the connection of a Terminal Module (TM54) which is used for Safety Integrated functionality.
Drive Objects are numbered in red.

Drive Components are numbered in purple.
Book-sized
Compact Motor
Module
A Axis
Drive Object 7
Drive Component 50
•X200 X201•
X202
•
828D CU
Drive Object 1 Motor 5
SMI- 51
X100 X101 X102 ENC- 52
• • • MOT- 53
4 Axis Combi Drive
SLM/ALM Spindle Motor Integrated X Axis Motor Y Axis Motor Z Axis Motor
Drive Object 2 Module Sensor Module Module Module Module
Drive Object 3 (SMI) Drive Object 4 Drive Object 5 Drive Object 6
•X200 Drive Component 10 Drive Component 14 Drive Component 20 Drive Component 30 Drive Component 40
X201 X220 X202 X203 X204

• • • • •
Motor 1 Spindle Motor 2 Motor 3 Motor 4

SMI- 11 DMS SMI- 21 SMI- 31 SMI- 41
ENC- 12 Encoder ENC- 22 ENC- 32 ENC- 42
MOT- 13 ENC- 15 MOT- 23 MOT- 33 MOT- 43
Notes :

B051
General Information Drive Module power Supply
Line and Motor Modules Power Requirements
Line and motor modules are responsible for supplying power The drive modules require two power supplies in order to op-
to the motors. erate.
The Sinumerik 828D operates with the Sinamics S120 Book-
size range of drive products. These are of a modular design A 3 phase AC supply (380V to 480V +10% (-15% < 1 min) to
and are for use with the Drive-CLiQ drive bus system. the bottom of the line module is used to produce the 600V DC
link. The DC link is distributed to the motor modules via a bus
Line modules require a 3 phase AC supply, this is rectified bar system on the front of the drive modules beneath a flip
into a DC supply which is then supplied to the motor modules down cover
via the DC link bus bars.
The +24V DC electronics supply is obtained externally from
Motor modules convert the DC link back into a controllable AC the user on connector X24. This is also distributed by a bus
supply which is used to drive the servo motors. bar system along the front of the drive modules.
By regulating the frequency and voltage of the AC supply to The electronic supply is used internally by the drive modules
the servo motors it is possible to precisely control the move- for powering of the electronic circuitry etc. Externally it is used
ment of motors. for supplying the Drive-CLiQ encoders and fault, ready and
enable signals.
Line and motor modules are available in different variants
depending on the machine requirements.
Each module requires a +24V DC control voltage, this is sup- X24– Electronic Supply 24V DC
plied by the user to the line module and then distributed to the
motor modules via a bus system.
“M” Terminal: Electronics ground
Example, Line module with two motor modules:-
“+” Terminal: +24V DC

(20.4V to 28.8V)
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
Notes :

Line Mod- B051
Motor Mod-
ule ules
B051
Smart Line Modules (SLM) Connector locations X21, X22 & X24
The SLM is responsible for rectifying the AC mains supply into

the DC link voltage which is then utilised by the Motor Mod-
ules.
This DC link voltage is non-stabilised on all SLM types
The SLM is also responsible for handling the regenerative cur-
rent caused by the
X21: X22: (SLM 5 & 10Kw
braking of motors. The regenerative current is fed back into the Enable, ready only)
mains network. This eliminates the need for braking resistors and fault sig- Regeneration and
and complex measures for heat dissipation. nals fault
The SLM is available in 5, 10, 16 & 36Kw variants with internal reset signals
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 accel-
eration/deceleration rates are not severe.
Smart Line Modules- 5 & 10Kw
The 5 & 10Kw SLM’s are not used on the Drive-CLiQ network, X24:
24V DC Elec-
because of this there are slight differences with terminal func- tronics supply
tionality compared to Drive-CLiQ type modules.
Example:-An internally cooled 10Kw SLM module showing

terminal locations etc.
SLM
X21: X22:
Various signals Various signals X22 Terminal description and functionality
X24:Electronics
supply
Electronics/DC link
bus bars (below flip Terminal Function Description
down cover)
1 +24V DC +24 V DC Supply for use with the functions
(Output) of X22.2 & 3 described below.
2 Disable Applying +24V DC will cause the regenera-

Regeneration tion function to be disabled.
(Input)
In some cases it may be necessary to stop
the
LED status regeneration of current caused by braking
Indicators motors. Example:- A poor quality mains
Network not able to handle regeneration.
Note:-The fitting of resistor modules to
dissipate
excess energy will be required when this
function is used.
3 Fault Reset Applying +24V DC will cause the resetting of

(Input) any drive faults.
A fault occurring on the drives system will

be latched, this can be reset with this func-
tion providing the cause of the original fault
X1: Mains supply is no longer present.
Protective earth (3-Phase AC)
4 0V DC Must be connected to the same 0V of the
connections
(Ground) electronics supply (X24).
Notes :

B051
X21 Terminal description and functionality LED Status Display
LED Colour Statu Explanation

s
Green On Module is healthy and operational.
READY Yellow On Pre charging of DC link active; Bypass relay

Terminal Function Description dropped out.
(Top)
1 Ready Switches high (+24V DC) when the following Red On Over temperature/current fault or electronics
Signal conditions are true:- power supply outside permitted range.
(Output)  Electronics supply present (X24).
Off Electronics power supply outside permitted
 DC Link is pre-charged. range.
 Pulses enabled (X21.3) DC LINK
Yellow On DC link voltage within tolerance.
(Bottom
 No over-temperature )
Red On DC link voltage outside tolerance.
 No over-current
It is recommended that the signal is connected di-

rectly to the 828D controller via connector X122 pin Smart Line Modules- 16Kw and above
1. This is the OFF1 enable signal.
2 Pre- Switches low when any of the following conditions These models are always required to be connected to the
warning arise:- Drive-CLiQ drive bus network.
(Output)
 Over-temperature threshold reached. The functionality of certain terminals is therefore different from
 I²t threshold reached. the non-Drive-CLiQ SLM modules.
 Mains fault making regenerative feedback Regeneration can be deactivated by parameter P3533-Inhibit
impossible. If feedback is intentionally regenerative operation.
deactivated (X22.2 is high) this warning is
disabled. Terminal locations of an internally cooled 36Kw SLM:-
This signal is for use by the manufacturer to set a
user alarm and alert the operator to a problem.
3 Enable Applying +24V DC will cause the pulses to be

X200/X201/
Pulses enabled. (Current consumption:10mA) X21:Pulse
(Input) X202:
enable Drive-CLiQ
This signal must be removed at least 10ms prior to
the 3-phase mains supply being removed. connectors
Failure to do this can lead to damaged drive mod-
ules. This is especially important when the axes/ X24:Electronic
spindles are decelerating and causing regenerative s supply
currents. if the mains circuit is opened these regen-
erative Electronics/DC
currents remain within the drive system causing link bus bars
damage to the modules. (below flip
down cover)
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 LED status

switched off and mains regeneration halted, the Indicators
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

Pulses supply.
(Ground)
Protective X1: Mains supply

earth (3-Phase AC)
terminals
Notes :

B051
Smart Line Module (SLM) continued LED Status Display
Connector locations X21, X24, X200, X201 & X202 LED Colour Status Explanation

range.
Green On Module configured and ready, Drive-CLiQ

communication is active.
X21:
Pulse enable Orange On Drive-CLiQ communication is being estab-
READY
(Top) lished/module not configured.
Red On At least one fault is present.

X202: Green/ Flash- Firmware download procedure is running.
Drive-CLiQ connector Red ing
2Hz
X201: Green/ Flash- Component recognition is active (p0124 = 1)

Drive-CLiQ connector Orange ing
or Red/ 2 Hz
Orange
X200:
Drive-CLiQ connector range.
DC
LINK Orange On DC link voltage within tolerance-Only if unit is
X24: (Botto configured and ready.
24V DC Electronics m)
Red On DC link voltage outside tolerance-Only if unit
Supply is configured and ready.
X21 Terminal description and functionality
Termi- Function Description

nal
1 Not used Not used
2 Not used Not used
3 Enable Applying +24V DC enables the pulses.

Pulses (Current consumption:10mA)
(Input)
This signal must be removed at least 10ms prior to the 3
-phase mains supply being removed.
Failure to do this can lead to damaged drive modules.
This is especially important when the axes/spindles are
regenerating. If the mains circuit is opened in this state,
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).
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.

Pulses supply.
(Ground)
Notes :

B051
Active Line Modules (ALM) Location of ALM connectors X21, X24, X200, X201 & X202
The ALM is responsible for the rectification of the AC mains

X21:
supply into the DC link voltage which is then utilised by the
Enable and
Motor Modules. Temperature sensor
This DC link voltage is also stabilised unlike the SLM mod- Connections
ules
The ALM is also responsible for handling regenerative current
X203:
caused by the braking of motors. Drive-CLiQ connec-
The regenerative current is fed back into the mains network. tor
This eliminates the need for braking resistors and complex
measures for heat dissipation. X202:
Regeneration can be deactivated by parameter P3533-Inhibit Drive-CLiQ connec-
regenerative operation. tor
The modules are available in 16, 36, 55, 80 & 120Kw variants
with internal or external cooling capability. X201:
The ALM is always connected to the Drive-CLiQ bus and has Drive-CLiQ connec-
four Drive-CLiQ connections. tor
The stabilised DC link makes the ALM suitable for high dy-
namic machinery where the acceleration and positioning of X200:
axes/spindles is critical. Drive-CLiQ connec-
tor
Terminal locations of ALM modules:-
X24:
24V DC Electronics
X21: X200/X201/ supply
Pulse enable, X202:
temperature Drive-CLiQ X21 Terminal description and functionality
sensor connectors
X24:Electroni Electronics/DC
cs supply. link bus bars
Terminal Function Description
(below flip
down cover) 1 + Temp Temperature sensor input from Active Interface
(Input) Module (Observe the polarity)
LED status
Indicators 2 - Temp Temperature sensor input from Active Interface
(Input) Module (Observe the polarity)
3 Enable Applying +24V DC enables the pulses.

Pulses (Current consumption:10mA)
(Input)
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 mod-
ules. This is especially important when the axes/
X1: spindles are regenerating. If the mains circuit is
3-Phase AC opened in this state, regenerative currents remain
Protective Mains supply within the drive system causing damage to the mod-
earth ules.
connections. It is recommended that this terminal is connected via
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.

Pulses supply.
(Ground)
Notes :

B051
Active Line Modules continued Motor Modules (MM)
Motor Modules are responsible for converting the DC link

LED Status Display voltage into a variable AC voltage in order to drive the mo-
tors.
The modules have to be connected to the Drive-CLiQ bus.
Single/double axis and internally/externally cooled versions
LED Colour Statu Explanation are available.
s
Double axis modules are equipped with four Drive-CLiQ con-
Off Electronics power supply outside permitted nectors, one more than the single axis modules.
range.
Green On Module configured and ready, Drive-CLiQ Single Axis MM

communication is active. Available in the following rated current output sizes:-
3, 5, 9, 18, 30, 45, 60, 85, 132 & 200A.
READY Orange On Drive-CLiQ communication is being estab-
(Top) lished/module not configured.
Red On At least one fault is present. Example:- A single axis MM showing connector locations etc.
Green/ Flashi Firmware download procedure is running.
Red ng
2Hz
Green/ Flashi Component recognition is active (p0124 = 1)

Orange or ng X200/X201/X202:
X21: Drive-CLiQ
Red/ 2 Hz
Orange Enables etc. Connectors
range.
DC
(Bottom configured and ready. Electronics/DC
) link bus bars
Red On DC link voltage outside tolerance-Only if unit is
(below flip down
configured and ready.
cover)
LED Status
Indicators
X11: Brake output
for MM of 45A and
above
X1: Output to
Protective Motor, including
earth the brake output
terminals for MM less than
Notes :

B051
Double Axis MM Terminal descriptions

Available in the following rated current output sizes:-3, 5, 9 &
18A
X21: Pulse
Enable etc.
Example:-A double axis MM showing connector locations.
These units will have two identical Motor/Brake connectors
X21: Pulse
(X1 & X2) and two X22: Pulse
Enable etc.
identical enable connectors (X21 & X22). Enable etc.
X203:
X202: Drive-CLiQ
Drive-CLiQ
X21:Motor 1 X22:Motor 2
X202:
Enables etc. Enables etc. X201: Drive-CLiQ
Drive-CLiQ
X201:
X200/X201/X202/ Electronics/DC
Drive-CLiQ
X203: link bus bars
(below flip down X200:
Drive-CLiQ
cover) Drive-CLiQ
connectors X200:
Drive-CLiQ
LED Status
Indicators X1 & X2 Output Single axis Double axis
to Motor, Module Module
including the
brake output for
MM less than
45A
Connector X21 & X22 (X22 only for double axis modules)
Protective
earth X11: Brake out-
connections put for MM of
45A and above

nal
1 + Temp Positive temperature sensor input from non-Drive-CLiQ

(Input) temperature sensor.
Type:- KTY84-1C130/PTC
2 - Temp Negative temperature sensor input from non Drive-CLiQ

3 Enable Applying +24V DC will cause the pulses of the individual

Pulses axis to be enabled. (Current consumption:10mA)
(Input) When the signal is low, “Safe pulse suppression” is
activated.
Note:-No electrical isolation occurs 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.

Pulses supply.
(Ground)
Notes :

B051
Motor Module (MM) continued
LED Status Display
LED Colour Status Explanation

range.
Green On Module configured and ready, Drive-CLiQ com-

munication is active.
READ Orange On Drive-CLiQ communication is being

Y(Top) established/module not configured.
Red On At least one fault is present.
Green/ Flashing Firmware download procedure is running.

Red 2Hz
Green/ Flashing Component recognition is active (p0124 = 1)

Orange 2 Hz
or Red/
Orange

range.
DC
(Botto configured and ready.
m)
Red On DC link voltage outside tolerance-Only if unit is
configured and ready.
Motor connector (MM less than 45A)
Screw terminals. Not

Fixing screw on Crimped cable Metal connector
types housing, also used
for cable shield
Brake: Negative Brake: Posi-

Connection tive Connec-
tion
Locating key- Locating key-

Changeable
Motor: Motor: Motor:

Phase U Phase V Phase W
For MM modules of 45A and above, the brake is supplied by a

separate connector (X11).
The brake control circuit is isolated therefore it is not permissi-

ble to connect the –ve brake connector to the 0 volt common of
the machine.
Notes :

B051
Combi Drive Modules
Combi Drive (Combined Line and Motor Modules).
The Combi drive unit consists of a Line Module and either 3 or 4 Motor Modules, the first of which is dedicated to the Spindle.
They must always be connected to the DriveCLiQ network via controller interface X100
The number of axes can be increased by adding Sinamics S120 Book-sized Compact
Motor Modules up to the maximum allowed by the system.
X21: Motor X12/X13: Fan Supply X224: +24V DC auxil-

Enables etc. and monitoring iary supply
X200 to X205:
Drive-CLiQ
connectors
X220: Interface
for TTL 5v DMS
encoder
LED Status
Indicators
X1: Line supply to

module
X2 to X5: Supply to
motors
Shielding and earth plate
X11: Connector for one

brake (Underneath)
Notes :

B051
Combi Drive Modules. Continued X22 Terminal description and functionality.
Detailed Terminal Description.
Top view of Combi Drive Unit:
X21/X22 X12/X13 Termi- Function Description

Enables and tem- Fan supply and monitoring nal
perature sensor. X224 +24V DC
auxiliary supply 1 + Temp Positive temperature sensor input from non-Drive-CLiQ
2 - Temp Negative temperature sensor input from non Drive-CLiQ

3 Safety Applying +24V DC will cause the pulses of the individual

Inte- axis to be enabled. (Current consumption:10mA)
grated. When the signal is low, “Safe pulse suppression” is
Enable activated.
Pulses Note:-No electrical isolation occurs between the Motor
EP +24 V module and the motor.
(Input) This enable signal is only operational if the Safety Inte-
grated 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 Safety Must be connected to the 0V of the enable pulses sup-

Inte- ply.
grated.
Enable
Pulses
EP M1
(Ground)
X21 Terminal description and functionality

X12/X13 Terminal description and functionality.

nal
nal 1 Ground Ground connection for fan monitoring circuit.
1 Not used Not used 2 Fan Fan monitoring signal, input from fan.
Monitor-
2 Not used Not used ing.
(Input)
3 Enable Applying +24V DC enables the pulses. (Current con-
Pulses sumption:10mA) 3 +24 V +24V DC supply to fan. Maximum 2 A. (1 x 2 A or 2 x
(Input) DC 1A)
This signal must be removed at least 10ms prior to the (Output)
3-phase mains supply being removed.
Failure to do this can lead to damaged drive modules. 4 Ground Ground for fan supply.
This is especially important when the axes/spindles
are regenerating. If the mains circuit is opened in this
state, regenerative currents remain within the drive
system causing damage to the modules.
It is recommended that this terminal is connected via

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.

Pulses supply.
(Ground)
Notes :

B051
Non Siemens fans may be used without the monitoring. In Front View of Combi Drive and Interfaces.
this case terminals 1& 2 must be linked.
X224 Terminal Description and functionality.

X220 5V TTL DMS
encoder
+ M

nal
+24 V DC +24V DC auxiliary supply to Combi drive module

+
(Input)
M Ground Ground for fan supply +24V DC auxiliary supply
X22 Terminal description and functionality.
X200 to X205 Terminal description and functionality
DriveCLiQ Interfaces:
X205 - DMS via SMC (If X220 not suitable)
X204 - Z axis motor feedback.
X203 - Y axis motor feedback.
X202 - X axis motor feedback.
X201 - Spindle axis motor feedback.

X1 Line X2 to X5 Motor Supply Output
Supply
Input
X200 - DriveCLiQ drive bus (From X100 828D
Controller).
X220 Terminal description and functionality (for 5V TTL

encoders)
Notes :

B051
Combi Drive Modules. Continued Supply and Enabling Examples
For trouble free operation it is essential that the drives are

Pin Signal Technical Information powered on/off and enabled correctly.
Motor temperature sensor positive connection (KTY If the mains supply switch/contactor is opened while the drive
1 + Temp
84-1C130) pulses are enabled and the drive is in regeneration mode,
the regenerative current which is normally fed back into the
2 Clock Clock Signal
mains will have no where to go, except that is into the motor
3 Clock* Inverse Clock Signal and line modules, this can result in damage to these mod-
4 P-Encoder 5V ules.
+5V Encoder Power Supply The solution is to use an auxiliary contact fitted to the mains
5 P-Encoder 5V switch and drive line contactor.
6 P-Sense +5V Sense Signal This auxiliary contact must open at least 10ms before the
main contacts open.
7 M-Encoder (M) Encoder Power Supply 0V
The contact is wired to the Pulse Enable terminal of the SLM/
- Temp
Motor temperature sensor negative connection (KTY ALM module.
8
84-1C130) If the Main switch or contactor is operated while the drive is
9 M-Sense 0V Sense Signal in operation the pulses will be disabled and the motors will
free wheel to a standstill. (Except when the Safety Integrated
10 R Reference Signal R function “Safe Stop” is enabled)
11 R* Inverse Reference Signal R* Any potentially harmful current will be unable to enter the
drive modules as the transistors are now switched off.
12 B* Inverse Incremental Signal B*
13 B Incremental Signal B
14 A* Inverse Incremental Signal A*

Below is the recommended timing diagram for the enabling
15 A Incremental Signal A of drives via the controller using a line Contactor.
Interfaces X1 to X5
Minimum 10ms-
if supply disconnected
while drive is operational
Mains supply
X1 Terminal Description and Functionality. E Stop active
DB2700.DBX0.1
Terminal Function Description Input to ALM/SLM via line switch
Enable Pulses
ALM/SLM
U1 U Phase Line Phase U X21.3
V1 V Phase Line Phase V Output/Input from/to 828D

In-feed ready.
From/to 828D
W1 W Phase Line Phase W Link X132.8 to
X122.1(OFF1)
PE Earth Protective Earth Output from 828D
Energise line
contactor–
X2 to X5 Terminal Description and Functionality. 828D X132.10
output
Input from N/O contact
Line contactor
Terminal Function Description energised-
828D X132.4
U2 U Phase Motor Phase U Input
Input to ALM/SLM
V2 V Phase Motor Phase V OFF3 Enable
from user to
W2 W Phase Motor Phase W 828D X122.2
PE Earth Protective Earth
Notes :

B051
Mains Supply and Enabling Examples

SLM 5 & 10Kw, no line contactor, user controlled enable.
X122
I2t alarm from SLM
to user
Main
supply
OFF1 Drive ready

Early break
SLM to 828D X132
contact
X21
Main Optional:-
Switch Pulse enable
via user PLC
+24V 24V DC 0V
PSU
Supply to other
equipment
OFF3 Drive
enable from
user to 828D
Filter Reactor
Notes :

B051

SLM 5 & 10Kw . User controlled line contactor (Early break contact) and 828D controlled enables.
X122
I2t alarm From SLM
to user
Mains
supply
OFF1 Drive ready

Early break SLM to 828D
contact X132
X21
Main
Switch Supply to other
equipment
Optional:-
Pulse enable
via user PLC
0V 24V
OFF3 Drive
enable from
Early user to 828D
break
contact Energise
Line
Line
Contactor
Line contactor
+24V 24V DC 0V
from user
contactor
PSU energised. PLC
to user PLC
Filter Reactor
Notes :

B051

ALM and SLM 16 & 36Kw-no line contactor, user controlled enables.
X122
Main
supply Drive
enable
from 828D
X100 X132.10 to
828D
Early break X122.1
contact X132 (OFF1)
X21
Main Drive-CLiQ
Optional:-
Switch Pulse enable
via user PLC
X200
+24V 24V DC 0V
PSU
Supply to other
equipment
OFF3
enable
(E stop)
from user
to 828D
X122.2
Filter Reactor
Notes :

B051

ALM and SLM 16 & 36Kw. User controlled line contactor (Early break contact) and 828D controlled enables.
X122
Mains
supply Drive
enable
from 828D
X100 X132.10 to
828D
Early break X122.1
Drive-
contact X21 X132 (OFF1)
CLiQ
Main Supply to other

Switch equipment
X200
Optional:-
Pulse enable
via user PLC
0V 24V
OFF3 enable
(E stop)
Early break from user to
contact 828D X122.2
Line
Contactor +24V 24V DC 0V
Line contactor
energised- Energise line
Filter Reactor to user PLC contactor-
from user PLC
Notes :

B051

ALM & SLM 16 & 36Kw . 828D controlled line contactor (Early break contact) and enables.
X122
Mains
supply
Drive
enable
from 828D
X100 X132.10 to
828D
Early break X122.1
Drive- X132 (OFF1)
contact
X21
Main
Switch Supply to other
equipment Line Energise
X200 contactor Line
energised contactor-
Optional:- Pulse -to 828D from 828D
enable via user x132.4 X132.12
PLC or 828D
X122/X132
0V 24V
OFF3 enable
(E stop)
from user to
Early break 828D X122.2
contact
Line
Contactor +24V 24V DC 0V
Filter Reactor
B051: END
Notes :

B051 END

B008 Profinet Connections and Diagnostics
Module Description:
The PLC periphery components of the 828D controller are connected to the Profinet network.
Periphery components are used to interface between the controller with the physical I/O of the ma-
chine.
Each periphery component needs to be configured, this is achieved with machine data and dip-
switches.
Periphery Components:
Machine control panels- The 828D controller uses one of three machine control panel variants for
handling signals such as mode selection, axis selection, federates, NC start etc.
- The MCP483 is 483mm in length and is recommended for use with the horizontal variant of 828D.
- The MCP310 is 310mm in length and is recommended for use with the vertical variant of the 828D.
- The 3rd variant is the OEM version (supplied/manufactured by OEM).
PP72/48 - The 828D controller uses up to five PP72/48 PN input/output modules for example, to
handle signals to coils and lamps, and signals from pressure switches, over-travel switches etc.
Module Objective:
Upon completion of this module the course participant will know how to configure and install the Sie-
mens machine control panel (MCP) and PP72/48 periphery I/O modules.
Content:
Sinumerik
Theory and Objective.
Machine Control Panel Types
MCP483 PN Front and rear Layout
MCP310 PN Front and rear Layout
Machine Control Panel Interface Signals
PP72/48 PN Description and Interface Signals
Profinet Configuration - MCP & PP72.48
B008
B008

B008
Profinet Connections and Diagnostics: Function

Electronic
The PLC periphery components of the 828D controller are Logbook:
connected to the Profinet network. START
Periphery components are used to interface between the con-
troller with the physical I/O of the machine.
Each periphery component needs to be configured, this is
achieved with machine data and dip-switches. Machine
Control
Periphery Components: Panel Types
Machine control panels- The 828D controller uses one of three
machine control panel variants for handling signals such as
mode selection, axis selection, federates, NC start etc.
MCP483
- The MCP483 is 483mm in length and is recommended for Front and
use with the horizontal variant of 828D. Rear layout
- The MCP310 is 310mm in length and is recommended for
use with the vertical variant of the 828D.
- The 3rd variant is the OEM version (supplied/manufactured
by OEM).
MCP310
Front and
PP72/48 - The 828D controller uses up to five PP72/48 PN
Rear layout
input/output modules for example, to handle signals to coils
and lamps, and signals from pressure switches, over-travel
switches etc.
Machine
Control Panel
Interface
Signals
PP72/48 PN
Description
and Interface
Signals
Profinet
Configuration
- MCP &
PP72/48
Electronic
Logbook:
END
Notes :

B008
Machine Control Panel Types:
MCP483 PN
S1
MCP310 PN
Notes :

MCP483 PN Front 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
MDA 10 100 T7 T8 T9
Axis Axis
MCS
Auto 1000 10000 T10 T11 T12
WCS
Page 5
Blank for Blank for Single Cycle Cycle Spindle Spindle Feed Feed Key
Reset T13 T14 T15 — Rapid + Switch
user user block Stop Start stop start Start Stop
Note:- Cycle stop, Feed stop & Spindle stop-signals are inverted i.e. Normally closed.
Buttons T1 to T15 are free for use by the manufacturer.
The two blanks can be removed to allow the user to add extra buttons/switches/lamps.
Notes :
B008
B008
MCP483 PN Rear Layout
B008
B008
X10
X53
X54 X60 X61
X3 X51
X52
X55
X20
H3
H2
X30 H1 X21
Page 6
X5
S2
Interface Description:- X51 Digital inputs X60 Hand-wheel - Not used on 828D
S2 Addressing switch. X52 Digital inputs X61 Hand-wheel - Not used on 828D
X5 Key-switch interface X53 Digital outputs
X10 24V DC supply X54 Digital outputs
X20 Port 1 Profinet connection in. X55 Digital inputs
X21 Port 2 Profinet connection out. LED Indicatots:-
X30 Feedrate override interface. H1 Power OK (Green)
X31 Spindle override interface. H2 BUSSYNC
H3 BUSFAULT
Notes :
SINUMERIK 828D
MCP310 PN Front Layout
SINUMERIK 828D
Spindle Spindle
JOG REP REF VAR T1 T2 T3 100 %
Dec. Inc.
Blank for
spindle
Teach Spindle Spindle Spindle override/
MDA T13 1 T4 T5 T6
In right stop left E stop
Auto T14 T15 10 T7 T8 T9 X Y Z
Single 4th 5th 6th

Reset T16 100 T10 T11 T12
Block Axis Axis Axis Feed
Override
Page 7
Cycle Cycle WCS Feed Feed
1000 - Rapid +
Stop Start MCS Stop Start
Key Blank for Blank for Blank for Blank for Blank for Blank for
Switch user user user user user user
Note:- Cycle stop, Feed stop & Spindle stop-signals are inverted i.e. Normally closed.
Buttons T1 to T16 are free for use by the manufacturer.
The six blanks can be removed to allow the user to add extra buttons/switches/lamps.
Notes :
B008
B008
B008
MCP310 PN Rear Layout
X10
X53
X54 X60 X61
X31 X51
X52
X55
X20
H3
H2
H1
X30 X21
X5
S2
Interface Description:- X51 Digital inputs X60 Hand-wheel - Not used on 828D
S2 Addressing switch X52 Digital inputs X61 Hand-wheel - Not used on 828D
X5 Key-switch interface X53 Digital outputs
X10 24V DC supply X54 Digital outputs
X55 Digital inputs
X20 Port 1 Profinet connection in. LED Indicators:-
H1 Power OK (Green)
X21 Port 2 Profinet connection out. H2 BUSSYNC
H3 BUSFAULT
X30 Feedrate override interface.
X31 Spindle override interface
Notes :

B008
The following tables show the interface signals for an MCP483 PN with the recommended start address of 112.
MCP483 PN Signals from machine control panel (keys)

Spindle override JOG TEACH IN MDA AUTO
IB112
D C B A
IB113 REPOS REF INC var. 10000 INC INC 1000 INC 100 INC 10 INC 1
Key- Key- Spindle start *Spindle stop Feed *Feed NC Start *NC Stop
IB114 switch switch posi- start stop
position 0 tion 2
Reset Key- Single block Feedrate override
IB115 switch posi-
tion 1 E D C B A
Direction keys Key switch Axis selection keys
+ - Rapid trav- position 3 X 4th axis 7th axis
IB116
R15 R13 erse R1 R4 R7
R14
Axis selection keys
IB117 Y Z 5th axis MCS/WCS R9 8th axis 6th axis
R2 R3 R5 R12 R8 R6
Unassigned customer keys
IB118
T9 T10 T11 T12 T13 T14 T15
IB119
T1 T2 T3 T4 T5 T6 T7 T8
IB122 KT8 KT7 KT6 KT5 KT4 KT3 KT2 KT1
IB123 KT9
Spindle override
IB125
E (16) D (8) C (4) B (2) A (1)
MCP483 PN Signals to machine control panel (LEDs)

Machine function Operating mode

QB112
INC 1000 INC 100 INC 10 INC 1 JOG TEACH IN MDA AUTO
Feed *Feed NC Start *NC Stop REPOS REF INC var. INC 10000
QB113 start stop
Direction X 4th axis 7th axis Single block Spindle start *Spindle stop
QB114 Minus R1 R4 R7 R10
R13
Z 5th axis MCS/WCS 8th axis 6th axis Direction Plus
QB115 R3 R5 R11 R9 R8 R6 R15
Unassigned customer keys Y
QB116
T9 T10 T11 T12 T13 T14 T15 R2
QB117
T1 T2 T3 T4 T5 T6 T7 T8
QB118 Reset R14
QB119 KT6 KT5 KT4 KT3 KT2 KT1
Notes :

B008
The following tables show the interface signals for an MCP483 PN with the recommended start address of 112.
IB112 *NC Stop Spindle - Spindle 100% Spindle + Single block JOG MDA AUTO
NC Start Spindle right *Spindle stop Spindle left Key-switch REF REPOS Teach IN
IB113 position 3
Feed start *Feed stop INC var. Key-switch

IB114 position 0
INC 1000 INC 100 INC 10 INC 1
Feedrate override
IB115 Reset Key-switch Key-switch E (16) D (8) C (4) B (2) A (1)
Direction keys Rapid

traverse
IB116 KT5 (X52.2) KT4 (X52.1) KT3 (X51.3) KT2 (X51.2) KT1(X51.1)
+ -
IB117 Axis selection
T16 KT6(X52.3) 6th axis 5th axis 4th axis Z Y X
IB118 T9 T10 T11 T12 WCS MCS T13 T14 T15

IB119 T1 T2 T3 T4 T5 T6 T7 T8
IB123 KT9
Spindle override
IB125
E (16) D (8) C (4) B (2) A (1)
MCP 310 PN Signals to machine control panel (LEDs)

*NC Stop Spindle Dec. Spindle 100% Spindle Inc. Single Block JOG MDA AUTO
QB112
NC *Spindle RESET REF REPOS Teach In
QB113 start
Spindle right
Stop
Spindle left
Feed Start *Feed Stop INC var. INC 1000 INC 100 INC 10 INC 1
QB114
QB115
Minus Plus Rapid trav- KT5 KT4 KT3 KT2 KT1
QB116 Direction Direction erse
QB117 T16 KT6 6th axis 5th axis 4th axis Z Y X
T9 T10 T11 T12 MCS/WCS T13 T14 T15

QB118
QB119 T1 T2 T3 T4 T5 T6 T7 T8
Signals marked with * are inverse signals.
Notes :

B008
Machine Control Panel Interface Signals PP72/48 PN Description and Interface Signals
User I/O pin assignment PP72/48 PN modules are a compact component which con-
nect to the Profinet network (Ports PN1 or PN2 of the PPU).
The 9 inputs and 6 outputs available on plugs X51 to X55 are
designed for use with switches/buttons and indicator lamps There are two variants, one of which is all digital while the
which can be installed in the blanked holes of the MCP. second offers both digital and analogue functionality.
Below shows the I/O assignment of each individual plug.
A 24V DC supply is required.
The input terminals in the normally open state measure 5V DC In total 72 digital inputs and 48 digital outputs are available on
(Supplied by the MCP) each of the two variants.
The inputs work by sinking the 5V DC signals to 0V (M). The analogue module has an additional two analogue inputs
and two analogue outputs.
The outputs terminals are supplied with +24Vdc from the MCP.
A maximum of 4 PP72/48 PN modules with the PPU260 and
No external voltages should be applied to the input and output PPU261 variants.
terminals. A maximum of 5 PP72/48 PN modules with the PPU280 and
PPU281 variants.
Input Assignment (X51, X52 & X55):
Part number:- 6FC5311-0AA00-0AA0 Digital only
(PP72/48D PN)
6FC5311-0AA00-1AA0 Digital/analogue
(PP72/48 2/2A PN)
I122.0 I122.3
1 1
I122.1 I122.4
2 2
I122.2 I122.5 S1
3 3
M (0 volts) M (0 volts)
4 4
X51 X52
I122.6 X111
1
I122.7
2
I123.0
3
M (0 volts)
4
X55
Output Assignment (X53 & X54):
X222
Q119.0 Q119.3
1 1
Q119.1 Q119.4
2 2
X2 X2
Q119.2 Q119.5
3 3
M (0 volts) M (0 volts) X333
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. X1
Notes :

B008
Ribbon cable connections. Pin assignment X333
The following Tables show the pins and I/O addresses for con- Pin Signal Pin Signal Pin Signal
nectors X111, X222, X333 This is assuming the PP72/48 PN is
1 0V DC 19 I8.0 37 Q4.6
configured with a start address of 0 (Input bytes 0, 1, & 2 and
output bytes 0 & 1).M 2 +24V DC O/P 20 I8.1 38 Q4.7
The first input byte of X222 has FAST gating hardware. 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
Pin assignment X111 6 I6.3 24 I8.5 42 Q5.3
7 I6.4 25 I8.6 43 Q5.4
Pin Signal Pin Signal Pin Signal
8 I6.5 26 I8.7 44 Q5.5
1 0V DC 19 I2.0 37 Q0.6 9 I6.6 27 Not used 45 Q5.6
2 +24VDC O/P 20 I2.1 38 Q0.7 10 I6.7 28 Not used 46 Q5.7
3 I0.0 21 I2.2 39 Q1.0 11 I7.0 29 Not used 47 +24V DC I/P
4 I0.1 22 I2.3 40 Q1.1 12 I7.1 30 Not used 48 +24V DC I/P
5 I0.2 23 I2.4 41 Q1.2 13 I7.2 31 Q4.0 49 +24V DC I/P
6 I0.3 24 I2.5 42 Q1.3 14 I7.3 32 Q4.1 50 +24V DC I/P
7 I0.4 25 I2.6 43 Q1.4 15 I7.4 33 Q4.2
8 I0.5 26 I2.7 44 Q1.5 16 I7.5 34 Q4.3
9 I0.6 27 Not used 45 Q1.6 17 I7.6 35 Q4.4
10 I0.7 28 Not used 46 Q1.7 18 I7.7 36 Q4.5
11 I1.0 29 Not used 47 +24V DC I/P
12 I1.1 30 Not used 48 +24V DC I/P
13 I1.2 31 Q0.0 49 +24V DC I/P
14 I1.3 32 Q0.1 50 +24V DC I/P
15 I1.4 33 Q0.2
16 I1.5 34 Q0.3
17 I1.6 35 Q0.4
18 I1.7 36 Q0.5
Pin assignment X222
Pin Signal Pin Signal Pin Signal

1 0V DC 19 I5.0 37 Q2.6
2 +24V DC O/P 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
11 I4.0 29 Not used 47 +24V DC I/P
12 I4.1 30 Not used 48 +24V DC I/P
13 I4.2 31 Q2.0 49 +24V DC I/P
14 I4.3 32 Q2.1 50 +24V DC I/P
15 I4.4 33 Q2.2
16 I4.5 34 Q2.3
17 I4.6 35 Q2.4
18 I4.7 36 Q2.5
Notes :

B008
IP addresses and Input/Output Assignment Default values of MD12986:
Each hardware item connected to the Profinet network needs

a unique IP address.
This is determined by the setting of S2 on the MCP and S1 on
the PP72/48.
Each profinet device has an IP address in the range
192.168.214.xxx . The switch setting determines the last part
of the IP address xxx.
The IP addresses are associated with general machine data
12986[0]….[6] which determines the input/output assignment.
Switch S1/S2
The selected IP address will determine the I/O that will be as- Compatibility
signed. This is seen in the following tables:
For all Profinet applications switch positions 9 and 10 need to To achieve compatibility across machines using the 828D
be set to on. controller it is necessary to assign individual hardware with the
same I/O address range.
The 1st PP72/48 modules should always start with I/O address
0 (MD12986[0] = -1). Further modules should be addressed in
Switch S1 - PP72/48 numerical order.
Switch S1/S2 Binary Value Switch S2 - MCP483/MCP310
Position
The MCP should always be assigned the start address of 112
(MD12986[6] = -1).
1 1
2 2
Recommended MD12986 use:
3 4 12986[0] 1st PP72/48 start address 0

4 8
12986[1] 2nd PP72/48 “ “ 9
12986[2] 3rd PP72/48 “ “ 18
5 16 12986[3] 4th PP72/48 “ “ 27
6 32
12986[4] 5th PP72/48 “ “ 36
12986[5] PN/PN Coupler ” “ 96
7 64 12986[6] MCP “ “ 112
8 128 12986[7] Not used
Example: MD12986 for use with MCP and two PP72/48
9 Profinet=ON modules.
10 Profinet=ON
Machine Data 12986

Each index of MD12986 has a preset I/O range. To release a
particular I/O range the value of -1 has to be entered into the
necessary index.
Switch
MD Profinet Input Output IP address
S1/S2
12986[x] Device Range Range 192.168.214.xxx
Setting
0 1&4
1. PP72/48 0 to 8 0 to 5 9
on
The machine data is activated by an NCK power off/on.
1 4
2. PP72/48 9 to 17 6 to 11 8
on
2 1, 2 & 3
3. PP72/48 18 to 26 12 to 17 7
on
3 2&3
4. PP72/48 27 to 35 18 to 23 6
on
4 1&3
5. PP72/48 36 to 44 24 to 29 5
on
PN/PN 3&5
5 96 to 111 96 to 111 20
Coupler on
7
6 MCP 112 to 129 112 to 119 64
on
7 n/a n/a n/a n/a n/a
B008: END
Notes :

B008: END

B034 PLC Interface Structure
Module Description:
Information to and from the different system areas of the controller is handled by interfaces. This
module shows how the different areas communicate .
Module Objective:
Upon completion of this module you will be know the Sinumerik 828D PLC interface structure and
use it to help write the PLC program and diagnose PLC faults.
Content:
Sinumerik
Interface Structure Overview
Operand Description and Ranges
Interface Description
B034
B034

B034
PLC Interface Structure: Description

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

B034
Interface Structure Overview
To enable the user to influence the system, an interface is provided. This interface operates with variables in Bit, Byte, Word &
Double Word formats. e.g:-
Bit:-DB1600.DBX0.0
Byte:-DB1600.DBB0
Word:-DB1600DBW0
Double Word:-DB1600.DBD0
Interface Structure:-
PLC User NC
Interface
PLC User
Program
Periphery Drives
Devices-
PP72/48, MCP.
HMI
Notes :

B034
Operand Description and Ranges
Operand identifiers Description Area

DB Data Blocks 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 SM0.6 (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)
Section (0 to 9)
Area Number (00 to 99)
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’
SM0.4 60 s cycle (alternating ’0’ for 30 s, then ’1’ for 30 s)
SM0.5 1 s cycle (alternating ’0’ for 0.5 s, then ’1’ for 0.5 s
SM0.6 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]
Notes :

B034
Interface Description
Machine Control Panel MCP483 PN

During commissioning the MCP address range is set to start at Input and output Bytes 112.

Spindle override JOG TEACH IN MDA AUTO
IB112
D C B A
IB113 REPOS REF INC var. INC 10000 INC 1000 INC 100 INC 10 INC 1
Key- Key- Spindle start *Spindle stop Feed *Feed NC Start *NC Stop
IB114 switch switch position 2 start stop
position 0
Reset Key- Single block Feedrate override
IB115 switch position
E D C B A
Direction keys Key switch Axis selection keys
IB116 + - Rapid traverse position 3 X 4th axis 7th axis
R15 R13 R14 R1 R4 R7
Axis selection keys
IB117 Y Z 5th axis MCS/WCS R9 8th axis 6th axis
R2 R3 R5 R12 R8 R6
IB118
T9 T10 T11 T12 T13 T14 T15
IB119
T1 T2 T3 T4 T5 T6 T7 T8
IB123 KT9
Spindle override
IB125
E (16) D (8) C (4) B (2) A (1)
MCP483 PN Signals to machine control panel (LEDs)
Machine function Operating mode

QB112
INC 1000 INC 100 INC 10 INC 1 JOG TEACH IN MDA AUTO
QB113 Feed *Feed NC Start *NC Stop REPOS REF INC var. INC 10000
start stop
Direction X 4th axis 7th axis Single Spindle start *Spindle stop
QB114 Minus R1 R4 R7 R10 block
R13
Z 5th axis MCS/WCS 8th axis 6th axis Direction

QB115 R3 R5 R11 R9 R8 R6 Plus
R15
Unassigned customer keys Y
QB116
T9 T10 T11 T12 T13 T14 T15 R2
QB117
T1 T2 T3 T4 T5 T6 T7 T8
QB118 Reset R14
QB119 KT6 KT5 KT4 KT3 KT2 KT1
Signals marked with * are inverse signals.
Notes :

B034
Machine Control Panel MCP310 PN
During commissioning the MCP address range is set to start at Input and output Bytes 112.

IB112 *NC Stop Spindle - Spindle 100% Spindle + Single block JOG MDA AUTO
IB113 NC Start Spindle right *Spindle stop Spindle left Key-switch REF REP Teach IN
position 3
Feed start *Feed stop INC var. Key-switch posi-
IB114 tion 0
INC 1000 INC 100 INC 10 INC 1
Feedrate override
IB115 Reset Key- Key-switch E (16) D (8) C (4) B (2) A (1)
switch position position 1
2
Direction keys
IB116
+ - Rapid traverse KT5 (X52.2) KT4 (X52.1) KT3 (X51.3) KT2 (X51.2) KT1(X51.1)
Axis selection
IB117 6th axis 5th axis 4th axis Z Y X
T16 KT6(X52.3)
IB118 T9 T10 T11 T12 WCS MCS T13 T14 T15

IB119 T1 T2 T3 T4 T5 T6 T7 T8
IB123 KT9
Spindle override
IB125
E (16) D (8) C (4) B (2) A (1)
MCP 310 PN Signals to machine control panel (LEDs)

QB112 *NC Stop Spindle Dec. Spindle 100% Spindle Inc. Single Block JOG MDA AUTO
NC *Spindle RESET REF REPOS Teach In
QB113 Spindle right Spindle left
start Stop
QB114 Feed Start *Feed Stop INC var. INC 1000 INC 100 INC 10 INC 1
QB115
QB116 Minus Plus Rapid trav- KT5 KT4 KT3 KT2 KT1
Direction Direction erse
QB117 T16 KT6 6th axis 5th axis 4th axis Z Y X
QB118 T9 T10 T11 T12 MCS/WCS T13 T14 T15
QB119 T1 T2 T3 T4 T5 T6 T7 T8
User Data Areas
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
Notes :

B034
Interface Description continued
DB1100 User Data 2 [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 Read:0 Start
Write:1
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]

-1207
1000 Variable Index
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 a specific location
1001 Area Number
1002 Column index for NCK variable x (Word)
1004 Line index for NCK variable x (Word)
1006
1008 Data to be written to NCK
Results:-The results of the task are output to the following areas:-

DB1200 NCK PLC [r]
2000 Error in job Request
Complete
2001
2002
Notes :

B034
DB1200- NCK PLC [r]

1207
3000 Fault Valid Variable
3001 Access result

0: No error, 1: Illegal access, 5: Invalid address, 10: Object does not exist
3002
3004 Data that was read from the NC variable (1 to 4 bytes)
PI Services
DB1200 PLC NCK [r/w]

4000 Start
4001 PI-Index
1: ASUP1, 2: ASUP2, Password Reset, Saving of Data, Tool Reloading via the PLC
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
PI Services:- Result
5000 Fault Finished
5001
5002
Notes :

B034

Retentive Data Area
DB1400 Retentive Data [r/w]
User area
0000
User area
0001
User area
0002
User area
0004
etc
User area
0126
User area
0127
User Alarms
DB1600 Activating alarms (Alarm number range 700000 to 700247) PLC HMI [r/w]
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
0030 700247 700246 700245 700244 700243 700242 700241 700240
DB1600 Variable for alarm. PLC HMI [r/w]
1000 Variable for alarm 700000 (4 bytes)
etc
Notes :

B034
DB1600 Active alarm response HMI PLC [r]
2000 Acknowledge Acknowledge PLC Stop Em. Stop Feed disable Read-in NC start
with power ON with DB1600. disable disable
DBX3000.0
DB1600 Alarm acknowledgement PLC HMI [r/w]
3000 Acknowl-
edge
Program Control Signals

DB1700 HMI signals HMI PLC [r]
0000 Test run M01 DRF

Feedrate Selected Selected
selected
0001 Program test Feedrate over-
selected ride
(Rapid) selected
0002 Skip Skip block 6 Skip block 5 Skip block 4 Skip block 3 Skip block 2 Skip Skip block
block 7 selected selected selected selected selected block 1 0
selected selected selected
0003 Skip Skip
block 9 block 8
selected selected
0007 Reset NC stop NC start
SMS Messenger
DB1700 Interface SMS messenger PLC [r]
3000 Variable-Settable via SMS
3001
3002
3003
Signals from HMI

DB1800 HMI PLC [r]
0000 Reset JOG mode MDA mode AUTO

mode
0001 Machine Machine

function:- function:-
REF TEACH IN
0002
0003
Note:- Signals present for only one plc cycle.
Notes :

B034
Signals from PLC
DB1800 Signals from PLC [r]
1000 Start-up archive Power up with Power up

was read in saved data with default
values
1001
1002
1003
1004 PLC cycle time in micro seconds (Double Integer)
1008 Year (Tens) BCD Year (Units) BCD
1009 Month (Tens) BCD Month (Units) BCD
1010 Day (Tens) BCD Day (Units) BCD
1011 Hour (Tens) BCD Hour (Units) BCD
1012 Minute (Tens) BCD Minute (Units) BCD
1013 Second (Tens) BCD Second (Units) BCD
1014 Millisecond (Hundreds) BCD Millisecond (Tens) BCD
1015 Millisecond (Units) BCD Weekday BCD (1, 2…….7) 1 = Sunday
Maintenance Planner
DB1800. PLC HMI Deactivate Maintenance Task [r/w]
Deactivate Maintenance 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. HMI PLC Alarm for Maintenance Task [r]
Alarm for Maintenance Task

3000
8 7 6 5 4 3 2 1

3001
16 15 14 13 12 11 10 9

3002
24 23 22 21 20 19 18 17

3003
32 31 30 29 28 27 26 25
Notes :

B034
Maintenance Planner-continued
DB1800. PLC HMI Maintenance task acknowledgement [r/w]

Maintenance Task acknowledgement
4000
8 7 6 5 4 3 2 1

4001
16 15 14 13 12 11 10 9

4002
24 23 22 21 20 19 18 17

4004
32 31 30 29 28 27 26 25
DB1800. PLC HMI Disable Maintenance task acknowledgement [r]
Disable Maintenance task acknowledgement

5000
8 7 6 5 4 3 2 1

5001
16 15 14 13 12 11 10 9

5002
24 23 22 21 20 19 18 17

5003
32 31 30 29 28 27 26 25
Signals from operator panel (retentive area)

DB1900. HMI PLC [r]
0000 MCS/WCS Simulation Cancel

selection active
0001 Active HMI area
0002
0003
0004 Active JobShop area
0006
0007
Notes :

B034
General selection/status signals from HMI (retentive area)
DB1900. HMI PLC [r]

1000
1001
1002
Axis number for hand-wheel 1
1003 Machine axis Hand-wheel Contour hand- C B A
selected wheel
Axis number for hand-wheel 2

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

DB1900. PLC HMI [r/w]
5000 Actual values in OP key
WCS disable
(0=MCS)
5001 External viewer- External

Monitoring only viewer
not
permitted
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
Notes :

B034
Auxiliary functions from NCK channel (read only)
DB2500. NCK PLC [r]
0000 up to
0003
0004 M fcts.5 M fcts.4 change M fcts.3 change M fcts.2 change M fcts.1 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 change H fcts.1 change

change
0013 up to
0019
Decoded M signals (M0-M99)
DB2500. NCK PLC

1000 Dynamic M functions
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
1012 M99 M98 M97 M96
1013 up
to 1015
Note:- Signals present for only one plc cycle.
Notes :

B034
Transferred T functions
DB2500. NCK interface PLC

2000 T function 1 (DINT)
2004
up to
2007
Transferred M functions
DB2500. M functions from NCK channel NCK PLC

3000 M function 1 (DINT)
3004 Extended address of M function 1 (Byte)
Transferred S functions
DB2500. NCK PLC
4000 S function 1 (REAL)
4004 Extended address of S function 1 (Byte)
4008 S function 2 (REAL)
4012 Extended address of S function 2 (Byte)
4016
4020
Transferred D functions
DB2500. NCK PLC

5000 D function 1 (DINT)
5004
Notes :

B034
Transferred H functions
DB2500. NCK interface PLC [r]

6000 H function 1 (REAL)
6004 Extended address of H function 1 (Byte)
NCK Signals-General Signals to NCK
DB2600. PLC NCK [r/w]

Protection level Ackn. emerg. Emerg. stop Braking along
stop contour in
0000 event of
4 5 6 7 Emerg. stop
Request axis Request INC Inputs
distances to Actual values in Mode
0001 go (*1) (*1) Group range
active
0002
0003
(*1) Used in conjunction with Data blocks DB5700 to 5707.
0000 Emergency
Stop active
0001 INCH measur- Probe 2 actu- Probe 1 actu-

ing system ated ated
0002 NC Ready Drive ready Drives in HMI ready

cyclic opera-
tion
0003 Air temp. NCK alarm is

alarm active
0004
0005
0006
Notes :

B034

NCK Signals-continued
0007
0008
0009
0010
0011
0012 Change counter for motions of hand-wheel 1
0013 Change counter for motions of hand-wheel 2
0014
0015 Change counter, inch metric unit system.
etc
0019
Notes :

B034
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 digital NCK inputs
0001 Input 8 Input 7 Input 6 Input 5 Input 4 Input 3 Input 2 Input 1
Disable digital NCK outputs
0004 Output 8 Output 7 Output 6 Output 5 Output 4 Output 3 Output 2 Output 1
Overwrite mask for digital NCK outputs
Values from the PLC for digital NCK outputs
Setting mask for digital NCK outputs
Disable external digital NCK inputs
1000 Input16 Input15 Input14 Input13 Input 12 Input11 Intput10 Input 9
Values from the PLC for the external digital NCK inputs
1001 Input16 Input15 Input14 Input13 Input12 Input11 Input10 Input 9
Disable external digital NCK outputs
1008 Ouput16 Output15 Output14 Output13 Output12 Output11 Output10 Output9
Overwrite mask for external digital NCK outputs
1009 Output16 Output15 Output14 Output13 Output12 Output11 Output10 Output 9
Values from PLC for the external digital NCK outputs
Setting mask for external digital NCK outputs
Notes :

B034
Signals From Fast Inputs & Outputs

DB2900. PLC NCK [r]
Actual values for digital NCK inputs
0000
Input 8 Input 7 Input 6 Input 5 Input 4 Input 3 Input 2 Input 1
Set-points for digital NCK outputs
0004
Output 8 Output 7 Output 6 Output 5 Output 4 Output 3 Output 2 Output 1

Actual values of external digital NCK inputs
1000
Input 16 Input 15 Input 14 Input 13 Input 12 Input 11 Input 10 Input 9
Set-points of external digital NCK outputs
1004
Output16 Output15 Output14 Output13 Output12 Output11 Output10 Output9
Operating Mode Signals

Reset Mode group Operating mode
changeover
0000 disable
JOG MDA Auto
Machine function
0001
REF Teach in
Machine function (to use the INC function DB2600.DBX1.0 must be set to 1)
0002 Continuous INC var. INC 10000 INC 1000 INC 100 INC 10 INC 1
travel
0003

Active mode
0000 828D Ready
JOG MDA Auto
Active Machine function
0001
REF Teach in
0002 Continuous INC var. INC 10000 INC 1000 INC 100 INC 10 INC 1
travel
0003
Notes :

B034
Channel Signals/Signals to NC channel

Activate dry run Activate M01 Activate single Activate DRF Activate feed Activate re-
0000 feedrate block (*1) forward verse travel
Activate program Enable protec- Activate

0001 test tion zones referencing
Activate skip Activate skip Activate skip Activate skip Activate skip block Activate skip Activate skip Activate skip
0002 block 7 block 6 block 5 block 4 3 block 2 block 1 block 0
Feed-rate override (31 position gray code)

0004 H G F E D C B A
Rapid traverse override (31 position gray code)

Feed-rate Rapid traverse Limited path Program level Delete number of Delete dis- Read-in disable Feed-rate
0006 override override active velocity abort subroutine cycles tance to go disable
active (*2)
Suppress NC stop axis plus NC stop NC stop at NC start NC start lock

0007 Start Lock spindle block 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 Activate channel Activate chan- Activate channel Activate channel Activate Activate chan- Activate
0010 specific protec- specific protec- nel specific specific protec- specific protection channel nel specific channel
tion zone tion zone protection zone tion zone zone specific pro- protection zone specific pro-
tection zone tection zone
Area 8 Area 7 Area 6 Area 5 Area 4 Area 3 Area 2 Area 1
Activate channel Activate channel Activate chan- Activate channel Activate channel Activate Activate chan- Activate
0011 specific protec- specific protec- nel specific specific protec- specific protection channel nel specific channel
tion zone tion zone protection zone tion zone zone specific pro- protection zone specific pro-
tection zone tection zone
Area 10 Area 9
0012
Do not disable Deactivate
0013 tool workpiece
counter
No tool change Circle Jog Activate associ- Neg. direction for Sim. Handwheel Handwheel
commands ated M01 sim. contour contour hand wheel 2 1
0014 h/wheel ON
Activate skip Activate skip

0015 block 9 block 8
0016 Program
branches
(GOTOS)
control
0017
0018
0019
(*1) Select single block type (SBL1, SBL2) via soft-key.

(*2) Even if feed-rate override is not active (=100%) the 0% is still effective.
Notes :

B034
Control signals to geometry axis (Axis in WCS)

Geometry axis 1 (Axis 1 in WCS)
1000 Traversing keys Rapid trav- Traversing key Feedrate stop Activate handwheel (*1)
erse override lock
+ - 2 1
1001 Machine function (*2)
Continuous Inc var INC10000 INC1000 INC100 INC10 INC1
travel
1002
1003
1004 Traversing keys
+ - Rapid trav- Traversing key Feedrate stop 2 1
erse override lock
travel
1006
1007
1008 Traversing keys
+ - Rapid trav- Traversing key Feedrate stop 2 1
erse override lock
travel
1010
1011
(*1) The type of numbering for the hand-wheel is determined by machine data
11234 HANDWH_VDI_REPRESENTATION (0=bit coded, 1=binary coded).
(*2) Machine function:- Only if DB2600.DBX1.0 is not set.
Notes :

B034
Signals from NC channel

B3300. NCK PLC [r]
Last action M0/M01 Approach Action block Forward Reverse travel Program
block active Active block activate Travel active active execution
active from
0000
external ac-
tive
Program test Transforma- M2/M30 Block search Hand-Wheel Rev. Referencing

0001 active tion active active active override feed-rate active
active active
0002
Channel status Program status
0003 Reset Interrupted Active Aborted Interrupted Stopped Wait Running
NCK alarm Specific NCK All axes sta- All axes ref- Stop Start
with alarm is ac- tionary erenced Request request
0004
processing tive
stop present
Contour hand - wheel active
(Bit/binary coded)
0005 H-wheel H-wheel
1 2
Protection
zones no
0007 longer guaran-
teed
Machine related protection zones pre-activated
0008
Area 8 Area 7 Area 6 Area 5 Area 4 Area 3 Area 2 Area 1
Machine related protection zones pre-activated
0009 Area 10 Area 9
Channel specific protection zones pre-activated
Channel specific protection zones pre-activated
0011
Area 10 Area 9
Machine related protection zones violated
Machine related protection zones violated
0013 Area 10 Area 9
Channel specific protection zones violated
Channel specific protection zones violated
0015 Area 10 Area 9
(*2) Machine function:- Only if DB2600.DBX1.0 is not set.
Notes :

B034

Status signals from geometry axis (Axis in WCS)
DB3300. NCK  PLC [r]
1000 Motion Command Travel request Active Hand-wheel (*1)
Plus Minus Plus Minus 2 1
Active machine function

1001 Continuous Inc var INC10000 INC1000 INC100 INC10 INC1
travel
Motion Command Travel request Active Hand-wheel (*1)

1004

travel

1008 Motion Command Travel request Active Hand-wheel (*1)

travel
Additional status signals from NC channel
G00
4000 active
Travel request Work-piece set- External

4001 for drive test point reached language
present mode active
4002 Dry run feedrate Associated M01/ Stop ASUP is

is active M00 active delayed stopped
No tool manage- Delay Delay

4003 ment commands FST suppress FST
active
Prog Event Display
4004 Start after Boot Operator panel Part program Part program
search run reset end start from
reset
4005 Jog Circle active Stop condition StopbyColl

Danger
4006 Dormant ASUP Any ASUP

active Active
4007
4008 Active Transformation Number
4008-4011 Reserved
Notes :

B034
Asynchronous sub routines

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

Asup 1 start not Asup 1 num- Asup 1 running Asup 1
possible ber not finished
1000 possible
Asup 2 start not Asup 2 num- Asup 2 running Asup 2 finished

possible ber not
1001 possible
G functions from NC channel

0000 Active G function of group 1 (8 bit Integer)
etc
M/S functions, axis specific-spindle specific

DB3705
0000 M function for spindle (Double Integer)
0004 S function for spindle (Real)
Notes :

B034

Signals to axis/spindle
DB3800- PLC NCK [r/w]

DB3805
Feedrate override
Override active Measuring Measuring Follow up mode Axis/spindle dis- Sensor for fixed Acknowledge
system 2 system 1 able stop fixed stop
0001 reached
Reference point value Clamping in pro- Distance to go/ Controller

gress spindle reset enable
0002 4 3 2 1
Axis/spindle enable Velocity/spindle Enable

0003 program test speed limiting approach to
fixed stop
Traversing keys Rapid traverse Traverse key lock Feedrate stop/ Activate Hand-wheel
0004 override spindle stop
Plus Minus 2 1
Machine function (only if DB2600.DBX1.0 = 0)

travel
Request PLC axis/ Activation signal Request NC

0008 spindle when signal when this axis/spindle
byte is changed
Parameter set-Servo
0009
C B A
Delay reference Modulo Limit 2nd software limit switch Hardware limit switch
point approach Reached
1000 Plus Minus Plus Minus
Jogging to position Jog fix-point Jog fix-point Jog fixpoint

1001 position 2 position 1 position 0
Activate Suppress
1002 program test program test
Signals to spindle
DB3805
Clear S value Spindle:-No Spindle resynchro- Spindle resynchro- Gear changed Actual gear stage
speed moni- nise 2 nise 1
2000 toring for gear C B A
change.
Invert M3/M4 Resynchronise spin- Feedrate

2001 dle during override valid
positioning for spindle
Setpoint direction of rotation Oscillation speed Oscillation via PLC

2002
CCW CW
Spindle override
2003
H G F E D C B A
Notes :

B034
Signals to PLC axis

DB3805
Start positioning Start spindle Start spindle Start spindle
3000 axis positioning turning oscillating
3001 Stop spindle Stop spindle

turning oscillating
Automatic gear Constant cutting Direction of rota- Hand-wheel Traversing Path Path
selection speed tion-same as M4 override dimension Condition: condition:
3002 on Inch Shortest path Incremental
(DC) (IC)
G function: G function:
Indexing position Absolute posi- Absolute nega-
3003 tive direction tive direction
(ACP) (ACN)
3004
3005
Position (Real number, with indexing axis, Double word)
3006
3007
3008
3009 Feedrate (Real number)
If = 0 value is taken from machine data POS_AX_VELO
3010
3011
Note:- IC, DC, ACP, ACN only one signal can be selected at any one time. If no signal is selected AC is active by default.
Signals to drive

DB3805
Open manual
4000 brake
Pulse enable Speed controller Parameter set selection

4001 integrator disable
C B A
4002
4003
Notes :

B034
Signals to technology functions
DB3805

Master/slave ON Torque equalisa-
5000 tion controller ON
5001
5002
Stop HIAxMove Stopp corr Stop DEPBCS Stop DEPMCS Resume HIAx- Resume corr Resume Resume
5003 Move DEPBCS DEPMCS
5004
Disable auto- Start gantry
5005 matic synchro- synchronisation
nisation
5006 Positioning the Automatic gear Specified direc- Specified direc- Spindle
spindle stage change tion of rotation tion of rotation STOP
(Spindle) CCW CW
5007 Delete synchronism

override
(Couplings)
5008
(SISITECH)
5009
(SISITECH)
General signals from axis/spindle

DB3905

Position reached Referenced/ Referenced/ Encoder limit Spindle/no
0000 synchronised 2 synchronised 1 frequency ex- axis
With exact stop- With exact stop- ceeded
fine coarse
Current controller Speed controller Position con- Axis/spindle sta- Follow up mode Axis ready Axis alarm
0001 active active troller active tionary active For
(n < nmin) operation
Power fixed stop Fixed stop Activate travel to Measurement Rotational feder- Hand-wheel
0002 limited reached fixed stop active ate overlay active
active
Axis stop
0003 Ready for opera-
tion
Travel command Travel request Active hand-wheel

0004

travel
PLC axis/spindle Neutral axis/ Exchange New type from NX axis/

0008 spindle possible PLC requested spindle
Servo parameter set

0009
C B A
PLC axis Position re- Position restored

0011 permanently stored 1 2
assigned
Notes :

B034
Signals from axis
DB3905
Modulo limit
1000 enabled
Active
Jog position Indexing axis in Jog fix point posi- Jog fix point posi- Jog fix point posi- Act jog fix Act jog fix point Act jog fix point
1001 reached position tion reached 2 tion reached 1 tion reached 0 point position position1 position 0
2
Rotary axis in Indexing axis in Positioning axis Path axis Lubrication

1002 position position pulse
Velocity re-
1003 duced by Colli-
sion check
Signals from spindle

DB3905
Gearbox Set gear stage
2000 changeover
C B A
Actual Speed monitoring Spindle in Set- Supporting Geometry moni- Set-point Set-point speed Speed limit
2001 direction is clock- point range range limit vio- toring speed in- limited exceeded
wise lated creased
Active spindle mode Rigid tapping GWPS active Constant cut-

ting velocity
2002 Control mode Oscillation mode Positioning mode Synchronous active
mode
Spindle in posi- Tool with dy-

2003 tion namic limiting
Signals from PLC axis

DB3905
Positioning axis Position reached Error Axis

3000 active during travers- cannot be
ing started
3001
3002
3003 Error number
Signals from drive

DB3905
Holding brake
4000 open
Pulses enabled Speed controller Drive ready Active parameter set

4001 integrator disabled
C B A
Variable signal- nact = nset nact < nx nact < nmin Md < Mdx Ramp up Temperature pre-warning
4002 ling function 1 completed
Heat Sink Motor
Vdclink <
4003 Vdclinkx
Notes :

B034

Signals from technology functions
DB3905

Master/slave Master/slave equali- Master/slave Master/slave
5000 active sation controller coarse fine
active
5001
ESR Acceleration Velocity warn- Superimposed
reaction initiated warning thresh- ing threshold motion
5002 old reached reached
Maximum Maximum Synchronisation Axis is Synchronism

5003 acceleration velocity running accelerating override
reached reached travel
Gantry axis Gantry leading Gantry group- Synchronisation Gantry warning Gantry shut-
5005
axis ing is synchro- ready threshold reached down limit
(Gantry) nising reached
5006
Synchronisa-
tion
5007 Override
Is factored in
5008 Active special axis

(Grinding) Axis 6 Axis 5 Axis 4 Axis 3 Axis 2 Axis 1
Tool Management
User interface loading, unloading, reloading
DB4000- PLC NCK Signals to TM [r/w]

DB40xx
(*1)
Acknowledge- Acknowledge- Acknowledge- Acknowledgement Acknowledgement Acknowl- Acknowledge- Total ac-
0000 ment step 7 ment step 6 ment step 5 step 4 step 3 edgement ment step 1 knowledgeme
step 2 nt
Acknowledge- Acknowledge- Acknowledge- Acknowledgement Acknowledgement Acknowl- Acknowledge- Acknowl-

0001 ment step 15 ment step 14 ment step 13 step 12 step 11 edgement ment step 9 edgement
step 10 step 8
Acknowledge- Acknowledge- Acknowledge- Acknowledgement Acknowledgement Acknowl- Acknowledge- Acknowl-

0002 ment step 23 ment step 22 ment step 21 step 20 step 19 edgement ment step 17 edgement
step 18 step 16
Acknowledge- Acknowledge- Acknowledgement Acknowledgement Acknowl- Acknowledge- Acknowl-

0003 Reserved ment step 30 ment step 29 step 28 step 27 edgement ment step 25 edgement
step 26 step 24
0004 to
0016 Reserved
Notes :

B034
Jobs for loading, unloading, reloading, positioning the magazine
DB4100- NCK PLC Signals from TM [r]

DB41xx (*1)

0000 Job
Job from NC pro- Positioning Relocating Unloading Loading

0001 gram
0002 Reserved
0003 Reserved
0004 Reserved
0005 Reserved
0006 Source magazine no. (Integer)
0008 Source location no. (Integer)
0010 Target magazine no. (Integer)
0012 Target location no. (Integer)
Load unload
0014 without mov-
HMI to PLC ing magazine
Feedback signal

DB41xx (*1)
Acknowledge- Acknowledge-
0100 ment error ment OK
0101 Reserved
0102 Reserved
0104 Fault status (Word)
(*1) xx = Loading position
Job status

DB41xx (*1)

0120 Reserved
0121 Reserved
0122 Reserved
0124 Current magazine number of the tool (Integer)
0126 Current location number of the tool (Integer)
0128 Target magazine number of the tool (Integer)
0130 Target location number of the tool (Integer)
(*1) xx = Loading position
Notes :

B034
User interface tool change

DB4200- PLC NCK Signals to TM [r/w]
DB42xx
(*2)
Acknowledge- Acknowledgement Acknowledge- Acknowledge- Acknowledge- Acknowledge- Acknowledge- Total ac-
0000 ment step 7 step 6 ment step 5 ment step 4 ment step 3 ment step 2 ment step 1 knowledgeme
nt
Acknowledge- Acknowledgement Acknowledge- Acknowledge- Acknowledge- Acknowledge- Acknowledge- Acknowl-

0001 ment step 15 step 14 ment step 13 ment step 12 ment step 11 ment step 10 ment step 9 edgement
step 8
Acknowledge- Acknowledgement Acknowledge- Acknowledge- Acknowledge- Acknowledge- Acknowledge- Acknowl-

0002 ment step 23 step 22 ment step 21 ment step 20 ment step 19 ment step 18 ment step 17 edgement
step 16
Acknowledgement Acknowledge- Acknowledge- Acknowledge- Acknowledge- Acknowledge- Acknowl-

0003 Reserved step 30 ment step 29 ment step 28 ment step 27 ment step 26 ment step 25 edgement
step 24
0004 to
0024 Reserved
(*2) xx = Tool holder
Notes :

B034
Jobs for tool change preparing and execute

DB43xx (*1)
0000 Job
Tool Manual tool Manual tool No old tool T0 Prepare Change tool Fixed location
0001 remains in spin- unload load change (Initiated by coded
dle M06)
0002 Reserved
0004 Reserved
0005 Reserved
0006 Source magazine no. for new tool (Integer)
0008 Source location no. for new tool (Integer)
0010 Reserved
0012 Reserved
0014 Reserved
0016 Reserved
0018 Target magazine no. for old tool (Integer)
0020 Target location number for old tool (Integer)
0022 Location type (Integer)
0024 Size, left (Integer)
0026 Size, right (Integer)
0028 Reserved
0030 Reserved
Tool status for new tool

0032 Master tool To be loaded To be Blocked Identifier for
unloaded tool
Tool status for new tool

0033 Tool has been in Tool is fixed Tool being Pre warning limit Measuring tools Tool Tool Active tool
use location coded changed reached disabled enabled
0034 New tool: Internal T no. of NCK (Integer)
0036 Reserved (Double word)
0040 Reserved (Double word)
0044 User defined parameter 1 (Double word)
Notes :

B034
Feedback signal
DB43xx
(*1)

0100 Acknowledge- Acknowledge-
ment error ment OK
0101 Reserved
0102 Reserved
0104 Fault status acknowledgement (Word)
Job status
DB4300- NCK PLC Job status [r]

DB43xx
(*1)

0120 Reserved
0121 Reserved
0122 Reserved
0124 Current magazine no. for new tool (Integer)
0126 Current location no. for new tool (Integer)
0128 Target magazine no. for new tool (Integer)
0130 Target location no. for new tool (Integer)
0132 Current magazine no. for old tool (Integer)
0134 Current location no. for old tool (Integer)
0136 Target magazine no. for old tool (Integer)
0138 Target location no. for old tool (Integer)

PLC machine data
INT values (MD14510 USER_DATA_INT)
0000 Int values (Word/2 bytes)
Up to
Notes :

B034
HEX values (MD14512 USER_DATA_HEX)

1000 Hex value (Byte)
Up to
FLOAT values (MD14514 USER_DATA_FLOAT)

2000 Float value (Real/4 bytes)
Up to
User alarm Configuration (MD14516 USER_DATA_PLC_ALARM)

3000 Alarm reaction/cancellation criterion-Alarm 700000
Up to
Synchronised actions
Signals to channel
DB4600 PLC  HMI [r/w] Deactivate synchronised action with ID...
0000 ID8 ID7 ID6 ID5 ID4 ID3 ID2 ID1
Notes :

B034
Signals from channel

DB4700 NCK  PLC [r] Synchronised action with ID... can be blocked from the PLC
Reading and writing PLC variables
DB4900 PLC interface [r/w]

0000 Offset 0
0001 Offset 1
0002 Offset 2
Up to Offset 4095
4095
Tool management functions from NC channel

Change signals for tool management functions
Tool limit value Tool
0000 reached warning limit
reached
Transferred tool management functions

1000 T number for tool warning limit (Double integer)
1004 T number for tool limit value (Double integer)
1008
1012
Notes :

B034
Axis actual values and distances to go

Signals from axis/spindle
5705

0000 Axis actual value (Real)
0004 Axis distance to go (Real)
Used in with:- DB2600.DBX1.1 Request axis actual value

DB2600.DBX1.2 Request axis distance to go
Tool management user interface
DB9900 Constant transfer step table [r]

0000 Transfer step 1
Source magazine no. (Integer)

Source location no. (Integer)

Target magazine no. (Integer)

Target location no. (Integer)




etc



Notes :

B034
Tool management user interface
DB9901 Variable transfer step table [r/w]

Transfer step 101
Transfer step 101

Transfer step 101

Transfer step 101

Transfer step 102

Transfer step 102

Transfer step 102

Transfer step 102

etc
Transfer step 164
Transfer step 164

Transfer step 164

Transfer step 164

Notes :

B034
Tool management user interface-continued
DB9902 Acknowledgement step table [r]

Acknowledgement step 1
0000 Transfer step for new tool. (Byte)
0001 Transfer step for old tool. (Byte)
0002 Acknowledgement status. (Byte)
0003 Reserved
0007 Reserved
etc
0119 Reserved
Maintenance planner user interface
DB9903 Initial data table [r]

0000 Interval 1 [Hours]
0002 Time of first warning 1 [Hours]
0004 Number of warnings to be output 1
0006 Reserved 1
0014 Reserved 2
etc
0254 Reserved
Notes :

B034 END
Maintenance planner user interface-continued
DB9904 Actual data table [r]

0002 Number of warnings output 1
0004 Reserved_1 1
0006 Reserved_2 1
0012 Reserved_1 2
0014 Reserved_2 2
etc
0252 Reserved_1 32
0254 Reserved_2 32
Easy Extend user interface
DB9905 HMI PLC [r/w]

Deactivate 1 Activate Enable
0000 1 1
0001
Error Activated
0002 1 1
0003 Device ID_1

0004 2 2
0005
Error 2 Activated
0006 2
0007 Device ID_2
etc
0248 64 64
0250
Error Activated 64
0252 64
0254 Device ID_64
B034: END
Notes :

B026 Creating a PLC program
Module Description:
The programming tool PLC828 is used to create the PLC program.

To maintain compatibility between machines fitted with the Sinumerik 828D controller it is essential
that the design criteria layed down in the PLC Design document is adhered to.
These requirements have been created so that the PLC program is easy to understand, this simpli-
fies the fault finding procedure, leading to minimal downtime in the event of a breakdown.
This module describes the PLC design requirements and shows how to use the PLC828
programming tool including uploading/downloading procedures.
Module Objective:
Upon completion of this module you will know how to use the PLC828 programming tool to:
 Create a PLC program
 Upload a PLC project from the controller to a computer
 Download a PLC project to the controller from a computer
You will also know the recommended PLC design requirements.
Content:
Sinumerik
PLC Design
S7-200 PLC Cyclic Operation
General PLC Interface Description
Toolbox Examples
Creating a PLC program
Symbol Tables
Cross Referencing
Loading a PLC program
B026
B026

B026
Creating a PLC Program: Description Creating

A PLC
Program:
The programming tool PLC828 is used to create the PLC START
program.
To maintain compatibility between machines fitted with the
Sinumerik 828D controller it is essential that the design crite-
ria laid down in the PLC Design document is adhered to. PLC Design
These requirements have been created so that the PLC pro-
gram is easy to understand, this simplifies the fault finding
procedure, leading to minimal downtime in the event of a
breakdown.
This module describes the PLC design requirements and
shows how to use the PLC828 programming tool including S7-200 PLC
Cyclic
uploading/downloading procedures.
Operation
General PLC
Interface
Description
Toolbox
Examples
Creating a PLC
program
Symbol Tables
Cross
Referencing
Loading a
PLC program
Creating
A PLC
Program:
END
Notes :

B026
PLC Design
PLC Design Requirements
The PLC design requirements have been put in place so that there is compatibility across machines fitted with the 828D control-
ler.
The design requirements are shown in the following table:-
Definition Description
1 Do not use Transfer Variables unless there is no alternative.

 It is not possible to status local variables
 Program blocks using transfer variables are difficult to understand for the customer and
the dealer.
2 Organisational block OB1 should perform organisational tasks only.

 Conditional subroutine calls
 Unconditional subroutine calls
3 The logic programmed should not exceed the width of the displayable area of the controller.
 The complete logic network should be displayable on the control.
4 Only use complex instructions when there is no alternative.

 Accumulator/Shift/Rotate
5 Network logic: Long and simple is better than short and complex
6 An output should only be “enabled/set/reset” once in the program.
7 A transitional marker should have only one function in the program.
9 Indirect addressing should not be used, only use absolute operand names in the program.
10 The servo-synchronous task should only be used when the absolutely necessary.
 The servo task is not called from OB!. It is therefore difficult for the customer/dealer to
be aware of its presence.
11 All blocks and networks should have comments
12 Symbols should be available for all periphery signals, these should be the same as the elec-
trical diagram.
13 Interruptions and fault conditions should generate a user alarm/message.
14 Block naming should be unique across machine types.
15 Easy Extend should be used for the machine builder options.
16 Maintenance Planner should be used for the planning of service intervals on the machine.
Notes :

B026
S7-200 PLC Cyclic Operation
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
Process Image Table At the beginning of the scan, the status of the inputs is trans-
(Inputs) ferred to the Process Image Table.
The INT_100 interrupt block can be used to influence the
Interrupt INT_100 Process Image Table (Inputs).
Main Routine OB1

Subroutine
Subroutine
Subroutine Subroutines are processed in the

order they appear in OB1.
Subroutine
Subroutine

Interrupt INT_101 Process Image Table (Outputs).
Process Image Table At the end of the scan, the status of the outputs is trans-
(Outputs) ferred to the Process Image Table.
End
of
Scan
The INT_0 interrupt block runs independently of

Interrupt INT_0
OB1.
It runs synchronously with the servo cycle. This
cycle time is very fast and could be used for ex-
ample with a fast turret where the signals need to
be decoded sooner than they can be achieved
with OB1.
it is recommended not to use it (see PLC design
document).
Notes :

B026
General PLC Interface Description
The PLC interface Data Blocks are used for interfacing between the PLC, HMI, NC & Drives.
The following Table shows a brief description of the interface Data Blocks. For a more detailed description
DB1000 User data (Area 1)

DB1100 User data (Area 2)
DB1200...DB1207 PLC functions and PI services
DB1400 Retentive data area
DB1600 PLC user alarms
DB1700 Program control (HMI to PLC) & SMS Messenger
DB1800 Mode signals (HMI to PLC), date/time (from PLC) & Maintenance Planner
DB1900 General status/selection signals to/from Operator Panel, RCS viewer inhibit
DB2500 Auxiliary functions M, T, S, D & H functions
DB2600 General signals to NCK
DB2700 General signals from NCK
DB2800 Signals to fast I/O
DB2900 Signals from fast I/O
DB3000 Operating mode signals (PLC to NCK)
DB3100 Operating mode signals (NCK to PLC)
DB3200 Signals to NCK channel, Signals to geometry axis
DB3300 Signals from NCK channel, Signals from geometry axis
DB3400 Signals for Asynchronous sub routines
DB3500 G Functions from NCK channel
DB3700...DB3707 M/S Functions from axis/spindle
DB3800...DB3807 Signals to axis/spindle/drive/PLC axis & technology functions
DB3900...DB3907 Signals from axis/spindle/drive/PLC axis & technology functions
DB4000...DB4300 Signals to/from tool management
DB4500 PLC machine data and PLC user alarm configuration
DB4600...DB4700 Synchronised actions
DB4900 Reading/writing PLC variables
DB5300 Tool management signals from NCK
DB5700...DB5707 Reading actual values/distance to go
DB9900...DB9902 Tool management-user interface
DB9903...DB9904 Maintenance planner user interface
DB9905 Easy Extend user interface
The Machine Control Panel is allocated to a certain Input/Output area.
IB112...IB125 Reserved for MCP 310/483 input signals

QB112...QB119 Reserved for MCP 310/483 output signals
Notes :

B026
Toolbox Examples Creating a PLC Program
PLC Project examples Example PLC projects from the Toolbox
The PLC program is created using the PLC828 Programming When creating a PLC program it is recommended that the ex-
Tool software package which is part of the 828D toolbox. ample project: “Sin828D_interface_symbols.ptp” project is
used. This project does not have any PLC logic but contains a
The toolbox also contains examples of PLC projects readymade symbols table which will save the user time and
The examples do not conform to the PLC design require- effort.
ments and machine test protocol. The symbols table is described on page 13
If an example is used it must be modified so the it meets the
requirements of the PLC Design and Machine Test Protocol Locate the “Sin828D_interface_symbols.ptp” and open by dou-
documents. ble clicking
Description of PLC examples:
Emergency Stop Example: Contains a plc project and an

electrical diagram for use with a safety relay.
MCP Examples: Contains plc projects for use with different

MCP types and machine configurations.
Milling machine with MCP310

Turning machine, turret behind the spindle with MCP310
Turning machine, turret in front of the spindle with MCP310
Milling machine with MCP483
Turning machine, turret behind the spindle with MCP483
Turning machine, turret in front of the spindle with MCP483 It is advisable that the project is saved under a different and
appropriate name. This will keep the example unchanged so
that it can be used again in the future.
Interface Symbols: Contains a readymade symbols table To save the project select “Save as” from the drop down menu.
which contains symbols for system interface signals and in- The name of the project can be entered then saved.
puts/outputs for PP72/48 modules. The table can be edited to The destination of the file can also be changed.
suit individual machines.
Symbols are assigned in order to associate operands with a
specific function.
Example:- I6.0 is used for signalling that the air pressure is
ok. A symbol such as AIR_PRESS_OK could be used for this
operand. This helps when writing programs and also when
diagnosing faults.
Notes :

B026
Creating a PLC Program continued Inserting a new subroutine
To insert a new subroutine select the “Edit” menu, then select

the “Insert” option followed by the “Subroutine” option.
The subroutine will take the next available number. The num-
ber and name can be changed if required. Comments and
information about the author can also be added.
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.
The program should be correctly structured using subroutines.
Separate Subroutines can be used, for example: a conveyor,
axis enables, lubrication unit etc.
Renaming a subroutine.
The example below shows how the existing default subroutine
SBR_0, is renamed. In this case the subroutine is going to be Calling a subroutine
used for the machine control panel.
A subroutine must be called otherwise the logic contained
Right click on the SBR and select the “Rename” option. Enter within it will not be processed.
a suitable name to identify the purpose of the subroutine. The block “MAIN” (OB1)” is used to call Subroutines, to open
the block first open the “Program Block” folder and double
click the “MAIN (OB1) “ block.
The subroutine has been re-

named to “MCP_483”. The block
will contain the logic for the inter-
facing of the MCP483 type
machine control panel.
Notes :

B026
Creating a PLC Program continued The subroutine needs to be entered here. The Subroutines
are found in the “Instructions” folder
The call to the subroutine can now be entered in OB1.
A normally open logic instruction is used. Bit logic operations
are found in the “Instructions” folder
A selection of operands is available

in the
instructions menu. The required op-
erand is selected by the double
clicking or drag and drop functions.
There are many mathematical func-
tions and logic operations available.
By hovering the mouse pointer over
a particular operand/instruction a
short
description will be displayed.
Double click the subroutine to enter it into the network.
Position the rectangle at the beginning of the network and

double click the “Normally open” logic instruction.
The subroutine will be unconditionally called and the logic
within it processed.
Instructions are added in the same way as in OB1. Instruc-

The instruction will appear in the network, an operand must tions known as coils are used for activating outputs and inter-
be entered. face signals.
To call a subroutine unconditionally, special marker SM0.0 is

used. SM0.0 is always equal to 1
Coils are inserted in the same way as the normally open con-
tact. They must also be given an operand.
Position the rectangle to the right of the normally open logic.
Notes :

B026
Creating a PLC Program continued Network 1: JOG mode selection.

I112.3 - JOG button
Entering Network Titles and Comments DB3000.DBX0.2 - Select JOG mode interface
bit.
To enter a network comment double click on the network title.
Network 2: JOG button LED selection.
DB3100.DBX0.2 - JOG mode active interface
bit. Q112.3 - JOG button LED
The network title can be changed and comments can be
added.
Network 3: MDA mode selection.
I112.1 - MDA button
DB3000.DBX0.1 - Select MDA mode interface
bit.
Network 4: MDA button LED selection.

DB3100.DBX0.1 - MDA mode active interface
bit.Q112.1 - MDA button LED
Symbol Tables
Network branches are achieved with the “Line down”, “Line The project already contains a symbol table which can be
up”, “Line left” & “Line right” buttons on the toolbar. edited.
Select the “Symbol Table” icon found on the left side.
The symbol table opens and displays the symbols for the
1st PP72/48 module.
Machine control panel Logic
The machine control panel logic is responsible for functions

such as mode selection, axis selection, NC stop/start etc.
The logic should be written so that it meets with the PLC de-
sign requirements shown on page 3.
The logic should also meet the specifications of the “Machine
test protocol” document, Example: If jogging an axis in the
plus direction & the jog minus key is pressed at the same time,
the axis should stop. The symbols are separated into different tables, each for a
specific function of the machine e.g Axes, Tool management
The interface signals for the machine control panel are found etc
in Module B034. The tables are selected at the bottom of the symbol table
The MCP is addressed via switches, this determines the start screen:
addresses of the inputs and outputs. For reasons of compati-
bility the standard start address is 112. This is explained in
Module B008.
Mode selection example:-

Buttons for Symbol
revealing table
further pages.
pages.
Notes :

B026
Symbol Tables continued
Displaying Symbolic Information in the program:-
The tables can also be selected in the directory structure:
If is selected via the “View” menu or the

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

Table selected:-
Creating a symbol table
A symbol table is created by right clicking on the “Symbol

Table” folder and selecting “Insert Symbol Table”.
The new table appear at the bottom of the existing list of ta-
bles, in this example “USR31 (USR31)” Cross Referencing.
The table can be renamed by right click- A Cross Reference table can be created, this lists information
ing and selecting “Rename” 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 tool-

The newly inserted table renamed to bar.
“MCP_483”:-
Results of the compile procedure are displayed at the bottom

of the screen.
The tables are easily edited:-
Notes :

B026
Cross Referencing continued. A warning that the procedure will overwrite any existing pro-
ject components will be displayed.
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 program blocks uploaded from the controller will ap-

pear in the “Program Block” folder.
The “Symbolic Addressing” option described earlier also func-
tions with the Cross Reference table.
The uploaded file should be saved under a suitable name:
Loading a PLC Program
Uploading to external computer
An online connection with the controller should be made be-

fore proceeding.
It may be necessary to save the existing program from the

controller to a computer. If this is the case open a new project
in the PLC828D programming tool.
Click on the “Upload” button found on the toolbar.
A choice can be made between which type of data class

blocks are to be included in the upload. All blocks should be
included for a full backup.
Notes :

B026
Loading a PLC Program continued. 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
Downloading the program that appears.
Select the “Download” button on the toolbar.

Ensure that the option: “Blocks (MAIN, SBR, INT, DB)” is
selected. A choice of data class blocks can also be made. For
a complete download both should be selected.
Select the “OK” button to continue.
The controller will carry out a warm restart, when this com-
plete there should be no errors relating to the PLC.
The functionality of the PLC program can now be tested.
A dialogue box warns about the dangers of downloading with

the PLC in run mode.
In certain cases i.e. when data blocks are downloaded, the
system will only accept a download in stop mode.
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.
B026: END
Notes :

B026 END

B019 S7-200 PLC Instructions
Module Description:
The Sinumerik 828D uses the in-built S7-200 PLC. Programming is performed with the software
package PLC828. This modules describes the instructions available to the user.
Module Objective:
Upon completion of this module you will know the PLC828 Programming Tool instruction list.
Content:
Sinumerik
Bit Logic Functions

Compare Functions
Convert Functions
Counter Functions
Floating Point Number Functions
Integer Functions
Interrupt Functions
Invert Functions
And Functions
Or Functions
Move Functions
Program Control Functions
Shift/Rotate Functions
Timer Functions
Libraries
B019
B019

B019
S7-200 PLC Instructions: Description

S7-200 PLC
Instructions
START
The Sinumerik 828D uses the in-built S7-200 PLC. Program- And
ming is performed with the software package PLC828. This Functions
modules describes the instructions available to the user.
Bit Logic
Functions
Or Functions
Compare
Functions
Move
Functions
Convert
Functions
Program
Control
Functions
Counter
Functions
Shift/Rotate
Functions
Floating Point
Number
Functions
Timer
Functions
Integer
Functions
Libraries
Interrupt
Functions
S7-200 PLC
Instructions
END
Invert
Functions
Notes :

B019
General Information Bit Logic Function

Address Formats:- Instruction Tree:-
The instructions are found in the menu tree to the left of the
Bit- This refers to a single element of logic e.g. I6.0, Q5.5, main programming area.
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 4 (IB4) contains the bits I4.0, I4.1, I4.2, I4.3, I4.4,
I4.5, I4.6, I4,7.
When working with bytes it must be remembered that the
numbering counts up from the left as shown below.
IB4
Bit no 7 6 5 4 3 2 1 0
Value 1 0 1 0 0 1 0 1
In this example I4.0, I4.2, I4.5 & I4.7 are equal to 1. Another
The instructions are divided into different sections, these are
term for being equal to 1 is that these bits are High.
expanded by clicking on the “+” symbol.
The bits equal to 0 are termed as being Low.
Output Bytes (QB) and Marker Bytes (MB) can also be used in
the same way.
Word- A Word is a collective of 16 bits of logic which encom-

passes two consecutive Bytes. Mouse pointer placed Right clicking on the oper-
on the operand re- and gives the chance to see
A Word can only be addressed as 0 or an even number (IW0, veals the type. a help file. Selecting Hide
IW2, IW4 etc) odd numbers are not allowed. will make the whole instruc-
tion tree disappear.
As with the Byte format the numbering starts from the right.
Example IW4 The PLC program is built up of a series of blocks called
IB5 IB4 subroutines. The blocks contain networks, the user PLC is
Bit no 7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0 written into these networks.
Value 1 0 1 0 0 1 0 1 0 1 1 1 0 0 1 1
The first instruction category in the list is Bit Logic. This
In this example I4.0, I4.1, I4.4, I4.5, I4.6, I5.1, I5.2, I5.5, I5.7. group is the simplest of the instructions.
are equal to 1. The individual items in the Bit Logic area are referred to as
Output Words (QW) and Marker Words (MB) can also be used Operands.
in the same way. These operands need to be addressed, the type of address
depends upon the
operand.
Double Word- A Double Word is a collective of 32 bits of logic
which encompasses two consecutive Words (Four consecutive
Terminology
Bytes).
Inputs:- Typically they are represent the physical state of
A Double Word can only be addressed as 0 or an even number
the machine i.e. Limit switches, buttons, pressure switches,
which is a multiple of four, (ID0, ID4, ID8, ID12 etc) odd num-
door switches etc. and are identified by the letter I e.g. I7.0.
bers are not allowed.
They can also appear in Byte, Word and Double Word for-
mats.
Example ID4
IB7 B6 B5 IB4
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 Outputs:- Outputs are used to switch on relays, contactors,
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 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
Output Double Words (QD) and Marker Double Words (MD) can appear in Byte, Word and Double Word formats.
also be used in the same way.
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.
Notes :

B019
Program Status Normally Closed Contacts.

The status of an operand can be checked by selecting the
“Program status” Icon. In this situation when the status of the operand is high (Equal
The centre of the operand becomes highlighted with a colour to one) the logic will be false.
when it is true. 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.
Program Q4.0 = 0 or Q4.0 = 1 or

Status Icon Low High
I6.0 = 0 (Low) I6.0 = 1 or (High)
Coils: As the names suggests, “Coils” are switched
on/off by “Contacts”.
Typical coil operands are Outputs, Markers, Variables, Data Set and Reset example:-
Blocks, Timer & Counters. It is also possible to have an input
as a coil but this can be deemed as bad
practice.
Output Q4.0 as a coil I6.5= 0, however Q4.5 I6.6 = 1, this has the ef-
remains high because it is fect of resetting Q4.5 to 0.
a “Set” output.
Contacts:
Immediate Contacts.
These operands are effective immediately upon activation,
The most commonly used operands are “contacts”. Combina-
they are not subject to the Process Image Table (Inputs). They
tions of contacts are used to achieve the end result of activat-
are identified by the letter “I”.
ing an output.
These contacts can be assigned to system/user variables,
markers, physical outputs or inputs and can be of the nor-
mally open or normally closed types.
Normally Open Immediate Normally Closed Immediate
Normally open contacts.
Not operands.
When the operand is high (Equal to one) the contact will be
closed and the logic will be true. The Not operand is used to reverse the state of the logic. i.e.
When the logic is true the centre of the contact will be col- A status of one will become a status of zero while a status of
oured. zero will become a status of one.
In the terms of an electrical service the contact will be closed
and current can flow.
I6.2 = 1 but Q4.2 remains low because the not operand inverts
I6.0 = 1 or High the signal.
I6.0 = 0 or Low
I6.2 = 0 but Q4.2 is high because the not operand inverts the
signal.
Notes :

B019
Positive Transition operands. Immediate Outputs.

These operands are effective immediately upon activation.
The Positive Transition operand monitors the preceding oper- The status is passed to both the physical output and the
and status for a rising edge (Signal state change from 0 to 1) Process Image Table (Outputs).
on seeing a rising edge the logic will become true for one scan They are identified by the letter “I”.
of the PLC.
Output Immediate Set Immediate Reset Immediate
Compare functions are used to compare two values. The

compare values can be Byte, Integer (Single and double) or
When I6.3 changes from 0 to 1, Q4.3 will become high for one Real format.
scan of the PLC cycle The available compare types are:-
Negative Transition operands. Equal To
Not Equal To
The Negative Transition operand monitors the preceding oper- Greater Than or Equal To
and status for a falling edge (Signal state change from 1 to 0) Less Than or Equal To
on seeing a falling edge the logic will become true for one Greater Than
scan of the PLC. Less Than
The following example is using the Compare Byte function to

compare Input
bytes 6 & 7.
Compare Functions
When I6.3 changes from 1 to 0, Q4.4 will become high for one Compare bytes for being equal
scan of the PLC cycle.
No Operation Operand (NOP):-
A network cannot be left in an unfinished state, this leads to

errors when the program is compiled and prevents the pro-
gram from being loaded.
IB6 = 14 and IB7 = 15, they IB6 = 14 and IB7 = 14,
are not equal so the status they are equal so the
is low. Q5.0 = 0. status is high. Q5.0 = 1.
Compare bytes for not being equal.

An unfinished network.
If the program is in the development stages then a “No Op-
eration” operand can be inserted, this prevents the network
from being operational and allows the program to be compiled
and loaded to the controller. IB6 = 14 and IB7 = 14, they IB6 = 15 and IB7 = 14, they
are equal so the status is are not equal so the status
low. Q5.1 = 1. is high. Q5.1 = 1.
Compare bytes for being greater than or equal.
An unfinished network with a NOP operand.
When a NOP operand is inserted it has to be given an numeri-

cal identifier.
This identifier can be selected from the range of 0-255. IB6 = 14 and IB7 = 15, IB6 IB6 = 15 and IB7 = 14, IB6
is less than IB7 so the is greater than IB7 so the
status is low. Q5.2 = 0 status is high. Q5.2 = 0.
This would also be the case
if the values were equal.
Notes :

B019
Compare bytes for being less than or equal.
Converting Double Integer to Real.

IB6 = 14 and IB7 = 7, IB6 is IB6 = 6 and IB7 = 7, IB6 is
greater than IB7 so the status less than IB7 so the status
is low Q5.3 = 0. is high. Q5.3 = 1
This would also be the
case if the values were
equal.
Compare bytes for being greater than 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.
IB6 = 6 and IB7 = 7, IB6 is Truncate (Converts 32-bit real to 32 bit signed integer).
IB6 = 15 and IB7 = 14, IB6
less than IB7 so the status is greater than IB7 so the
is false. Q5.4 = 0. status is high. Q5.4 = 1.
The Truncate Function takes a 32 bit Real number and cov-
Compare bytes for being greater than erts 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 trans-
ferred to MD8 as a value of –1. Output Q4.5 was set high by
the ENO output.
IB6 = 15 and IB7 = 14, IB6 IB6 = 6 and IB7 = 7, IB6 is
is greater than IB7 so the less than IB7 so the status
status is low. Q5.5 = 0. is high.
Q5.5 = 1.
The same principle applies to the other number formats of

Integer, Double Integer and Real
Binary Coded Decimal to Inte-
Convert Functions This function will convert a value from BCD to an integer.
Permitted ranges:-
Convert functions are used to change one number format into
another. BCD Decimal
The functions available are:- Hex
Double Integer to Real Minimum 0000 0000 0000 0000 0
Truncate 0
Binary Coded Decimal to Integer Maximum 1001 1001 1001 1001 9999 9999
Integer to Binary Coded Decimal
Example:- When input I6.2 is true the value in MW0
When the block is inserted into the network it needs to be (0000000001010100 = 54) will be converted into an integer
parameterised. The input is the number that is to be con- and the result placed in MW12. Output Q4.6 will become high
verted, the output is the result of the conversion. provided that the value in MW0 is within the ranges specified
The number format of the input and output is dependant on above and I6.2 remains true.
the type of conversion i.e. word, double word, byte.
The source and destination of the input/output can be a Sys-
tem/User Variable, Input, Output or Marker.
Notes :

B019
Integer to Binary Coded Decimal. Below:-Network 19 count up counter C1. The count value
can be seen to be equal to six, this mean that the CU input
This function will convert a value from an integer to BCD . (I6.4) has detected a rising edge on 6 occasions since the
Permitted ranges:- reset (I6.4) was triggered.
Network 20 is an example of how the counter can be used in
BCD Decimal the PLC logic. In this case the preset value (PV) of 10 has
Hex not been reached so the status is low.
Minimum 0000 0000 0000 0000 0
0 Counter C1 with a
Maximum 1001 1001 1001 1001 9999 9999 count value of 6.
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.
Preset value (PV) = 10
Counter functions
Count up counters
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 Below:-Network 19 count-up counter C1. The count value
low to high. can be seen to be equal to ten, this means that the CU input
When the counter is first selected in the user program it needs (I6.4) has detected a rising edge on 10 occasions since the
to be given a name (Available range C0 to C63). reset (I6.4) was triggered.
A preset value is entered in the PV input field as an integer, Network 20 is an example of how the counter (C1) can be
when the count value is equal to or above this value the used in the PLC logic. In this case the preset value (PV) of
counter will be true. The counter operand (e.g. C1) can then 10 has been reached so the status is high, this results in
be used elsewhere in the user PLC program. output Q4.7 being switched high.
The C1 operand will remain high until the reset input R (I6.5)
Below:-A counter selected in the user program but not yet detects a rising edge. The count value stored in C1 will then
parameterised. be set back to zero.
The name of the counter

needs to be entered here
e.g. C1
C1 count value = 10
A preset value is
entered here e.g 10
Notes :

B019
Below:-The reset input has been switched from low to high Below:-Countdown counter C2 showing a count value of 4.
resulting in the count value being reset to zero and the C1 This means that the CD input has detected a rising edge from
operand becoming false. No further counting can take place I7.0 on 6 occasions since the preset value of 10 was entered.
until the reset signal is set to low.
Counter C2 with a
count value of 4.
C1 count value = 0 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 en-
tered. 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.
Countdown counters
Countdown counters are used to monitor the rising edge of a Counter C2 with 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 be-
comes high.
Prior to using the countdown counter a value has to be en-
tered 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).
Output Q5.6 set
high as a result of
countdown counter
Below:-Count down counter C2 with a PV of two, this PV C2 reaching zero.
value will be entered into the 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.
Notes :

B019
Below:-Countdown counter C2 showing a count value of 10 Below:- When the count value is less than the preset value
after the LD input detected a rising edge from input I7.1. This the C3 operand will be low. In this example the count value is
also results in the C2 operand becoming false as seen in net- 9 after the countdown input I7.4 was switched from low to
work 22. high.
The counter C3 has a count
C2 count value = 10 value of 9 which is less than

The C3 operand is low
due to the counter
value being less than
the preset value. In
Countdown/count-up counters this example the out-
put Q5.7 is not set by
Countdown/count-up counters are used to monitor the rising the C3 operand.
edge of two signals. One signal (CU) increases the count
value while the other signal (CD) decreases the count value.
Below:- When the count value is more than the preset value
A preset value (PV) can be entered. The counter operand will
the C3 operand will be high. In this example the count value
become high if the actual count value matches or is above this
is 11 after the count-up input I7.3 was switched from low to
preset value. As soon as the value less than the preset value
high.
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 11 which is more than the pre-
The counter C3 has set value.
a count value of 10
which is equal to the
preset value.
Preset value (PV) = 10 The C3 operand is

high due to the
The C3 operand is high counter value being
due to the counter value more than the
and the preset value preset value. In this
being equal. In this ex- example the output
ample the output Q5.7 is Q5.7 is set by the C3
set by the C3 operand. operand.
Notes :

B019
Floating Point Number Functions Subtraction of real numbers
Addition 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
Below:- The function requires parameterisation on first selec- subtracted from the IN1 value and the result placed in OUT.
tion.
Values to be added:
IN1 32 bit real number
IN2 32 bit real number added to IN1
Result:-
OUT 32 bit real number
Confirmation:- Below:- Example of the subtract function. MD100 - MD104 =

ENO Bit goes high if operation successful MD112 (16 - 2 = 14) Output Q6.1 is high.
Below:- The ADD function prior to parameterisation.
Multiplication of real numbers
The Multiply function is parameterised in the same way as the

ADD function.
Below:- Example of a parameterised ADD function before When the function runs the IN1 and IN2 values will be multi-
being executed. plied together and the result placed in OUT.
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)
Below:- Example of the multiply function. MD100 x MD104 =

MD112 (16 X 2 = 32)
Output Q6.2 is high.
MD100 has been assigned to IN1 and has a value of 16.0
MD104 has been assigned to IN2 and has a value of 2.0
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 func-
Notes :

B019
Floating Point Number Functions continued
Integer Functions
Division of real numbers Addition and Subtraction of integers.
Below:- The function requires parameterisation on first selec-

The Divide function is parameterised in the same way as the tion.
ADD function.
When the function runs the IN1 value will be divided by the It is also possible to add/subtract/multiply/divide integers in
IN2 value and the result placed in OUT. 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:-
Below:- Example of the divide function. MD100 ÷ MD104 = ENO Bit goes high if the operation was successful.
MD112 (16 ÷ 2 = 8) Output Q6.3 is high.
Below:-Examples of adding/subtracting Integers and double
integers.
Adding Integers
Square root of real numbers MW200 + MW202 = 204

(100) + (25) =
(125)
The Square Root function calculates the square root of a real Adding Double Integers
number. The number to be calculated goes to the IN signal,
the result is output to the OUT signal.
MD200 + MD202 =
MD204
(9000) + (3000) =
Subtracting Integers (12000)
MD100 has been MW200 - MW202 =

assigned to IN1 and MW204
Below:- Example of the Square function. (100) - (25) = (75)
has a value of 16.0
√MD100 = MD112 (√16 = 4) Subtracting Double Integers
Output Q6.4 is high.
MD208 - MD212 =
MD240
(9000) - (3000) = (6000)
Notes :

B019
Integer Functions continued

Multiplication of integers. The value in MB100
is incremented by
Incrementing Byte one and the result
This function multiplies two words and converts the result into sent to MB232
a double word.
The value in MB100

is incremented by
Incrementing Word one and the result
sent to MB232
MW200 x MD202 = MD240 The value in MD208

(100) x (25) = (2500) is incremented by
Incrementing Double Word one and the result
Division of integers. sent to MD212
This function divides one word by another and converts the

result to a double word.
The value in MB200
The result is in two parts, the high word section of the double is decremented by
word represents the whole number while the low word repre- Decrementing Byte one and the result
sents the remainder. The format is hexadecimal. sent to MB201
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.
The value in MW200
is decremented by
Decrementing Word one and the result
sent to MW208
The value in MD212

is decremented by
MW200 ÷ MD204 = MD252 Decrementing Byte one and the result
(100) ÷ (8) = (000C0004) sent to MD236
= 12 remainder 4
Increment and Decrement Functions.
These functions allow a number to be incremented or decre-

mented by a value of one.
The formats can be Byte, Word or Double Word.
This is a once only occurrence, further switching of the con-
trol bit does not result in further increments/decrements.
Below:- Examples of increment and decrement functions.
Notes :

B019
Interrupt Functions The addresses to be monitored need to be typed in the Ad-

dress column and the format set to binary.
Interrupt Function
In the example below it can be seen that the status of the
The interrupt function will freeze the processing of the PLC in inputs is the exact opposite of the output status.
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 ele-
ment, Input 11.2 is true.
And Functions
With the interrupt active, the output Q8.1
The AND function compares two bytes, words or double
remains set even though the proceeding
words. If two corresponding bits are high the relevant output
element, Input 11.2 is no longer true.
bit will be set.
And Byte
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. And Word
It is better to look in the chart status area.
Invert Byte
And Double Word
Invert Word
This is better seen in the Chart Status area.
Invert Double Word
I7.0 and I9.0 are high

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

low:-
To locate the chart status area select the following icon on the
toolbar.
Notes :

B019
Or Functions Exclusive Or Functions
The OR function compares two bytes, words or double words. The Exclusive OR function compares two bytes, words or dou-
If either one or both of the corresponding bits are high the ble words. If either one but not both of the corresponding bits
relevant output bit will be set. are high the relevant output bit will be set.
OR Byte
Exclusive OR Byte
OR Word
Exclusive OR Byte
OR Double Word
Exclusive OR Double Word

If either input or both are

high M238.x will be set
If either input but not both

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

B019
Move Functions Swap Function
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 MW68 prior to running the Swap function.
MW68 after running the Swap function.

Move Word
Program Control
Jump Instruction & Labels
Move Double Word
The Jump Instructions and labels are used together. When

the Jump is activated the program will skip to the Label
specified by the Jump.
Move Real Number 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.
The jump instruction has to be used in the same program-
ming block.
Immediate move functions as the name suggests, have an
immediate effect on the PLC. They are only available for use Example of how a Jump/Label might be used.
with bytes.
The Immediate Read function is used to read physical inputs,
these can then be read out to Markers, Variables, Inputs, Out-
puts, Accumulators and Load instructions.
The Immediate Write function writes only to an output byte Jump Instruction to Label 1 is not active.
from Markers, Variables, Inputs, Outputs, Accumulators and
Load instructions.
I7.2 switches Q8.7 in the expected manner.
Move Byte Immediate Read
Move Byte Immediate Write Jump Instruction to Label 1 is active.
I7.2 does not switch Q8.7 because the

program jumps to Label 1.
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.
Notes :

B019
Program Control Continued

The Conditional Return Instruction is active.
Jump Instruction to Label 1 is active. Q9.3 remains low despite I7.7 being high.
This is
because I7.7 was set high after the Condi-
I7.2 does switch Q8.7 because it was high tional Return was activated.
before the program Jump Instruction was
activated.
Conditional End Instruction.
The Conditional End Instruction is used only in OB1 and re-

sults in the program scan restarting at the beginning of OB1.
No further operations after the Conditional End will be proc-
Jump Instruction to Label 1 is active. essed.
Q8.7 remains high despite I7.2 being low Example of how the Conditional End Instruction might be
this because I7.2 was set low after the used.
program Jump Instruction was activated.
Conditional Return Instruction.
The Conditional Return Instruction is used to terminate a sub- The Conditional End Instruction is not active.
routine.
Example of how a Conditional Return Instruction might be I6.2 is high which switches Q4.1 high.
used:-
The Conditional Return Instruction is not

active.
The Conditional End Instruction is active.

I7.7 switches Q9.3 in the expected manner.
I6.2 is high which but Q4.1 remains low. This

The Conditional Return Instruction is active. is because program end is now in the previ-
ous network.
I7.7 does not switch Q9.3 as the subroutine When the Conditional End Instruction is active, no further
has been terminated by the Conditional processing takes place.
Return. Outputs, markers etc which were already high will remain so
until influenced from elsewhere in the program.
The Conditional Return Instruction is active. Shift Left Byte.
The shift Left Byte function allows the bits within a byte to be
Q9.3 remains high despite I7.7 being low. moved to the left by up to 8 places. In the example below the
This is
because I7.2 was set low after the program
contents of IB9(IN) will be shifted left by 4 places (N). The
Conditional Return was activated. result will be placed in MB100 (OUT) The maximum number of
places that can be moved is eight. If a larger number is en-
tered the value will default to eight.
Notes :

B019
Program Control Continued Shift Right:
The example below shows the result when viewed in ladder

status, a better idea of this is seen in Chart Status.
The Results:
Byte to be shifted The result of the Shift
No of places to be Byte Left instruction will
shifted (4) be stored 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 Left Double Word & Shift Right Double Word
Below:-The Chart Status shows that status of IB9 has been The contents of a Double Word can be shifted left or right in
shifted left by four places and the result placed in MB100. the same way that the contents of a Byte or Word can be
shifted. The maximum number of moves is 32.
Shift Right Byte.
Below:-Examples of shifting Double Words.
The Shift Right Byte function operates in the same way as the
Shift Left Byte, except that the move is to the right. Shift Left:
Below:-Example of a Shift Right Byte by 2 places operation.
Shift Right:
Shift/Rotate Functions The Results:
Shift Left Word & Shift Right Word.
The contents of a Word can be shifted left or right in the same Timer Functions
way that the contents of a Byte can be shifted. The maximum
number of moves is 16. Timer are used to delay the effects of a signal when it
switches. There are a total of 128 timers available (T0 to
Below:-Examples of shifting words. T127).
T0 to T15 have an input resolution of 100ms with a maximum
Shift Left: preset time (PT) value of 327.67 seconds.
T16 to T127 have an input resolution of 10ms with a maxi-
mum preset time (PT) value of 3276.7 seconds.
Notes :

B019
Timer Functions continued 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
On-Delay Timer switched output Q5.0 high.
When a timer is selected it needs to be given a name (To to

T127) and a Preset Time value (PT). T1 value has sur-
passed the PT of
Timer name - Txxx 50
Preset Time (PT) T1 operand is now

high, Q5.0 is also
Below:-On-Delay timer T1 has been a PT value of 50 this high as result
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 Below:-Input I7.0 has gone low and the T1 time value is reset
is reached the T1 operand will switch high. As a result Q5.0 to zero. The T1 operand also goes low as a result.
will be come high (Network 8) as long as I7.0 remains high T1
will continue to count and the T1 operand will remain high.
When I7.0 becomes low, the count value of T1 will reset to
zero and the T1 operand will go low.
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
Below:- Input I7.0 is high and T1 has started to count. The T1 removed the Timer operand remains high. The Timer
operand in network 8 is still low as the PT value of 50 has not operand will need to be reset by the user which also
been reached. resets the time value to zero.
Below:- Retentive On-Delay timer T2 has been triggered

T1 value has
by I7.1 and the time value has passed the 10 second PT
reached 20 value (100 x 100ms = 10 seconds). The T2 operand is
high and has switched Q5.1 high.
Notes :

B019
Timer Functions continued 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
The Input I7.1 is now low, T2 has stopped counting but retains network 12.
the count value. The T2 operand remains high. If I7.1 be- When the timer detects a falling edge on the IN input the time
comes high again the time value in T2 will continue. value in T3 will count up, when this value reaches the value of
PT (75 x 100ms = 7.5 seconds) the T3 operand will be set to
zero.
Timer retains the

count value The IN signal has
gone low, T3 starts
to count up
Timer operand remains high

Timer operand T3 remains high
The timer is reset using the Reset function which can be seen
in network 8 below.
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.
Timer reset by I7.2
Timer count value

reset to zero
The time value has
reached the value
set in PT
Timer operand goes low
T3 operand is now zero

Off-Delay Timer
The Timer has counted up to the PT value, as a result the T3
The Off-Delay Timer T3 shown below monitors the IN input. operand has been reset to zero. The timer value is reset to
When this input is high, the T3 operand is also high as seen in zero when the IN input goes from low to high.
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 operand will be set to
zero.
Timer value sits at zero
Timer operand T3 is high
Notes :

B019
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 mod-

ules.
B019: END
Notes :

B019: END
B019
B033 PLC Functions
Module Description:
The following functions are available in the PLC:
 Initialise ASUP
 Start ASUP
 Reset password
 Save data
 Tool reloading
 Read axis positions
 Read and write NC variables
 Exchange data between the NC and PLC
 Control an axis from the PLC
Module Objective:
Upon completion of this module you will be able to perform the above listed PLC tasks.
Content:
Sinumerik
PI Services (Program Invocation Services)
Reading Axis Positions
Reading and Writing of NC Data
Data Exchange between NC & PLC
PLC controlled axis
B033
B033

B033
PLC Functions: Description

PLC
Function:
START
The following functions are available in the PLC:
 Initialise ASUP
PI Services
 Start ASUP (Program
 Reset password Invocation
 Save data Services)
 Tool reloading
 Read axis positions
 Read and write NC variables Reading Axis
 Exchange data between the NC and PLC Positions
 Control an axis from the PLC
Reading and
Writing of
NC Data
Data Ex-
change
between NC &
PLC
PLC con-
trolled
axis
PLC
Function:
END
Notes :

B033
PI Services (Program Invocation Services) ASUP behaviour:-

The behaviour of the ASUP when it is called is affected by
PI Services the following interface signals:
A PI Service is an NC task which can be initiated from the LIFTFAST: When the ASUP is requested, fast retraction of
user PLC program. Interface signals are used to select the the tool from the contour takes place prior to the ASUP run-
required service, initialising, starting and monitoring the status ning.
of the service are available at the interface.
BLSYNC: When the ASUP is requested, the current program
PI Services that can be used:- block is processed prior to the ASUP running.
 ASUP - Asynchronous User Program
PI Services Start Bit Function
 LOGOUT - Password Reset
 _N_DASAVE - Saving of Data DB1200.DBX4000.0 Start PI Service
 TMMVTL - Tool Reloading via the PLC PI Service: LOGOUT - Password Reset
PI Index (DB1200.DBB4001) Function
PI Service: ASUP - Asynchronous User Program
3 Password Reset
A PLC ASUP is a program which can be initialised and started
from the user PLC independently of the normal NC operations. PI Services Start Bit Function
Two ASUPS are available (PLCASUP1.SPF and DB1200.DBX4000.0 Start PI Service
PLCASUP2.SPF). These have to be created by the user and
stored in the “Manufacturer cycles” directory. There are no PI parameters required for LOGOUT.
The required ASUP is initialised by entering a value of 1 or 2
into the PI index PI Service: _N_DASAVE - Saving of Data
interface. PI Index (DB1200.DBB4001) Function
Each ASUP first requires initialising before it can be run, this is 4 Save data automatically
achieved by setting the “Start PI service” bit high when the
relevant “PI index value” is active. The ASUP remains initial- PI Services Start Bit Function
ised until the control is powered off/on:- DB1200.DBX4000.0 Start PI Service
There are no PI parameters required for _N_DASAVE.

PI Service: TMMVTL - Tool Reloading via the PLC
PI Index Function Interrupt Priority PI Index Function
(DB1200.DBB4001) (DB1200.DBB4001)
1 Initialization of ASUP1 1 5 Initiate order for tool reloading
2 Initialization of ASUP2 2
PI Parameters for TMMVTL:
Interrupt Priority:-
If ASUP1 & ASUP2 are called together, ASUP1 will run and
PI Address Function Permitted
not ASUP2. Parameter Values
If ASUP2 is already running and ASUP1 is called, ASUP2 will
be stopped and ASUP1 will run. 1 DB1200.DBW4004 Tool Number 1 to 31999
If ASUP1 is running and ASUP2 is called, ASUP1 one will
2 DB1200.DBW4006 Source Location 1 to 31999
complete before ASUP2 starts. Number
3 DB1200.DBW4008 Source Maga- 1 to 31999
zine Number
PI Parameters for ASUP1 & ASUP2:
4 DB1200.DBW4010 Target Location 1 to 31999
Number
PI Parameter Address (Word) Signal Permitted values 5 DB1200.DBW4012 Target Maga- 1 to 32000
(1 to enable) zine Number
1 DB1200.DBW4004 LIFTFAST 0 or 1 PI Services Start Bit Function

2 DB1200.DBW4006 BLSYNC 0 or 1 DB1200.DBX4000.0 Start PI Service
Notes :

B033
Interface signals for PI services
The following interface signals are reserved for use with the PI Services function.
DB1200 PLC NCK [r/w]

4000 Start
4001 PI-Index
1: ASUP1, 2: ASUP2, Password Reset, Saving of Data, Tool Reloading via the PLC
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 [r]
5000 Fault Finished

5001
5002

0000 Asup 1
start
0001 Asup 2
start
0002
0003

Asup 1 start Asup 1 num- Asup 1 run- Asup 1
1000 not possi- ber not ning finished
ble possible
Asup 2 start Asup 2 num- Asup 2 run- Asup 2 finished
1001 not possi- ber not ning
ble possible
Notes :

B033
Example: Initialise and start an ASUP A subroutine should be created in which to write the PLC
code to initialise and start the 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. Select PI Service no.
Path = NC data\Cycles\Manufacturer cycles. 1 (ASUP1) by putting
a value of 1 into
DB1200.DBB4001.
Initialise the ASUP with the

“Start PI Service signal”.
(DB1200.DBX4000.0 high).
Reset the “Start PI Service

signal”.
Start ASUP1 with the “ASUP1

Start signal” (DB3400.DBX0.0
high).
Reset the “ASUP1 Start signal.
LED to indicate ASUP1 is

running.
The file will open automatically to allow the program com-
mands to be entered. In this example a 10 second dwell is
used with an operator message The ASUP will run in all modes. Any program running in
automatic mode will be interrupted while the ASUP runs, this
program will then continue when the ASUP has finished.
Notes :

B033
PI Services (Program Invocation Services continued
Example: LOGOUT-Resetting the password Select PI Service

no. 4 by putting a
value of 4 into
The following example can be used to reset the active pass-
DB1200.DBB4001.
word.
Start the PI service

by switching
Start the PI service
by switching
DB1200.DBX4000.0
high.
Select PI Service no.
3 by putting a value of
3 into
B1200.DBB4001.
Reset the PI service
PI service finished start signal.
Start the PI service signal when
by switching
DB1200.DBX4000.0
high.
PI Service complete signal used to set

PI service fault signal
when
Reset the PI service
start signal.
MCP Reset key used to reset Q4.1.
The active password will be deleted and the access level will
be determined by the key-switch position.
Example: _N_DASAVE-Saving data

The following example can be used to automatically save
data to the internal flashcard. There is no on-screen indica-
tion that a data save function has been performed. Interface
signals are available to indicate when a PI service is success-
ful.
Notes :

B033
Reading Axis Positions
Reading axis actual positions and distances to go
The actual position and distance to go of an axis can be read in the PLC.
The following PLC interface areas are reserved for this function.

5707

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

Request axis Request axis
0001 distances to go actual values
The following table shows the DB addresses for each axis when reading axis positions/distance to go.
Actual position Distance to go Axis

DB5700.DBD0 DB5700.DBD4 1
DB5704.DDD0 DB5704.DBD4 5
Example: Reading axis actual position and distance to go
Moving the 1st axis actual position into MD100 using the
MOV_R instruction.
The value is read only when DB2600.DBX1.1 is high.
Moving the 1st axis distance to go into MD200 using the

MOV_R instruction.
The value is read only when DB2600.DBX1.2 is high
Notes :

B033
The result of the example can be seen below:
Reading and Writing of NC Data
Up to eight variables can be addressed at any one time, identified by substituting a number (0 to 7) in place of the 4th digit of the
DB number. Example
DB1200.DBB1000 - 1st variable
DB1201.DBB1000 - 2nd variable
DB1202.DBB1000 - 3rd variable etc.
Variables that can be read/written:-

- Cutting edge (read/write)
- Number of cutting edges (read only)
- Settable work offsets (read only)
- Number of machine axes (read only)
- R parameters (read/write)
- Tool magazine location type (read only)
- Tool location status (read only)
- Tool number (read only)
Interface signals for read/write NC Data

The following interface signals are reserved for use with reading and writing NC data.
DB1200 PLC  NCK [r/w]

Read:0
0000 Write:1
Start
1200 0001 Number of variables to be read/written
DB1200-
PLC  NCK [r/w]
1207

Variable type:
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 a specific location
1001 Area Number
1002 Column Index number of NC variable x +1 (Word)
1004 Line Index of NC variable x (Word)
1006
1008 Writing data to NC variable
Notes :

B033
DB1200 NCK  PLC [r]

Request com-
2000 Error in job
plete
2001
DB1200-
Line Index number of NC variable x +1 [r]
1207
3000 Valid 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
The following tables show the interface signals required for each of the variables.
Type 1: CuttEdgeParam - The cutting edge value of a tool can be read/written.
Cutting Edge Parameter (Read/write)
DB120x.DBB1000 1
DB120x.DBB1001 —
DB120x.DBW1002 (Cut. Edge No -1) * numCuttEdgeParams + 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 - 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)
Notes :

B033
Reading and Writing of NC Data continued
Type 3: linShift - Settable work offsets.

(only if MD18601MM_NUM_GLOBAL_USER_FRAMES > 0).
Settable work offsets (Read)
DB120x.DBB1000 3
DB120x.DBB1001 —
DB120x.DBW1002 Frame index * numMachAxes + AxisNumber
DB120x.DBW1004 —
DB120x.DBD1008 —
DB120x.DBD3004 Read: Data to NCK variable x (Real number)
Valid frame index numbers:
0: ACTFRAME = Current resulting work offset

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)
Type 4: numMachAxes - The highest existing axis number.
Highest existing axis number (Read)
DB120x.DBB1000 4
DB120x.DBB1001 —
DB120x.DBW1002 —
DB120x.DBW1004 —
DB120x.DBD1008 —
Notes :

B033
Type 5: R Parameters Type 9: Tool number
R Parameters (Read/write) Tool number $TC_MPP6 (Read)
DB120x.DBB1000 5 DB120x.DBB1000 9
DB120x.DBB1001 —
DB120x.DBB1001 —
DB120x.DBW1002 Location number
DB120x.DBW1002 R Number + 1
DB120x.DBW1004 Magazine number
DB120x.DBW1004 —
DB120x.DBD1008
DB120x.DBD1008 Write data to NCK variable x (Real number)
DB120x.DBD3004 Read: data from NCK variable x (Real number)
Example: Reading data from an R parameter
Type 7: Magazine data-Location data
>0: Location type for virtual location Selection of the number

=0: “Match all” (Buffer) of data sets to be trans-
ferred. (In this case only
9999: Undefined (No virtual location) one) Up to eight can be
transferred in the same
operation.
Location type $TC_MPP2 (Read)
DB120x.DBB1000 7 Selection of the
type of variable to
DB120x.DBB1001 — be transferred. (R
Parameter = 5).
DB120x.DBW1002 Location number
DB120x.DBW1004 Magazine number Selection of the

Variable number + 1
DB120x.DBD1008 (R parameter 10 +
1= 11).
Type 8: Location status

Start signal.
The read/write signal as be set to

Location status $TC_MPP4 (Read)
Read. (0 = Read).
DB120x.DBB1000 8
DB120x.DBB1001 — Reset Start signal.
DB120x.DBW1002 Location number Reset Read signal.

DB120x.DBW1004 Magazine number
DB120x.DBD1008 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:
Meaning of the results in location status DB120x.DBW3004.
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
Notes :

B033
Reading and Writing of NC Data continued
R parameter 10 is used in the example, Cursor to R10 and

enter a value, confirm with the “Input” key. Example R10 =
99.
Value of 25 written
to
DB1200.DBD1008
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.
The read/write signal has to

be set to Write.
(1 = Write).
Reset Start signal.
Reset Write signal.

The value from R10 will now appear in DB1200.DBD3004.
This value remains there only as long as the start signal is The value from DB1200.DBD1008 will now appear in R10.
present. This value remains there until the start signal is removed.
Example: Writing data to an R parameter

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
DB1200.DBD1008. Network 4 below shows how this can be
done.
Notes :

B033
Data exchange between NC and PLC This can be checked in the Chart Status of the PLC828 pro-
gramming tool:
The 828D controller has a 4095 byte memory area for use
with data exchange between the NC program and PLC.
The function is also available with SYNACT.
The memory available is from DB4900.DBB0 to

DB4900.DBB4095, allowing data to be exchanged directly To read data in the opposite direction is a similar operation.
between the user PLC and for example a part program. In the MDA area type the line: R11=$A_DBR[4].
This will copy the contents of $A_DBR[4] into R11.
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.
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).
When the cycle start button is pressed the value be copied 3. A maximum of 3 sets of data can be written by the NC
from R10 to the destination variable. in the same
program block.
Notes :

B033
PLC controlled axis
It is possible to control a servo axis using the PLC interface. Various interface signals are available for this task.
A tool magazine is an example of when a PLC controlled axis could be used.
There are 3 possibilities for positioning a PLC axis:
 Variable positioning using the PLC interface

 Pre-defined positioning from a table in the “General Machine Data” area.
 Equidistant positioning determined via “Axis Machine Data”
Interface signals are used to facilitate the movement of a PLC axis.
PLC interface signals:

DB3807

Request PLC Activation signal Request NC
0008
axis/spindle for NC/PLC axis/spindle
axis
changeover
Start position-
3000 ing axis
Traversing Path Path

3002 dimension Condition: condition:
Inch Shortest path Incremental
(DC) (IC)
G function: G function:
3003 Indexing posi- Absolute posi- Absolute nega-
tion tive direction tive direction
(ACP) (ACN)
3004
3005
Position (Real number for variable positioning, double word when using fixed index positions)
3006
3007
3008
3009 Feedrate (Real number)
If = 0 value is taken from axis machine data POS_AX_VELO
3010
3011

DB3907
Positioning axis Position Error Axis
3000 active reached during travers- cannot be
ing started
3001
3002
3003 Error number
Notes :

B033
The PLC axis will now move to the position entered in
Prior to commissioning a PLC axis it is necessary to declare DB3805.DBD3004.
the axis as a PLC axis.
It is possible to do this permanently via Axis machine data

30460 or using interface signals to switch between PLC/NC
control.
A geometry axis cannot be assigned as a PLC axis.
Firmly assigning the axis to the PLC via machine data:

By the changing the value of DB3805.DBD3004 it is possible to
move the axis to varying positions, For example, the value
entered here could be taken from the Tool Management inter-
face and used to position a tool carousel in preparation for a
tool change.
Positioning using an index table.
The number of indexing positions is entered via machine data:

Variable positioning using the PLC interface
General MD: 10900 $MN_INDEX_AX_LENGTH_POS_TAB_1
The following example shows how to position a PLC axis 10920 $MN_INDEX_AX_LENGTH_POS_TAB_2
using a variable from the PLC interface.
There are two index tables (Machine data arrays) available
where index positions can be entered:
General MD: 10910 $MN_INDEX_AX_POS_TAB_1

Select the axis as a 10930 $MN_INDEX_AX_POS_TAB_2
PLC axis by setting
I1.0 high.
The index array to be used is selected via Axis machine data:
Axis MD: 30500 $MN_INDEX_AX_ASSIGN_POS TAB_1

Initiate the PLC axis
by setting I1.1 high.
The following example shows how to position a PLC axis using
the positions entered in an index table found in the “General
Select incremental Machine Data” area.
moves by setting
I1.2 high.
The 10 positions are divided equally into 36 degree incre-
ments.
Command position
of the axis (“real”
value).
Start the positioning

procedure with I1.6.
Notes :

B033
PLC controlled axis
PLC requirements:
Select the axis as a

PLC axis by setting
I1.0 high.
Initiate the PLC axis

by setting I1.1 high.
Select positioning
by index table. Bit
1.7 = high.
Selecting the
index position
e.g. 5.
Start the position-

ing sequence.
The axis will now move the position entered into the 5th value
(Index 4) of General Machine data 10910
$MN_INDEX_AX_POS_TAB_1.
B033: END
Notes :

B33 END

B031 PLC Alarms and Messages
Module Description:
Alarms and messages are essential to inform operators, maintenance personnel etc. of the state of
the machine.
Alarms and messages can be configured to have different behaviour on the operation of the ma-
chine.
User help files can be created to give a more detailed description of each alarm/message.
This module describes how the alarms and messages are activated.
The effect an alarm has on the system is described and how to acknowledge an alarm.
Module Objective:
Upon completion of this module you can configure, activate and set the attributes of
messages and alarms and create user help files.
Content:
Sinumerik
General Information
Alarm and Message Screens
Alarm Configuration
Entering the Alarm Text
User Help Files
Alarm Log
B031
B031

B031
PLC Alarms and Messages: Description PLC Alarms

And
Messages:
START
Alarms and messages are essential to inform operators,
maintenance personnel etc. of the state of the machine.
Alarms and messages can be configured to have different
behaviour on the operation of the machine.
General
User help files can be created to give a more detailed de-
Information
scription of each alarm/message.
This module describes how the alarms and messages are
activated.
The effect an alarm has on the system is described and how
to acknowledge an alarm. Alarm and
Message
Screens
Alarm
Configura-
tion
Entering the
Alarm Text
User Help
Files
Alarm Log
PLC Alarms
And
Messages:
END
Notes :

B031
General assignment Alarms and Message Screen
The alarms/messages are sub-divided into the following ranges: The 828D controller allows 248 user PLC alarms/messages
to be configured (numbered 700000 to 700247).
Range Description Each alarm/message has an interface bit for activation
(DB1600.DBX0.0 to DB1600.DBX30.7).
0 - 9999 General alarms
10000 - 19999 Channel alarms The alarms/messages can be displayed in red or black. Red
is traditionally used to indicate a more serious alarm and
20000 - 29999 Axis/Spindle alarms black is used for a message type situation.
60000 - 64999 Cycles alarms Siemens The effect an alarm/message has on the machine is configur-
able via general machine data 14516. The same machine
65000 - 69999 Cycle alarms Customer data is used to determine how the alarm/message is acknowl-
edged.
100000 - 199999 HMI alarms
The alarm/message text can be input via the controller or
200000 - 299999 Sinamics alarms created offline.
300000 - 399999 General drive alarms
The extended alarm function allows the same alarm/message
number to be used for different situations by substituting part
400000 - 499999 PLC alarms Siemens
of the text for a numerical variable. The following shows infor-
700000 - 700247 PLC alarms/messages Customer mation required for setting and configuring alarms.
As soon as a fault occurs on the machine, an alarm together When alarms and messages are triggered they are separated
with the alarm number, alarm text and the acknowledgement/ and displayed on different screens. The time and date of the
clearance will be shown on the screen. alarm/message occurrence is given.
1 2 3 A configurable alarm log is available to show past alarms/

messages including when they occurred and when they were
cleared. The log can be saved and forwarded to technical
personnel if necessary.
Select the following keys to locate the screen where the ac-
tive 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

1 Number of alarm which result in the machining process being halted.
2 Acknowlegement of alarm
3 Alarm text The “Messages” screen displays less serious
alarms which may not necessarily result in the ma-
chining process being halted.
A description of the system alarms, their cause and remedy is
documented in the Online Help of the controller and in the
diagnosis manual on DOConCD.
Notes :

B031
Alarms and Message Screen Alarm Configuration
Below is an example of two alarms in the Alarm list. The table below shows the alarm numbers and their associ-
ated interface signals and configuration machine data.
Alarm Activation bit Configu- Variable for extended

Number ration alarm function
Machine
Data
700000 DB1600.DBX0.0 14516[0] DB1600.DBD1000
700001 DB1600.DBX0.1 14516[1] DB1600.DBD1004
700002 DB1600.DBX0.2 14516[2] DB1600.DBD1008
700003 DB1600.DBX0.3 14516[3] DB1600.DBD1012
700004 DB1600.DBX0.4 14516[4] DB1600.DBD1016
700005 DB1600.DBX0.5 14516[5] DB1600.DBD1020
700006 DB1600.DBX0.6 14516[6] DB1600.DBD1024
700007 DB1600.DBX0.7 14516[7] DB1600.DBD1028
Alarms/messages are also displayed on the top line of the
screen. When more than one alarm/message is present a 700008 DB1600.DBX1.0 14516[8] DB1600.DBD1032
downwards pointing arrow appears to the right of the alarm/
700009 DB1600.DBX1.1 14516[9] DB1600.DBD1036
message number.
700010 DB1600.DBX1.2 14516[10] DB1600.DBD1040
...
The alarms can be made to appear in turn after a set time.
700247 DB1600.DBX30. 14516 DB1600.DBD1998
This is controlled by
7 [247]
Display Machine Data 9056.
Below:- An example of how Alarm 700000 might be activated
via input I8.0.
Configuration machine data:-

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:-
With values of less than 500 there is no rotation cycle. Values

of 500 to 10000 set the time that each alarm/message is dis- 14516[xx] Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
played for.
The units are milliseconds. Acknowl- Power Acknowl- PLC Emer- Feed Read in NC
edge/Effect off edged by stop gency disable disable start
The machine data is activated with an NC reset. DB1600. stop inhibit
DBX3000
.0
Notes :

B031
Alarm Configuration continued Extended alarm function:-

It is possible to include a numerical variable within the alarm
text string. This is done using the variables shown in the
Bits 0 to 4 determine how the controller reacts to that particu-
“Variable for extended alarm function” column of the table
lar alarm, while Bits 6 & 7 determine how the alarm is ac-
on page 8.
knowledged.
The MD is set via a bit pattern which is revealed when the MD
Each alarm is assigned a Double Word variable for this pur-
is highlighted and the “Select” key is pressed.
pose. By selecting one of the following identifiers and enter-
The bit is then activated with the “Select” or “Space” key and
ing it into the alarm text, the contents of the Double Word
confirmed with the “OK” soft-key.
will appear in place of the identifier when the alarm is trig-
gered.
%d Decimal value
%x Hexadecimal
%b Binary
%o Octal
%u Unsigned integer
%f Floating point number
Example:-
The alarm number 700003 is to be used to signal that sev-
eral axes are in the parked position.
The bit to activate this alarm is DB1600.DBX0.3 and that the
extended function variable is DB1600.DBD1012.
In the alarm text type:-

“Axis %d in parked position”.
In the Variable DB1600.DBD1012 the value of 1 is entered.

This is done by a move command.
This variable is a Double Word and as such it has to use the
“MOVE_DW” instruction (Move Double Word).
Machine Data 14516 is also used to determine whether the
message/alarm appears on the alarm or message screens. Below is an example of how a value 2 is moved into the
variable DB1600.DBD1012 when input I8.3 is equal to one.
If neither bits 6 & 7 are used, then the message/alarm requires This would display the number 2 in place of the “%d” and
no acknowledgement and will clear as soon as the activation activate alarm 700003.
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.
Below is the alarm 700003 as displayed on the controller.
By moving different values into DB1600.DBD1012 it is pos-

sible to use the same alarm number to display slightly differ-
ent messages.
Notes :

B031
Entering the Alarm Text
The PLC alarm text can be created directly on the controller,

the details are then saved automatically to an XML file.
It is also possible to edit the xml file off the machine, this is The data is now saved to an xml file in the following location:-
usually the better option when a large number of alarms are SystemCF card\oem\sinumerik\hmi\lng
to be used.
The file name is:-
The alarm file determines the text that is displayed when a oem_alarms_plc_eng.ts. The “eng” part of the name is the
particular alarm is activated. language identifier.
Creating the text on the controller Language identifier examples:-

Locate the Alarm texts screen with the following key se- eng = English
quence. deu = German
fra = French
ita = Italian
esp = Spanish
chs = Chinese (Simplified)
cht = Chinese (Traditional)
kor = Korean
Use the cursor key to highlight the User PLC alarm texts op-
ptb = Portuguese (Brazil)
tion alarm type and select “OK”.
Locate the file:-

SystemCF card\oem\sinumerik
\hmi\lng\oem_alarms_plc_eng.ts
The file can be edited on the controller or saved externally for
editing/forwarding elsewhere. Select the “Open” soft-key to
open the file.
Up to 248 alarm numbers with text can now be typed in using

the key board.
Existing alarms can also be edited here.
The text entered earlier can be seen within the file. When edit-
ing is important only to change the alarm number within the
<source> tag and the alarm description within the
<translation> tags. the rest of the file structure should be left
unchanged.
The file is automatically saved when the “Exit” soft-key is se-
lected.
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.
Add further alarms in the same way. Select “OK” when all the
alarms have been entered then reboot the HMI.
Notes :

B031
Entering the Alarm Text continued When the search soft-key is selected further options are re-
vealed which can be used to locate alarms and text in the
The alarm text editing screen has search, copy, paste delete alarm list.
functionality. This is useful when editing exiting alarm texts.
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.
The search function can be used to search for text or alarm

numbers. Cancels the operation.
The option to search forward or backward is available as well
as a case sensitive option. Confirms data entry/starts the search function.
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 find-
ing a particular alarm.
Example 1. Example 2.
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 find-
ing a particular alarm.
Notes :

B031
User Help Files
General Information
To further enhance the fault finding procedure it is possible to create a “Help” file.
When the HELP key is pressed the details of the selected alarm will be displayed on the screen.
Help file information and Rules:-

The help file is of the type HTML (HyperText Markup Language) and needs to be stored in a specific directory.
File location for English language:
System CF-Card\oem\sinumerik\hmi\hlp\eng\sinumerik_alarm_plc_pmc
The italicised text denotes folders that require creating. Separate folders are required for each language where the Help
file is to be utilised.
Examples:-
English - eng\sinumerik_alarm_plc_pmc
German - deu\sinumerik_alarm_plc_pmc
Chinese (Simplified) - chs\sinumerik_alarm_plc_pmc
Chinese (Traditional) - cht\sinumerik_alarm_plc_pmc
Portuguese - ptb\sinumerik_alarm_plc_pmc
Korean - kor\sinumerik_alarm_plc_pmc
The HTML file name is also fixed:

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

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

Information/more tags entered here
etc.
</html> Closing the “html” tag
Common HTML Tag

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

B031
User Help Files continued
Example help file

Below is an example help file for alarm 700001. the text has been coloured to assist with understanding the contents. Due to
page width restrictions, some of the entries are shown on two lines. In the HTML file these would normally be on a single
line.
<html>
<head><meta http-equiv="Content-Type" content="text/html; charset="UTF-8"/><title></title></head>
<body>
<table>
<tr>
<td width="15%"><b><a name="700001">700001</a></b></td>
<td width="85%"><b>Hydraulic Oil Pressure Low</b></td>
</tr>
<tr>
<td valign="top" width="15%"><b>Parameter:</b></td>
<td width="85%">N/A</td>
</tr>
<tr>
<td valign="top" width="15%"><b>Explanation:</b></td>
<td width="85%">I8.1 is low.</td>
</tr>
<tr>
<td valign="top" width="15%"><b>Reaction:</b></td>
<td width="85%">Emergency Stop Initiated</td>
</tr>
<tr>
<td valign="top" width="15%"><b>Remedy:</b></td>
<td width="85%">The hydraulic unit has indicated a fault. Check oil level. Check
pressure switch. <br />Clean filter if necessary.</td>
</tr>
<tr>
<td valign="top" width="15%"><b>Part number:</b></td>
<td width="85%">Hydraulic oil type: AAA. Pressure switch type: BBB <br /> Filter type CCC</td>
</tr>
<tr>
<td valign="top" width="15%"><b>Program continuation:</b></td>
<td width="85%">Machine restart required</td>
</tr>
</table>
<p></p>
</body>
</html>
The system is able to cross reference the highlighted alarm with the entry under the “a” tag.
<td width="15%"><b><a name="700001">700001</a></b></td>
The contents of the table containing the correct anchor are now displayed.
Adding further alarms to the HTML file is simply a case of copying/pasting the existing Table tag and its contents and editing
to suit the individual alarm.
The contents of the “Head” tag should be left as it is. This determines the content type and text format.
Notes :

B031
User Help Files continued Creating the help files/directories on the controller
The folders can be created directly on the controller or by using
Testing the help file on the controller the RCS Commander software package.
To test the Help file the alarm specified in the Help file should
be activated. Creating the help file folders on the controller:-
Alarm 700001 is activated by DB1600.DBX0.1
Locate the directory where the folders are to be created.
With the alarm active locate the “Alarms/Messages” screen. System CF-Card\oem\sinumerik\hmi\hlp
The alarm will appear in either the “Alarmlist” or “Messages”

screen depending how it has been configured.
If several alarms exist cursor to the alarm correct one.
Cursor to the “hlp” directory and select the “New” soft-key.
Select the “Directory” soft-key, this is usually already selected

The HELP function is activated by the “HELP” key located to by default.
the bottom right of the screen.
Enter the directory name, this is the language directory. Sev-

eral will have to be created help files are to be available for
more than one language. See previous page for language
specific folder names.
Below:-Creating a folder for English.
Notes :

B031
User Help Files continued Creating the help files/directories on an external PC
Highlight the new folder and select the “New” soft-key. As mentioned previously it is possible to create the directo-
ries/help files directly on the controller or offline using an AS-
CII editor (e.g. Notepad®). This is usually a more comfortable
method than stood at the controller. These files have to be
transferred to the controller and placed in the correct folders.
This can be done via the USB /CF Interfaces or with the RCS
Commander software.
The files need to be placed in certain folders on the controller.

The new directory has to be named The “sinumerik_alarm_oem_plc_pmc.html” has to be
“sinumerik_alarm_plc_pmc”. placed in any of the following:-
“System CF card\user\Sinumerik
\hmi\hlp\eng\sinumerik_alarm_plc_pmc”
“System CF card\oem\sinumerik
\hmi\hlp\eng\sinumerik_alarm_plc_pmc”
Creating the help file:-

Cursor to “sinumerik_alarm_plc_pmc” directory and select the
“New” soft-key followed by the “Any” soft-key. Alarm Log
A log of alarms that have occurred can be seen by selecting

the “Alarm protocol” soft key.
This shows the time when the alarm occurred and when it
was cleared.
Type in the help file name

“sinumerik_alarm_oem_plc_pmc.html“.
The file will automatically open in readiness for the HTML code
to be entered,
The file is closed with the following soft-keys:-
Notes :

B031
Alarm Log continued Time controlled: The log will be saved at the interval entered
in the Write interval area (max. 32000 seconds).
The “Display new” soft key is used to refresh the list and dis-
play any alarms that have recently occurred.
This option carries similar risk to the “At every event” option
and the same warning is displayed.
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 us- The controller needs to be restarted to make the changes
ing the cursor and select keys and confirmed with the “OK” effective.
soft key:-
Store log:-This allows the log file to be manually saved in a

file which can be retrieved and used for diagnostic purposes.
Number of entries:-
This sets the maximum number of alarms displayed on the
alarm log page.
Write mode file:-
The file destination is displayed at the bottom of the screen
Off: No storing of the log file will take place to the internal
for several moments after pressing the “Store log” soft key.
flash memory (Compact flash card)
At every event: Each time an alarm occurs this will be re-
corded to the compact flash memory.
Use the following soft key sequence to locate the log file:-
Use the “Cursor” and “Input” to locate the “alarm log” direc-
When this option is selected, a warning is displayed. By leav- tory.
ing this option permanently set, the life of the internal flash
card will be reduced.
The controller needs to be restarted to make the changes

effective.
Notes :

B031 END
Alarm Log continued
The file can be viewed by using the “Open” soft

key.
The file can be copied and pasted to other desti-

nations such as an external storage device. This
could then, for example be forwarded to techni-
cal personnel for assistance.
B031: END
Notes :

B058 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 faulty inputs or outputs to be software rewired.
Module Objective:
Upon completion of this module you will be able to use the 828D PLC viewer to diagnose PLC re-
lated problems. You will be able to rewire inputs and outputs using the ladder editor
Content:
Sinumerik
PLC Diagnostics
Interrupt Routines
B058
B058

B058
PLC Onboard Diagnostics: Description

PLC Onboard
Diagnostics:
START
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 faulty inputs or outputs to be software
rewired. PLC
Diagnostics
Interrupt
Routines
PLC Onboard
Diagnostics:
END
Notes :

B058
PLC Diagnostics Data Blocks (DB):-

Address Formats:- System Data Blocks are used for interfacing between differ-
ent areas of the controller and the User PLC Module B034
Bit- This refers to a single element of logic e.g. I6.0, Q5.5, describes this in more detail.
M100.6, V38040002.1. The user can also create Data Blocks.
The Bit part is the number after the decimal point. The value of
a bit is either 1 or 0. Data Blocks can be written in different formats e.g.:-
Byte- A Byte is a collective of 8 bits of logic in the same DB3804.DBX0.0 Data Block 3804 Bit 0.0
group. e.g. DB3801.DBX1000.7 Data Block 3801 Bit 1007.0
Input Byte 4 (IB4) contains the bits I4.0, I4.1, I4.2, I4.3, I4.4, DB3801.DBB1000 Data Block 3801 Byte 1000
I4.5, I4.6, I4,7. DB3804.DBW0 Data Block 3804 Word 0
When working with bytes it must be remembered that the DB3804.DBD0 Data Block 3804 Double Word 0
numbering counts up from the left as shown below.
IB4
Bit no 7 6 5 4 3 2 1 0 To locate the PLC status screens use the following soft key
Value 1 0 1 0 0 1 0 1 sequence.
In this example I4.0, I4.2, I4.5 & I4.7 are equal to 1. Another
term for being equal to 1 is that these bits are High.
The bits equal to 0 are termed as being Low.
Output Bytes (QB) and Marker Bytes (MB) can also be used in
the same way. By default the first page displayed is the “PLC-CPU” screen
contains information regarding the PLC project and cycle
Word- A Word is a collective of 16 bits of logic which encom- time information.
passes two consecutive Bytes.
A Word can only be addressed as 0 or an even number (IW0,

IW2, IW4 etc) odd numbers are not allowed. Operating Status
As with the Byte format the numbering starts from the right. Name: Taken from
Example IW4 the PLC828D project
name. Last Changed:
IB5 IB4 Last time the project
Bit no 7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0 was modified.
Value 1 0 1 0 0 1 0 1 0 1 1 1 0 0 1 1
Version Information:
In this example I4.0, I4.1, I4.4, I4.5, I4.6, I5.1, I5.2, I5.5, I5.7. Supplied by the sys-
tem.
are equal to 1.
Output Words (QW) and Marker Words (MB) can also be used
in the same way.
Cycle Time: The cycle
time of PLC-CPU
Double Word- A Double Word is a collective of 32 bits of logic processor.
which encompasses two consecutive Words (Four consecutive
Bytes).
Processing Time: The
time taken to process
A Double Word can only be addressed as 0 or an even number the PLC logic.
which is a multiple of four, (ID0, ID4, ID8, ID12 etc) odd num-
bers are not allowed.
The processing time information display can be
Example ID4 reset by the
IB7 B6 B5 IB4 “Reset pro. time” soft key
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 Double Words (QD) and Marker Double Words (MD) can
also be used in the same way.
Notes :

B058
Operating Status: The “Delete all” soft key will delete all entries on the list.
The operating status can be in Run or Stop mode, this is indi-
cated 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 Individual entries can be edited/deleted by using the Insert,
and start the PLC to clear PLC related faults. Delete and Cursor keys found on the keyboard.
PLC Run:-
For test purposes it may be necessary to manually change

PLC Stop:- (Force) an operand. This is achieved with the “Change” soft
key.
NC/PLC Status The operand in question has to be highlighted and the new
The status of the operands/variables used within the PLC value entered and confirmed with the “OK” soft key.
program can be checked via the “PLC Status” soft key.
The operands are typed into the left hand column. They can
be viewed in different formats. The format is changed by us- Changing M8.0 from 0 to 1.
ing the cursor key to highlight the letter in the “Format” col-
umn and then toggling with the “Select” key
B = Binary
D = Decimal
H = Hexadecimal
F = Floating point number (only for
Double Words)
The marker M8.0 should now have changed to a value of 1.
By using the “Operand +” and ”Operand -” soft keys it is pos-

sible to quickly locate a different operand in a similar range.
Notes :

B058
PLC Diagnostics continued The default screen shows all available variables. To find a
particular variable the “Filter/Search” function is available.
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 Filter
may occur. The Filter is available to narrow down the number of vari-
It is not possible to force operands which are being addressed ables on display. Cursor to the filter tab, the list is revealed
by the PLC program. by selecting the “Insert” key.
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.
Confirm the filter selection with the “Input” key.
Insert Variable
Search
The “Insert Variable” soft-key opens a list system variables Ensure the “Search” tab is highlighted and type all or part of
which can be directly selected for monitoring. 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 :

B058
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.
In the example shown the first axis is displayed by default,

this is seen determined by the values within the square brack-
ets.
[U1,1]
1 is for the 1st NC axis

2 is for the 2nd NC axis etc.
By selecting the “Operand +” & “Operand -” soft keys the vari-

able can be change to view different axes.
Type a suitable name for the file.
Further information about the variable can be displayed by

selecting the “Display Comments” and “Details” soft-key.
Confirmation of the file save is displayed above the horizontal

soft-keys for several seconds.
Notes :

B058
PLC Diagnostics continued
Load Mask: Previously saved files can be loaded using this

function.
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 cur-
sor keys.
A further method of checking the status of operands is via the

“Status list” soft key. The operands can also be forced via the
”Change” soft key.
Viewing the Ladder Logic:

The PLC program ladder logic can be seen by selecting the
“Window 1 OB1” soft key.
The default list of operands is shown in the above screen.

The “Set address” soft key allows this list to be configured.
Notes :

B058
Example:-Network 2 of SBR2 shown in absolute format.
The displayed block can be switched between “Absolute ad-

This opens up OB1 of the user PLC. The status of the PLC is dress” to “Symbolic address” via soft keys.
shown by selecting “Program stat. ON” soft key. The oper-
ands which are true are highlighted in blue. It is recom-
mended 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:-
By selecting the “Symbolic” option, the operands will be dis-

played with letter notation taken from the symbols table.
The “Absolute” selection will display numerical notation.
“Window 2 SBR0” is a second soft key for looking at the lad- Example:-Network 2 of SBR2 shown in Symbolic format.
der 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 dis-

played, 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.
Notes :

B058
PLC Diagnostics continued
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 dis-
played.
Further information can be displayed if the “Input” key is
pressed.
Default display.
Example:-The display at maximum magnification.

Display after “Select” key is
pressed.
The search function allows operands etc to be located easily
in the program.
Display after “Input” key is

pressed.
The display can be magnified via the “Zoom +” and “Zoom -”

soft keys.
By pressing the select key it is possible to choose between

“Find operand”, “Go to” or “Find subroutine command” in-
structions. Use the cursor keys to highlight the option re-
quired.
The “Select” key is used to expand the menu and reveal the
choices which are confirmed by the “Enter” key.
After typing in the search target it is possible to choose be-

tween “Find all”, “Search downwards” or “Search upwards”.
Example:-The display at minimum magnification.
Notes :

B058
It is also possible to search in the current program block or all Refer to the previous
program blocks. pages for examples of
search options.
Symbol Info
The symbol information for a network can be viewed by select-
ing the network followed by the “Symbol info” soft key
When the search parameters are correct the “OK” key is se-
lected to start the search.
A table will appear containing the symbol information for that

After a successful search the target will be highlighted by an particular network.
orange rectangle.
To search for further occurrences of the target the Due to space restrictions some operand names may be trun-
“Continue search” soft key is available. cated. To view the operand in full, use the cursor keys to se-
When all occurrences have been found a message lect the operand and then the “Select” key display.
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 information boxes are cleared with the “Back”

Soft key.
The “Find subroutine command” option is used for searching

for a specific instruction within the program.
Notes :

B058
PLC Diagnostics continued Saving the changes
Symbol table The changes now need to be loaded into the CPU:-
The “Symbol table” soft key allows different symbol tables to

be selected, the tables can also be edited here.
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”
A dialogue box is displayed momentarily and the PLC oper-

ating status is now in STOP.
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.
When the dialogue box clears the PLC has to be placed in

A combination of these soft-keys and the “Insert” key RUN.
is used to edit the symbol table
After approximately 30 sec. the Operating Status of the PLC

should change to run.
Notes :

B058
To rename the symbol table use the “Change symbol table”

soft-key.
The new entry should be visible when the symbol table is
viewed.
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.
Different symbol tables can be selected via the “Select sym.

table” soft-key.
Cross Reference
The “Cross ref.” function allows the user to see what operands
are in use and in which blocks they are used.
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 con-
firmed with the “OK” soft-key.
Operands can be located with the “Search” function or the

cursor keys.
The “Delete” soft-key” is used to remove any unwanted sym-

bol tables. The table is deleted immediately the soft-key is
pressed, no confirmation dialogue box is shown.
Notes :

B058
PLC Diagnostics continued 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 Arithme-
tic error in user program: Type 1 SBR3 network 1”.
This tells us that we need to examine network 1 of SBR3

(Subroutine number 3).
If the search target appears in the cross reference list more

than once, use the “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 When SBR3 is opened and network 1 examined it can be
“Open in window 2” soft-keys. seen that the “Divide” operation is attempting to divide 200
by 0, this is not permitted and so the PLC is put into stop
mode.
OR The program needs to be corrected and then loaded to the
controller.
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.
Notes :

B058
Interrupt Routines
Subroutines INT_100 and INT_101
While it is not possible to edit the PLC program on the controller, there is the 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
Process Image Table At the beginning of the scan, the status of the inputs is trans-
(Inputs) ferred to the Process Image Table.
Interrupt INT_100 Process Image Table (Inputs).
Main Routine OB1

Subroutine
Subroutine
Subroutine Subroutines are processed in the

order they appear in OB1.
Subroutine
Subroutine

Interrupt INT_101 Process Image Table (Outputs).
Process Image Table At the end of the scan, the status of the outputs is trans-
(Outputs) ferred to the Process Image Table.
End
of
Scan
The INT_0 interrupt block runs independently of

Interrupt INT_0
OB1.
It runs synchronously with the servo cycle. This
cycle time is very fast and could be used for ex-
ample with a fast turret where the signals need to
be decoded sooner than they can be achieved
with OB1.
it is recommended not to use it (see PLC design
document).
Notes :

B058
Interrupt Routines continued
Inserting the Subroutines
It is possible that the user PLC program does not contain the
interrupt blocks.
The blocks can be added via the controller providing General
Machine Data 19730[0] bit 25 is selected. To check the ma-
chine data use the following key selection:-
Interrupt Routine INT_100
The option to add interrupt block INT100 is given. Details can

be added to identify the author and indicate the purpose of
the block.
To display the individual bits use the “Select” key. Use the “OK” soft-key to complete the action.
Locate option bit 25, if the “Check mark” is not present as
seen below, use the “Select” key to enable the bit.
Press the “OK” soft-key to confirm.
The machine data is activated with an NCK reset.
The interrupt should now appear in the list.
To check/install the interrupt blocks use the following soft-

keys:- To add interrupt INT_101 the same procedure is followed.
OR
Use the “Insert” key to reveal the list under the „Number of
interrupt program” heading.
The list shows that the blocks are not loaded. To load the Select the number “101” with the mouse and press the “OK”
blocks select the “Add” soft-key. soft-key.
Notes :

B058
A number of choices are available:-
OR
For inserting or deleting networks.

Insert:- A network is added after the network that is high-
lighted.
Deleting:- The highlighted network is deleted.
The interrupt should now be shown in the “Program block” Networks are automatically re-numbered.
list.
To add logic to the block the “Line” in the network has to be

highlighted and the “Insert operation” soft-key selected.
To open a block first highlight it and then select the “Open”

soft-key. 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.
The selected block will open in readiness for editing. The operation now appears in the network.
The “Operand” soft-key should be pressed to assign the op-

eration an operand.
Type the name of the operand in to the box, in this example

I6.0 is used.
Select the “Edit” soft-key.
Notes :

B058 END
Interrupt Routines continued This function can be used in the event of a hardware failure
of the periphery components.
The value is confirmed with the “Input” key.
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 hard-

To add the next operation the next part of the network should ware and unnecessary editing of the PLC.
be selected with the cursor key and the “Insert Operation” soft-
key.
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
The available operations are limited to:- be carried out by trained personnel.
NOT
Positive Edge
Negative Edge Interrupt Routine INT_101
Standard Coil
Set Coil Editing of the INT101 interrupt routine is exactly the same as
Reset Coil. for INT100.
This example is using a standard coil.
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.
The operation should be assigned an operand e.g. I7.0. 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 hard-

ware and unnecessary editing of the PLC.
The save procedure should be carried out as with INT_100.
B058: END
Notes :

B053 Axis and Drive Diagnostics
Module Description:
In the event of a problem with the machine it may be necessary to check the status of an axis/
drive. The information obtained from these status screens can be very useful to technical person-
nel and help speed up the fault finding process.
Module Objective:
Upon completion of his module you will be able to use the Axis & Drive diagnostic functions.
Content:
Sinumerik
Service Overview Screen
Axis Diagnostics
Drive Diagnostics
B053
B053

B053
Axis and Drive Diagnostics: Description

Axis and Drive
Diagnostics:
START
In the event of a problem with the machine it may be neces-
sary to check the status of an axis/drive. The information ob-
tained from these status screens can be very useful to techni-
cal personnel and help speed up the fault finding process.
Service
Overview
Screen
Axis
Diagnostics
Drive
Diagnostics
Axis and Drive

Diagnostics:
END
Notes :

B053
Service Overview Screen The displayed axes can be changed to suit personal prefer-
ences.
To navigate to the relevant diagnostics page please use the
following key presses.
The “Active axes” soft-key will only display axes

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

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

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

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

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

perature problem on Axis 1.
Notes :

B053
Axis Diagnostics Drive Diagnostics
Axis specific information Drive specific information
For more detailed information regarding each individual axis For more detailed information regarding each individual drive,
select the “Service axis” soft key. select the “Service drive” soft key.
This detailed information is very useful when a problem oc-

curs 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.
The drive diagnostics screen shows useful information regard-

ing the motor and drive states such as motor temperature, DC
link voltage etc.
More diagnostics information is revealed by us-

ing the page/cursor keys
Further drive diagnostic information, specifically Sinamics re-

lated, 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 op

eration.
A drive object with a warning e.g. enable missing.
A drive object with a fault.

Useful information about the axis in question ranging from
positional data to current and torque readings is available.
Further information can be seen by using the page/cursor
keys.
Notes :

B053
Drive Diagnostics continued The “Status indicator” information indicates that the OFF1
enable signal is not present.
The CU is the only drive object displayed, to view the other The lower half of the screen offers further information.
drive objects press the “Input” key.
Use the “Drive object +” & “Drive object -” soft-keys to check

the status of other axes
A more serious situation is indicated by the appearance of

red cross symbol.
The following screen shows a healthy system, indicated by the Example– MX1 (Servo 1) axis showing a fault with encoder 1
green tick symbols. (SMI20).
The screen will display information regarding the cause of

the problem
Drives not ready or in a fault condition will display yellow or

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

B053
Two further soft-keys are also available for displaying further

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

information which indicates a problem with en-
coder 1.
The alarms and warnings can also be seen on the alarm

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

information which indicates a problem with en-
coder 1 Drive component 15.
The alarms displayed can be filtered via machine data 13150

“SINAMICS_ALARM_MASK”.
The “Help” key, found to the lower right of the vertical soft-
keys can be used to get more information about Warnings/
Faults.
Many alarms are generated when the system detects a com-

ponent error. The machine data is used to filter out alarms
which may be confusing. The default value is 0909 this sets
bits 0, 3, 8 & 9. For service and commissioning work it maybe
necessary to view more alarms. Setting the machine data to
FFFF will result in all alarms being displayed.
The default value should always be re-entered when the ser-
vice/commissioning work is complete.
Notes :

B053
Drive Diagnostics continued The component names can be changed to a more suitable
name if desired:
Topology
The topology of the drive system can be seen when the

“Topology” soft-key is selected.
Topology shows the DriveCLiQ interconnections of the drive
objects and components.
Example: Changing the name of SERVO 1 to X Axis.
Press the “OK” soft-key to confirm the changes, wait for the
dialogue box to clear.
The topology display can also be used to help identify faults.
CU (Drive object 1) is con-

nected via X100 to a motor
module (Drive object 2) socket
X200.
The topology display can be changed via the “Display op-

tions” soft-key:
When a drive object has a fault,

the text will be displayed in red
or grey.
Notes :

B053
Firmware: When the process is running the Top LED of the drives will
flash red. Other DriveCLiQ components will also indicate the
Firmware is a small software program that is written to the process in a similar way.
internal flash memory of the DriveCLiQ components. Firm- When the update has finished a complete power off/on of the
ware updates are used to keep the hardware up to date with controller/drives is required.
the latest technological advances. It is important that the
DriveCLiQ components are all of the same firmware version.
The firmware version is dependant upon the current system
software version.
Automatic Firmware Update:

When replacement drive hardware is fitted it is important that
the firmware version is correct. In normal circumstances the
system automatically loads the firmware to any modules not
at the correct firmware level. If the firmware is not automati-
cally updated the “Load firmware” soft-key can be used.
The configuration area has several further functions:
The Drive Object and Component names can be changed via

the “Change” soft-key.
Manual Firmware Update: The system assigns names to the objects/components. It is
The “Load firmware” soft-key located in the Configuration not always apparent from these names what the function of
area which is accessed via the “Configuration” soft-key. each object/component is.
Using more suitable names can help with object identification
in the event of a problem.
The changes are accepted when the “OK” soft-key is pressed.
Notes :

B053
Drive Diagnostics continued Display Settings
Electronic Rating Plates The level of displayed information about the components can
be controlled with the “Display options” function.
Useful information is displayed when the “Details” soft-key is
selected.
These are known as the ”Electronic Rating Plates”.
Example: Details of MX1 axis Motor Module:
Comparison Levels:
Some of the information on the screen can only be viewed by

using the cursor left/right keys.
Example: Details of MX1 Servo Motor:
To the right of the screen a column named “C.level” can be

seen.
This is used to set the comparison level for the DriveCLiQ
components.
The system compares the stored details of the electronic
rating plate of each object with the actual components con-
nected to the DriveCLiQ bus.
Once the drive system is configured it is continually moni-
The “Sort” soft-key is used to view the components in a par- tored. Alarms will be displayed if a fault occurs or an un-
ticular order according to Drive Object, Wiring, Component known object is detected.
number or Axis number:
Notes :

B053
To change the level of comparison select the “Change” soft-

key and then the “Insert” key.
The comparison level can now be se-

lected, the “Input” key confirms the se-
lection.
Comparison Levels:
High-Compares the complete electronic rating plate
Medium– Compares the component type and order number
Low– compares the component type
Minimum– Compares the component class.
Service case 1: If a new component is to be fitted to a sys-

tem to replace a faulty one it is not necessary to change the
comparison level. The system should automatically load the
Parameter r2 can also be used to view the status of the drives.
correct firmware to the new component.
Service case 2: If two existing components are to be inter-

changed to prove a fault e.g. Motor Module 1 & Motor Module
2, the system will detect this and issue alarms depending on
the setting of the comparison level.
In this case setting the comparison level to low would allow
the modules to be interchanged without alarms occurring.
Diagnostics Parameters
The status of the CU can be viewed via CU parameter r2.
When the parameter is highlighted and the select key is

pressed a list of operating status numbers and their meanings
is displayed.
B053: END
Notes :

B053 END

B084 Encoder Adjustment
Module Description:
All positioning axes require referencing in order for the controller to position them. The procedures
for the referencing of incremental and absolute encoders is described along with the most impor-
tant machine data.
Module Objective:
Upon completion of this module you will be able to synchronise/adjust the measuring system for
the Sinumerik 828D controller.
Content:
Sinumerik
Referencing Incremental Encoders
Referencing Absolute Encoders
Machine Data Information
Automatic Referencing
B084
B084

B084
Encoder Adjustment: Description

Encoder
Adjustment:
START
All positioning axes require referencing in order for the con-
troller to position them. The procedures for the referencing of
incremental and absolute encoders is described along with
the most important machine data. Referencing
Incremental
Encoders
Referencing
Absolute
Encoders
Machine
Data Infor-
mation
Automatic
Referencing
Encoder
Adjustment:
END
Notes :

B084
Referencing Incremental Encoders
General Information
Axes equipped with incremental encoders require referencing

each time that the NCK is powered off/on or reset.
This usually entails traversing the axis to a switch which then
initiates the referencing
Procedure. Certain machine data's are available to influence
this procedure and adjust it to individual requirements.
Some axes have a second encoder fitted for positioning op-
erations. It needs to be checked which measuring system is
active, as that will be the one which requires
referencing.
To check which measuring system is active we can look at the
“Axis diagnostics” area.
Machine data 30240[0] & [1] should be checked depending

Look for the “Measuring system 1 active” and “Measuring sys- upon the active measuring circuit.
tem 2 active”. A green tick symbol indicates which measuring If the active measuring circuit is number 1 then machine data
system is active for each axis., typically the motor encoder. A 30240[0] index 0 is active. If the active measuring circuit is 2,
2nd measuring circuit is typically a linear scale axes or an the machine data 30240[1] index 1.
encoder for a spindle. Incremental encoders =1
Some manufacturers may also switch between measuring Absolute encoders = 4
systems. If there is uncertainty about this please contact the
manufacturer for information. To reference an axis having an incremental encoder, an in-
terface 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 refer-

ence point approach variable.
Variable DB380x.DBX1000.7 “Delay Ref. Pt approach” inter-

face signal needs to be set to high to initiate the referencing
procedure.
Each axis has its own variable which is identified by chang-
ing the x for a numerical value which represents the axis,
see below-
If it is uncertain whether an axis has an incremental or abso- 1st axis - DB3800.1000.7
lute encoder fitted, this can be checked via axis machine data 2nd axis - DB3801.1000.7
30240. 3rd axis - DB3802.1000.7
To check the machine data use the following soft key se- etc.
quence.
Notes :

B084
Before referencing can be initiated the controller needs to be

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

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

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

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

ence switch. The direction is set up via machine data. .
The axis should now continue towards the reference switch.
Some systems require that the jog direction button is con-
tinually depressed throughout the reference cycle, it is more
common to find that the axis will continue to move even
when the jog direction button is released.
Notes :

B084
Example: Referencing diagram for incremental encoder
In the event of the values of machine data 34080 & 34090 equalling less than the stopping distance of the axis, the controller will
automatically readjust to the correct position.
34040 $MA_REFP_VELO_SEARCH_MARKER = 0
34080 $MA_REFP_MOVE_DIST + 34090 $MA_REFP_MOVE_DIST_CORR = > 0
Velocity
Reference point cam
switch activated
MD34020 Ref. point approach velocity
34070 Ref. point position velocity
MD34040 Ref. point search marker velocity
Position
Cam switch 1 0
Axis referenced. Marker pulse detected Reverse direction
The control receives a reference axis command, the axis accelerates to the feed-rate in machine data
34020 $MA_REFP_VELO_SEARCH_CAM then searches for the reference switch input to become high.
The reference switch is operated and the axis decelerates.
The axis reverses direction at the feed-rate set in machine data.

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

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

machine data 34070 $MA_REFP_VELO_POS to a position which is the sum of machine data 34080
$MA_REFP_MOVE_DIST and
34090 $MA_REFP_MOVE_DIST_CORR.
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.
The position display will indicate the axis is referenced and display any values stored in machine data 34100
$MA_REFP_SET_POS
Notes :

B084
Referencing Incremental Encoders continued 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.
Referencing Absolute Encoders

Check that machine data 34200 ECN_REFP_MODE is set
General information:- to 0 This enables the control to take over the value in ma-
Absolute encoders need referencing on first commissioning chine data 34100 $MA_REFP_SET_POS.
and remain referenced until a problem occurs with encoder or Check that machine data 34210 ENC_REFP_STATE is set
the NCK. Re loading of an archive will also necessitate the to 1. This is to enable encoder calibration to take place.
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.
upon the active measuring Check whether machine data 34010
circuit. REFP_CAM_DIR_IS_MINUS is set to 0 or 1.

upon the active measuring circuit.
If the active measuring circuit is number 1 then machine data
30240[0] index 0 is active. If the active measuring circuit is 2,
the machine data 30240[1] index 1.
Incremental encoders =1
Absolute encoders =4 The axis to be referenced should be moved to the known
mechanical position using “Jog” mode in the direction deter-
mined by the value of machine data 34010
REFP_CAM_DIR_IS_MINUS. A value of 0 and the ap-
proach will be in the positive direction, a value of 1 will make
the approach negative.
The feed rate when approaching this position should be re-
duced to avoid inaccuracies caused by backlash.
Before referencing can be initiated the controller needs to be

placed into Reference Mode by selecting the “REF.POINT”
button on the machine control panel. The LED should Illumi-
nate, the “JOG” mode LED remains illuminated.
Notes :

B084
Referencing Absolute Encoders continued Machine Data Information
Confirmation that the correct mode is selected can be seen at A list and brief description of the most common machine
the top of the screen. data.
If a machine does not have reference switch cam it is possi-

ble 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 refer-
ence 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.
Select the axis to be referenced and then press The initial approach speed for referencing is determined by
the same direction key used to position the machine data-
axis earlier. 34020 $MA_REFP_VELO_SEARCH_CAM (Default value
The axis will not physically move but the posi- 5000.0 mm/min)
tion display will change to show the axis is ref-
erenced symbol and the reference point set If the axis fails to reach the reference cam it is probably due
position will be shown as the position of the to machine data-
axis (150 mm). 34030 $MA_REFP_MAX_CAM_DIST (Default value 10000
Machine data 34210 will have changed to 2 to mm) This is the maximum distance to the reference cam.
indicate a successful procedure. 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 ma-
chine 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.
Notes :

B084
Automatic Referencing
Machine Data Information continued
Automatic referencing cycle
If the axis fails to reach the reference marker it is probably due
To set the automatic referencing function it has to be decided
to machine data-
in what order you want the axes to referencing. It is common
34060 $MA_REFP_MAX_MARKER_DIST (Default value 20
for example that on a milling machine the Z axis needs to be
mm) This is the maximum distance the axis can travel without
referenced first, this helps eliminate the chance of a collision.
finding the marker..
The order is set by axis machine data
The controller will issue alarm:-20002 Channel %1 axis %2
$MA_REFP_CYCLE_NR (Default 1)
zero mark missing.
Possible entries:-
0 = no referencing cycle participation.
When the marker is detected the axis will either stop or move
1 to 15 = allowable range for setting the sequence.
to a position determined by the values of two machine data
-1 = no reference required for Cycle start.
(34080 & 34090 see below for further explanation)
The speed at which this position sought is determined by ma-
Up to five axes can be referenced at the same time.
chine data-
34070 $MA_REFP_VELO_POS (Default value 10000.0 mm/
min).
34080 $MA_REFP_MOVE_DIST (Default value -2.0 mm).

Once the marker has been detected it is advisable to move
the axis away from the marker (Into the machining area). This
is achieved by putting a value in machine data 34080.
If the axis was asked to reference again while still on the
marker this could result in the axis going toward the end of the
slide.
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 to-
gether 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) To initiate the automatic cycle the necessary interface bit has
The value entered in here will be displayed on the screen as to be set. This is
soon as referencing is complete. This is used when the refer- variable DB3200.DBX1.0 which is channel related.
ence position is not the mechanical zero of the machine. The
machine data does not result in the axis physically moving. Example of how the automatic referencing cycle could be
initiated.
Interface signal DB3300.DBX1.0 changes to 1 while the ref-

erencing cycle is active.
B084: END
Notes :

B084 END

B009 Easy Extend
Module Description:
Easy extend is a system which gives the seller of the machine a mechanism to enable the hardware
options which are offered by the machine tool builder, without the necessity for service intervention.
A machine option could typically be a:
 Tailstock
 Parts catcher
 Barfeed
 Coolant filter
Module Objective:
Upon completion of this module you will be able write Easy extend scripts to enable and activate
machine builder options.
Content:
Sinumerik
General Information and Concept.

User PLC Program
Creating XML scripts
Enabling and Testing Devices
Example of XML Scripts
Creating and Restoring Rollback Archives.
Additional Axis
Addressing of variables.
General Tag Descriptions
Tag Descriptions - Dialogue Screens
B009

B009
East Extend: Discription
Easy extend is a system which gives the seller of the Easy Extend:
START
machine a mechanism to enable the hardware options Tag
which are offered by the machine tool builder, without Descriptions
the necessity for service intervention. Dialogue
Screen
A machine option could typically be a: General
Information
and Concept
 Tailstock
Easy Extend:
 Parts catcher END
 Barfeed
 Coolant filter
User PLC
Program
Creating
XML scripts
Enabling and
Testing
Devices
Creating and
Restoring a
“rollback“
archive
Additional
Axis
Addressing
of Variables
General Tag
Descriptions
Notes :

B009
General
 Each OEM option is assigned to an Easy Extend device.
 A maximum of 64 devices can be configured.
 The dealer can enable activate an option when it is purchased.
XML Files
Easy Extend uses Extended Mark-up Language.
The agm.xml file is the main file and entry point for Easy Extend.
All Easy Extend devices originate from the agm.xml file, this can include calls to other xml files to simplify the programming
structure.
The XML language used in the 828D is none standard and has been extended to allow the following data processing and high-
level language elements:-
 Archiving of NC/PLC data

 Reading and writing of NC/PLC/Drive data
 Conditional jumps within an xml block
 Execution of program loops
 Execution of arithmetic operations
 Creation of local variables
 Loading/creating archives
 Displaying messages
User PLC
Data Block EE_IFC (DB9905) is located in the PLC828D library and has to be integrated into the OEM´s PLC project.
Interface signals for activating and deactivating devices are to be found in the Data Block.
A user Data Block is required for password protecting devices.
Device Enabling
Devices first need to be enabled, this can be done using one of two methods.
Enabling by PLC variable:- A PLC variable is declared in the agm.xml file, the status of the variable is checked. This method is
used if the device is to be password protected.
Enabling by machine data:- A user machine data is declared in the agm.xml file. If the corresponding bit of the machine data is
ser the device will be enabled.
Device Activation
Once a device has been enabled it can be activated. Activation is done with a soft-key on the Easy Extend screen and with PLC
interface signals for acknowledgement.
Toolbox Examples
The 828D toolbox supplied with the controller contains various Easy Extend and PLC project examples which can be used to
supplement the information supplied in this module.
Notes :

B009
Easy extend Concept
Notes :

B009
An example of the Easy Extend screen from an actual machine showing some of the types of options which can be handled us-
ing the Easy Extend function.
Possible sequence to follow in order to use a builder Option.
ENABLE Device - with or without Password
STARTUP Device - 1st Startup of Device

With or without input parameters
ACTIVATE Device - To enable device useage
DEACTIVATE Device - To remove device
Notes :

B009
User PLC Program
The Data Block will now appear in the Data Block folder of the
project. Other Data Blocks may also be present.
Adding system data block DB9905 to the user PLC
For ―Easy Extend‖ to work a system Data Block (DB9905) is

required. The Data Block is found in the Library of the Pro-
gramming Tool and is used for the communication between
PLC and the HMI.
Data Block in the library of the PLC828 programming tool:
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 device status.
User PLC requirements
The example will require a user Data Block (DB9030) to be cre-

ated so that the defined and entered passwords can be compared.
The DB to be used is defined in the xml file with the ―password
refvar” tag. It is also possible to use the same DB to signal the
Double clicking the DB will open up the properties and allow HMI that the device is enabled. This is determined by the
the Data Class to be selected, also the author can enter ―OPTION_MD” tag.
details if required.
Right click on the Data Block folder and select ―Insert Data Block‖.
Select the ―OK‖ button:
Enter a suitable name and select the required Data Block

number. Select ―OK‖ to confirm.
The Data Block will now appear in the Data Block folder of the
project. Other Data Blocks may also be present.
Notes :

B009
The user DB will require certain information to be entered depending on the number of devices in use.
The following PLC example can be used for enabling and activating devices using a password and the PLC interface signals and
the previously created user Data Block.
Defining the required password as 123456
Comparing the entered password matches

defined password; enable signal is then set.
Fault reset on first power on.
Password reset on deactivation of the device.
Notes :

B009
Creating XML Scripts
The ―agm.xml‖ file is required for Easy Extend. Type in the name-‖agm.xml‖ (Lower case!) and confirm with
the ―OK‖ soft-key.
Only one file with this name is allowed, this file is required for
all Easy Extend devices.
It is possible to use separate xml files with Easy Extend. These
files are called from within the agm.xml file.
The xml files use tags, these tags are required for code
execution.
Executing script is written between tags, the script is written

after the ―open tag‖ and finishes at the ―Close tag‖.
Example:
<name of tag> “open tag”
Enter script in here Editing agm files using RCS Commander
</name of tag> “close tag with / slash”
Due to editing restrictions on the controller, editing the XML
Short Version <name of tag...Enter script in here…/> files offline and loading them to the controller using the RCS
commander is more practical.
The agm tag is the root element of the agm.xml.
All other tags are written inside this tag. Start RCS commander:
Creation of the xml file can be done in several ways depending

on personal choice.
In the following directory, directly on the controller or indirectly
using the RCS commander.
The required directory is found under the following path:

System CF card\oem\sinumerik\hmi\dvm
Locate the ―dvm‖ folder .
Use the following soft-key sequence to locate the syatem data
area of the controller
Notes :

B009
Enabling and Testing Devices Device Enabling
The following example shows how to configure Easy Extend Inputting the password:
Device 1 including the device is enabling/activation signals in To input the password first locate the ―Easy Extend‖ screen via
the user PLC. the following soft-key selection.
The name ―Test Password‖ is given to the device, the device
will be enabled with a user defined password
Rather than have one file containing all the code for many
devices, it makes sense to have one file for each device.
These separate files can then be called from within the
agm.xml file. The device created in the AGM file will be listed.
Example of an agm.xml file with ―include src‖ command (Blue
text for information only; orange text to be typed into the
―agm.xml‖):
<!Password example for device 1/>

<!Data block 9030 is required in the user PLC program/>
<AGM> Open the AGM tag
<OPTION_MD name = "plc/db9030.dbw0" index="0" />

<!OPTION_MD name = "plc/db9030.dbw2" index="1" />
OPTION_MD tag: To enable the device select the ―Enable function‖ soft-key.
Declaring the PLC variable for enabling the devi-
ces in user DB9030.
Index 0 - Devices 1 to 16 Bits 0 - 15
Index 1 - Devices 17 to 32 ― 0 - 15
Index 2 - Devices 33 to 48 ― 0 - 15
Index 3 - Devices 49 to 64 ― 0 - 15 The password (123456)needs to be entered.
<?include src= "Password_test.xml" ?>
Include src tag:

Call to the individual device xml files eg
―Password_test.xml‖
</AGM> Close the AGM tag
The xml files for each individual device should be placed in the The device will now be enabled, this is indicated by a green
same directory as the agm.xml file. tick in the ―Function‖ column.
Example: Password_test.xml ((Blue text for information only;
green text to be typed into the ―password_test.xml‖):
<DEVICE> Open the DEVICE tag

<list_id> 1 </list_id> Device number e.g. 1
<name> "Password Test" </name> Device name
<password refvar = "plc/db9030.dbd4" />
password_refvar tag:
The password entered on the Easy Extend screen
will be stored here i.e DB9030.DBD4
</DEVICE> Close the DEVICE tag
Power the controller off/on to activate the xml files
Notes :

B009
The device is enabled but it is not operational until it is activated. This is achieved by pressing the ―Activate‖ button.
A green tick symbol will appear in the ―Activated‖ column to confirm this.
When the activation is successful the ―Activate‖ interface signal will be high for one PLC cycle. This should be used in the PLC
logic to set the ―Activated‖ interface signal.
Defining the required

password:123456
Device enabled:
Entered password matches required
password, enable signal is then set.
Device activated:
Activation interface signal is set.
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
Device disabled:
Password no longer matches, enable signal = 0
Activation interface
signal is reset
Password is reset to zero by deactivate

interface signal
Notes :

B009
Message Box Test: Message Box Attributes:-
The agm.xml file has to be modified to include the new file:- text - The text to be displayed in the message box.
Using the characters ―%n‖ results in a new line.
<AGM>
caption - The header of the text box.
<OPTION_MD name = "plc/db9030.dbw0" index="0" />
<!OPTION_MD name = "plc/db9030.dbw2" index="1" /> retvalue -
<!OPTION_MD name = "plc/db9030.dbw3" index="2" /> Defines the variable where the return value is copied.
<!OPTION_MD name = "plc/db9030.dbw4" index="3" /> Return values– OK = 1, CANCEL = 0.
<?include src= "MessageBox_test.xml" ?> 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
</AGM> the usual way.
The “Set_Active” tag
The script within the Set_Active tag is run when the

―Activate” soft-key is pressed. Likewise, the ―Deactivate‖ soft-
key runs the script included in the Set_Inactive tag.
“MessageBox_test.xml”
<DEVICE>
<list_id>1</list_id>
<name> "Message box" </name>
<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>
<LET name = "var_return"> 0 </LET>

<MSGBOX text="Deactivate Option 1. %n Press
OK" caption="Deactivation of
Option" retvalue="var_return" type="BTN_OK" />
</SET_INACTIVE>
</DEVICE>
Notes :

B009
Switching on an output using the file When the device is activated the option to cancel is now avail-
“Write_PLC_output.xml” able
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 ―$actionresult‖ is set
to 0. This interrupts the processing of the function.
<DEVICE>
<name> "Write PLC output" </name>
<SET_ACTIVE>
<MSGBOX text="Activate Option 1. %n Press OK%n%
nAbort press Cancel" caption="Activation of Option" ret-
value="var_return" type="BTN_OKCANCEL" />
<IF>
<condition> var_return==1 </condition>
<THEN>
<DATA name = "PLC/Q4.7"> 1</DATA>
</THEN>
<ELSE>
<OP>"$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>
<DATA name = "PLC/Q4.7"> 0</DATA>
</THEN>
<ELSE>
<OP> "$actionresult" = 0 </OP>
</ELSE>
</IF>
</SET_INACTIVE>
</DEVICE>
Notes :

B009
The Test Tag To run the Test function first enter the ―Start up‖ area of the
This tag is used to check that the requested actions have Easy Extend area. The ―Function test device‖ soft-key should
been successfully achieved. In the example below the tag be pressed to initiate the test. A dialogue box will display the
has been used to check that the output Q4.7 is set to one. result of the test.
<DEVICE>
<name> "Write PLC output" </name>

Q4.7 = 1 Q4.7 = 0
<SET_ACTIVE>
<MSGBOX text="Activate Option 1. %n Press OK%
n%nAbort press Cancel"
caption="Activation of Option" ret-
value="var_return" type="BTN_OKCANCEL" /> The Form Tag
<IF> One custom screen can be defined for each device, this is
<condition> var_return==1 </condition> done using the form tag. The custom screen can include texts
<THEN> and bitmaps. Input fields can be linked to machine variables
<DATA name = "PLC/Q4.7"> 1 </DATA> allowing the operator to set machine parameters.
</THEN> The ―Addition. parameter‖ soft-key is reserved for the
<ELSE> instructions contained in the Form tag.
<OP>"$actionresult" = 0</OP>
</ELSE> Within the Form tag the following tags can be utilised:-
</IF>
</SET_ACTIVE> LET
INIT
<SET_INACTIVE> PAINT
<LET name = "var_return"> 0</LET> TIMER
<MSGBOX text="Deactivate Option 1. %n Press CLOSE
OK%n%nAbort press Cancel" CAPTION
caption="Deactivation of Option" ret- SOFTKEY_OK
value="var_return" type="BTN_OKCANCEL"/> SOFTKEY_CANCEL
<IF>
<THEN> Creating the picture_test.xml
<DATA name = "PLC/Q4.7"> 0 </DATA>
</THEN> The following example shows how a bitmap is selected and
<ELSE> positioned on the screen:-
<OP> "$actionresult" = 0 </OP> The bitmap has to be placed in the same folder as the agm
</ELSE> files.
</IF>
</SET_INACTIVE> <DEVICE>
<TEST> <list_id>1</list_id>
<IF> <password refvar="plc/db9030.dbd4"></password>
<condition> <name> "Picture Test" </name>
"PLC/Q4.7" == 1
The condition of Q4.7 is <FORM>
</condition> checked for a value of 1
<THEN> <init>
<op> "$actionresult" = 1 </op> If the above condition is true, <caption>Easy Extend Picture Test</caption>
</THEN> a value of 1 is written to the </init>
<ELSE> system variable $actionresult <paint>
<op> "$actionresult" = 0 </op> <img xpos = "155" ypos = "90" name =
</ELSE> If the condition is false, a "tiger.bmp" height="250" width="250"/>
</IF> value of 0 is written to system </paint>
variable $actionresult </FORM>
</TEST>
</DEVICE>
</DEVICE>
Notes :

B009
The script will result in a device named ―Picture Test‖ System variables
When the device is enabled and the ―Addition. parameter‖ soft-
key is selected, the ―tiger.bmp‖ picture will appear on the The following examples shows how R parameters can be
screen in the position specified by the IMG tag. The caption used:
―Easy Extend Picture Test‖ will be displayed in the title bar.
<DEVICE>
<name> "Picture Test" </name>
<password refvar="plc/db9030.dbd4"></password>
<FORM>
<init>
<caption>Easy Extend Picture Test</caption>
<control name = "r_param_0" xpos = "100" ypos = "30" refVar

= "nck/channel/parameter/r[0]" />




</init>
<paint>
<text xpos = "40" ypos = "30">R0</text>
<img xpos = "190" ypos = "120" name = "tiger.bmp"

height="180" width="180"/>
</paint>
</FORM>
</DEVICE>
The following screen shows the R parameters and the resized

image.
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.
Notes :

B009
These values can be checked in the ―User variable‖ area.
Values can be typed directly on the Easy Extend screen and

confirmed with the ―OK‖ soft-key.
It is possible to write to other system variables, addressing

these variables is described in Section 9.
Creating and Restoring a “Rollback” Archive
It is possible to create a complete NC/PLC/Drives/HMI archive

from within Easy Extend\IBN Start up area. This is achieved by
selecting the ―IBN Start-up‖
The ―Undo‖ and ―Repetition‖ soft-keys are available to switch soft-key. The fixed name for the archive is ―rollback.arc‖.
each single entry between its new and original value. If an error occurs while initialising a device, the ―rollback‖
archive can be used to return the controller to its original
status.
The ―IBN Start-up‖ soft-key is only available if the ―START_UP‖
tag is used within each individual device.
The ―START_UP‖ tag does not need to contain any instruc-
tions.
The ―Last configuration‖ soft-key is available to restore all the
entries to their original values. Example:
<DEVICE>
<name> "Archives" </name>
<password refvar="plc/db9030.dbd4"></password>
<START_UP>
</START_UP>
</DEVICE>
Notes :

B009
To create the archive:-
The archive is created with the following soft-keys
Acknowledge the confirmation bopx with the ―OK‖ soft-key
The dialogue box will clear when the read-in is complete.

An archive file with the name of ―Rollback.arc‖ will now be Additional Axis
created and stored in the ―dvm_rb‖ folder.
Activating and deactivating axes
A common requirement is for an extra axis to be added.

A machine can be initially commissioned to include all axis
possibilities. The optional axis can then be deactivated until
required.
An example of how axis number five is activated/deactivated is

shown below :
<DEVICE>
When the archive has been created the following dialogue box <name> "switch drive active" </name>
will be displayed, the device will be activated when the „OK― <password refvar="plc/db9030.dbd4"></password>
soft-key is selected.
<SET_ACTIVE>
<data name = "drive/dc/p105[DO5]">1</data>
<data name = "$MC_AXCONF_MACHAX_USED[4]">5</data>
<while>
<condition> "drive/dc/p971[DO5]" !=0 </condition>
</while>
<control_reset resetnc ="true" resetdrive = "true"/>
</SET_ACTIVE>
<SET_INACTIVE>
<data name = "$MC_AXCONF_MACHAX_USED[4]">0</data>
<while>
<condition> "drive/dc/p971[DO5]" !=0 </condition>
Restoring a “Rollback” archive </while>
<control_reset resetnc ="true" resetdrive = "true"/>
In the event that the previously created archive needs to be </SET_INACTIVE>
restored, the ―Restore‖ soft-key can be selected and the dia- </DEVICE>
logue box acknowledged.
Notes :

B009
After activation/deactivation, the system waits for drive Additional Axis continued
parameter ―p971 Save drive objects parameters‖ to become
zero (condition), an NC and drive reset is then carried out to
activate the changed machine data. The deactivated axis does not The deactivated axis does not
appear on the machine page: appear on the machine page:
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.
Addressing of Variables
Machine and Setting Data
The $ character must be used before the name of the data.
Machine data addresses:- $MX_<Name[index, AXyy]>

To activate/de-activate the axis in the NC part of the system,
channel machine data MN - General machine data
―20070 MC_AXCONF_MACHAX_USED‖ is used. MC - Channel machine data
The additional axis is the 5th axis therefore a value of 5 or 0 is MA - Axis machine data
entered into 20070[4] to activate/deactivate.
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:
Drive parameter ―P971Save drive object parameters‖ is set to Example:-

1 to save the drive Parameters. When the data has been Axis index with the index number obtained from the variable
saved the parameter automatically reverts to a value of 0. called ―axis‖. This would be written as AX$axis.
Examples:-
<data name=“$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
$MA_CTRLOUT_MODULE_NR, index 0.
Indirect addressing:-
<let name=“axisindex”>1</let> Declaring a temporary vari-
able called ―axisindex‖ and setting the value to 1.
<data name=“$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.
Notes :

B009
Addressing user data PLC Addressing
The GUD path is first specified followed by the specific area. If x = variable numeric identifier, b = Bit number.
a field is to be used, this follows next and is contained in
Inputs:- Ix.b Outputs:- Markers:-
square brackets.
IBx Qx.b Mx.b
The following GUDS can be addressed:- IWx
SGUD Siemens GUDS. IDx
MGUD Manufacturer (OEM) GUDS.
UGUD User GUDS. Data Blocks:- DBx.DBx.b
GD4 DBx.DBBx
GD5 DBx.DBWx
GD6 DBx.DBDx
GD7
GD8 Examples:-
GD9 <data name = “plc/mb200”> 1 </data> Writing a value of 1
to MB200
<data name = “plc/db9905.dbx2.4”> 1 </data> Writing a

Examples:- value of 1 to db9905.dbx2.4
<data name=“gud/channel/mgud/syg_rm[0]”>1</data>
Defining the channel <data name = “plc/q0.5”> 0 </data> Writing a value of 0 to
manufacturer gud - syg_rm, index 0 and writing a value of 1 to q0.5
it.
<op>“gud/channel/mgud/syg_rm[0]” = 5*2</op> The result NC Variables:-
of the multiplication of two numbers (5 x 2) is written to the
syg_rm[0] gud. <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 ―TempStatus‖.
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 drive index number can also be read from a local variable:
-
Example: Parameter p0970 with the drive object number ob-

tained from the variable called ―drive‖.
This would be written as p0970[do$drive]
Notes :

B009
Examples:- Special XML characters
<data name=“drive/cu/p0092”>1</data> Writing a value of
1 to the cu, p0092 Some XML editors can incorrectly display certain characters.
These have to be re-written.
<data name=“drive/dc/p0092[do1]”>1</data> Writing a
value of 1 to do1 p0092 The following characters are affected:-
Indirect Addressing:-
<let name=“driveIndex”>0</let> Declaring a temporary Character XML Notation
variable called ―driveindex‖ and setting the value to 0.
< < (Less than)
<op>driveIndex = $ma_ctrlout_module_nr[0, AX1]</op>
Reading the value of the NC variable (ctrlout_module_nr Axis > > (Greater than)
1) into the temporary variable (driveindex)
& & (Ampersand)
<data name =“drive/dc[do$driveIndex]/p0092”>1<data>
― " (Quotation)
Using the temporary variable to determine the drive object
number and writing a value of 1 into p0092. , ' (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)
&&, Logical AND opertaion

&&amp
+ 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.
Notes :

B009
General TAG Descriptions Tag Function
A condition used if the instruction was not ful-
Tag Function ELSE filled.(Used in conjunction with IF, THEN)
For the creation and restoring of archive files.
Main Tag, defines the device. All other
AGM Attributes:
tags are contained within this tag. Create=“true” - Command to create an archive
BREAK Conditional Interrupt. Name=“filename.arc” or “filename.ard”- File-
name
For reboot of the NC (resetnc) or Drive specified by user (.arc = complete archive, .ard
CON- = dataclass archive)
(resetdrive)
TROL_RES Class - Specifies that the archive will be a
Eg <control_reset resetnc=―true‖ />
ET ―Data class‖ archive.(Choice of User, Manufac-
<control_reset resetdrive=―true‖/>
turer or Individual)
For writing directly to the NC, PLC, GUD and If a class is not specified a standard archive
Drive areas. containing NC, PLC, HMI & Drive data will be
Attributes: name variable address created.
Group - Specifies the data groups to be in-
All alphanumeric values can be used as tag cluded in the archive.(Choice of NC, PLC, HMI
values. When writing directly from a local vari- & Drive data)
able the $ symbol should be used immediately FILE
in front of the variable name. Examples:-
DATA Examples: Read in a standard archive called
<data name=“plc/mb160”>1</data> (Writing ―complete.arc‖-
a value of 1 into mb160. <file name=”complete.arc/>
<let name= “tempvar”>7</let> (Declaring a Read in a data class archive called
variable named ―tempvar‖ and loading a value ―dataclass.ard‖-
of 7 into it.) <file name=”dataclass.ard/>
<data name= “plc/mb170”>$tempvar</ Create a standard archive called ―user.arc‖-
data> (Writing the contents of the variable into <file name=”user.arc create=“true” />
marker byte 170. Create a data class archive called ―user.ard‖-
<file name=”user.ard” create=“true”
For saving/restoring the listed drive and ma- class=“manufacturer individual user”
chine data. Up to 20 group=“nc plc hmi drv”>
addresses can be listed line by line. The archives are stored in the following path:-
Attributes: System CF
Action=“read” - saves the value of the vari- card\OEM\Sinumerik\HMI\DVM\Archives.
able into temporary memory.
The Form tag contains the user dialogue de-
Action=“append” - Attaches the value of the
scription. One dialogue is permitted per device.
listed variable to an existing list.
The ―Addition. Parameter‖ soft-key displays the
Action=“write” - writes the saved values into
user dialogue that is entered under this tag.
the machine data
Attributes:
Id=“name” - Label given to the temporary
color - Background colour of the dialogue
DATA_LIST memory screen.
Examples: Reading the values of R200, R201
label - Optional name for the form.
& R202 into the temporary memory called
FORM xpos - X Position of the upper left-hand corner
―name‖:-
of the dialogue box
<data_list action=“read” id=“<name>”>
ypos - Y Position of the upper left-hand corner
nck/channel/parameter/r[200]
of the dialogue box.
width - Extension in the X direction (Pixels).
height - Extension in the Y direction (Pixels).
</data_list>
Writing the values back into the listed machine
Example:- <FORM name=―dialog name‖
variables:-
color=―#ff000‖/>
<data_list action=“write” id=“<name>”>
Function call-Executes the functions within the
DEVICE Used to describe the device. ―name‖ attribute.
FUNCTION Attribute:
The version number of the drive is copied into Name - ―Name of the function body‖.
DRIVE
the $driveversion variable that is valid within Example:<FUNCTION name=―function name‖/>
VERSION the Device tag
Notes :

B009
Tag Function Tag Function
Contains the function body of a sub- Setting up of a local variable with a user
function. This should be specified name.
programmed within the AGM or DEVICE Attribute:
tags. Globally used name - variable name
functions should be set up in the AGM tag. type - The format of the variable can be
integer (INT),
FUNCTION Attribute: double (DOUBLE) or string (STRING). The
BODY name = ―Name of the function body‖ default of INT is
Example: assumed if no format is specified.
<FUNCTION_BODY name=“function Examples:
name”> <LET name=“variable_name”
… type=“STRING”/>
… It is possible to assign a value to the vari-
</FUNCTION_BODY> able eg 99:
LET <LET name=“variable_name”
ID Dialogue screen index of the device. type=“STRING”>99</LET>
NC and PLC variables can be saved in a
Conditional instruction (IF, THEN, ELSE) local variable using the ―=― operation. The
format of the local variable automatically
Used with the THEN and ELSE tags. takes the format of the NC/PLC variable.
Following the IF tag, a condition is de- Variable that are required to be globally
clared. If this condition is true, the THEN available should be set up directly after the
tag is executed. Should the condition be AGM tag.
false the ELSE tag will be executed. When used with a dialogue box, processing
Example: of the message opens up the correspond-
The following example checks IF MB120 ing DEVICE tag, this tag is closed after the
has a value not equal to 5. If this id true, the message is executed and as such deletes
THEN tag contains the instruction to load a all variables within the DEVICE tag.
value of five to MB120.
IF MB120 was already had a value of 5, the A message box is opened with this tag, the
IF THEN tag would be ignored and the code in return value can be used to make a branch.
the ELSE tag would be auctioned. Attributes:
text - The text to be displayed in the mes-
<IF> sage box.
<CONDITION> ―plcmb120‖ !=5 </ Using the characters ―%n‖ results in a new
CONDITION> line.
<THEN> caption - The header of the text box.
MSGBOX retvalue - Defines the variable when/where
<OP> ―plc/mb120‖ =5 </OP>
</THEN> the return value is
<ELSE> copied. 0 - CANCEL, 1- OK,
… type - Acknowledgement possibilities.
… ―BTN_OK‖ - OK button.
</ELSE> ―BTN_CANCEL - CANCEL button.
</IF> ―BTN_OKCANCEL‖ - OK or CANCEL but-
tons.
This tag is used to call other XML files from
within the AGM.XML. Execute instruction. For carrying out
INCLUDE Example:- mathematical
<?include src=―name of xml file to be in- Operations with system and temporary
cluded‖?> variables.
Examples:
For displaying a message specified in the Setting a temporary variable equal to PLC
tag. This can be used in the case of alarm OP system variable MB100
MSG numbers, the dialogue box would display <op> tmpVar=“plc/mb100” </op>
the text associated with the alarm number. Multiplying a variable by 2.
<op> tmpVar= tmpvar * 2 </op>
The NAME instruction defines the name of
Setting PLC system variable MB100 equal
NAME a device to be displayed in the dialogue
to a temporary variable.
screen.
<op> “plc/mb100”=tmpVar </op>
Notes :

B009
Text can be output in the dialogue line or This tag is used for the enabling of the op-
copied into a variable. tion.
Attributes:- Enabling via PLC machine data:-
name - Name of the variable where the text 14510 $MN_USER_DATA_INT[0] to
is to be saved (optional) $MN_USER_DATA_INT[3]
text - The text to be output. The devices are assigned to the machine
Values:- Number of variables whose val- data in logical order, each machine data
PRINT ues should be inserted in the text. handles 16 devices-
Format:- d Integer $MN_USER_DATA_INT[0] Devices 1 to
f Floating point value 16 (Bits 0 to 15)
s String “ “ “ “ [1] “ 17 to
Example: 32 (Bits 0 to 15)
<print name=―variable name‖ text=―text‖ % “ “ “ “ [2] “ 33 to
formatting‖> 48 (Bits 0 to 15)
variable..</print> “ “ “ “ [3] “ 49 to
64 (Bits 0 to 15)
Data within this tag is used to activate the Bit assignment examples:
SET_ACTIVE device.
$MN_USER_DATA_INT[0] bit 15 = device
16 $MN_USER_DATA_INT[2] bit 12 =
Data within this tag is used to de-activate
SET_INACTIVE the device. device 45
$MN_USER_DATA_INT[3] bit 1 = device
Data within this tag is used to commission 50
START_UP OPTION_MD Attributes:-
the device.
name - machine data address -
STOP Stops a sequence at this position $MN_USER_DATA_INT
Index - index of machine data - [x]
The switch tag allows the value of a vari- Example:-<option_md
able to be compared with a number of con- name=“$MN_USER_DATA_INT0[0]/>
SWITCH stants. If a match is found the value will be Enabling via PLC variable:-
written into the variable specified in the Example DB9030.DBWx.
DATA tag. When only devices 1 to 16 are in use, no
Used with the IF, & ELSE commands. See index is required:
THEN the description for IF <option_md name=“PLC/
DB9030.DBW0”/>
For Loop – This tag checks for a condition, When more than 16 devices are in use, the
if the condition is false, the loop will end. index must be specified:
Example:- Declaring a local variable as <option_md name=“PLC/DB9030.DBW0”
―count‖ with an initial value of 0. Set the index=“0”/>
condition to check that the variable is less <option_md name=“PLC/DB9030.DBW2”
than or equal to 7. Increment the count by index=“1”/>
increments of one. When the value of the <option_md name=“PLC/DB9030.DBW4”
variable is more than 7 (False) add 1 to the index=“2”/>
count value and place the result in output <option_md name=“PLC/DB9030.DBW6”
byte 10. index=“3”/>
FOR <let name=―count=0‖</op>
<for> When this tag is used for a device and the
<init> option is not set, a soft-key is available
<op> count=0 </op> which allows the entry of a password.
</init> The entered password is placed in the
<condition> count <= 7 </condition> specified variable and should be verified by
<increment> the user PLC. Acknowledgement of this to
<op count = count +1</op> PASSWORD the HMI is required using the relevant inter-
</increment> face bit (DB9030).
<op ―plc/qb10‖ = 1+count</op> Attribute:
</for> refvar - name of the reference variable.
Example: Declaring DB9030.DBD4 as the
target for the entered password-
<password refvar=“plc/db9030.dbd4”/>
Notes :

B009
Tag Function TAG Descriptions - Dialogue Screens
The interface signals are handled as stan- Tag Function

dard by DB9905. This tag allows the inter-
face to be re-defined. The Form tag contains the user dialogue de-
PLC_INTERFA scription. One dialogue is permitted per de-
Attribute:
CE Name - Address of the new interface. vice. The ―Addition. Parameter‖ soft-key dis-
Example: <plc_interface name=“address plays the user dialogue that is entered under
of the new interface”/> this tag.
The following tags are processed by the Form
With this tag a message will appear in- tag:-
structing the operator to power down the
POWER_OFF system. The message text is fixed by the LET
System. INIT
PAINT
VERSION Version Information TIMER
Used for testing that a device is functional.. CLOSE
The test result should be entered into the CAPTION
$actionresult variable. If the variable con- SOFTKEY_OK
TEST tains a value of one, then the device is SOFTKEY_CANCEL
FORM
functional. A value of zero indicates a
faulty device. Attributes:
color - Background colour of the dialogue
While Loop - This tag executes a se- screen.
quence of instructions for a multiple num- name - Optional name for the form.
ber of times providing that a certain condi- xpos - X Position of the upper left-hand corner
tion is true. The sequence is halted when of the
the condition becomes false. dialogue box
Example:- Set the condition that IB9 ypos - Y Position of the upper left-hand corner
WHILE should be equal to 0. Providing that this is of the
the case, write a value of 15 into QB11 dialogue box.
using the data tag. width - Extension in the X direction (Pixels).
<while> height - Extension in the Y direction (Pixels).
<condition> ―plc/ib9‖ ==0</condition>
<data name ―plc/qb11> 15 </data> Example:- <FORM name=―dialog name‖
</while> color=―#ff000‖/>
Do-While Loop - This tag executes a se- The INIT tag is executed immediately after the
quence for instructions and then checks for generation of the dialogue box. All the screen
a condition, if the condition is true, the in- INIT input elements and hotlinks should be written
structions will be processed again. The in here.
processing stops when the condition is
false. The PAINT tag is executed when the dialogue
Example:- Write a value of 15 into QB11 box is
PAINT Displayed. All texts and graphics for the dia-
using the data tag. Then check the condi-
DO_WHILE tion that IB9 should be equal to 0. logue box should be written in here.
Providing that this is the case, again write The CAPTION tag contains the title of the dia-
a value of 15 into QB11. When the condi- logue box and should be used within the INIT
tion is false, stop the loop. CAPTION tag.
<while> Example:- <caption> Title of Dialogue box </
<data name ―plc/qb11> 15 </data> caption>
<condition> ―plc/ib9‖ ==0</condition>
</while>
?UP Update Agent Syntax -
Notes :

B009
The CONTROL tag generates the control ele-
ments. If any integer value should be assigned to
Attributes:- an expression then the value=“value“ at-
name:- label of the field. The label also repre- tribute must be added to the tag. Instead of
sents a local variable. the consecutive numbering - the control
xpos:- X position of the upper left hand cor- variable now contains the assigned value of
ner. the item.
zpos:- Y position of the upper left hand cor- Example:
ner. <control name = "button1" xpos = "10" ypos
fieldtype:- Field type (Optional). = "10" fieldtype=‖ combobox ―>
―edit‖ - Data can be changed <item value = ―10‖ >text1</item>
―readonly‖ - Data cannot be <item value = ―20‖ >text2</item>
changed. <item value = ―12‖ >text3</item>
―combobox‖ - A drop down list with <item value = ―1‖ >text4</item>
text that can </control>
accept a value or be used for se- CONTROL Note: The hotlink attribute results in the
lection purposes. appropriate control being cyclically updated.
This means that if a value is entered, then
If no type is specified, the default is set to the next update cycle overwrites the value
―edit‖. that has been entered. In order to avoid this,
use the DATA_ACCESS tag to activate the
refvar – label of the reference variable that can function where entered data is immediately
be linked to the field. (optional) saved.
An additional possibility is to include the
hotlink – ―TRUE― the field is automatically SOFTKEY_OK tag in the form. This tag is
updated when data is changed (optional) then run before the dialog box is closed. In
this block - using the UPATE_CONTROLS
CONTROL format – formatting data, refer to the print tag instruction - data can be aligned between
(optional) the control and reference variables.
time – specifies the refresh rate of the data

(optional) The tag controls the behavior of the dialog
The following refresh rates are possible: screens when saving user entries.
―super fast― - refresh time < 100ms The behavior should be defined within the
―fast― - refresh time, approx. 100ms INIT tag.
―normal― - refresh time, approx 200ms If the tag is not used then the entries are
―slow― - refresh time, approx. 500ms always buffered.
If the combo box field type is selected then the Exception: The hotlink attribute is set to
expressions to be displayed also have to be true.
defined. The tag <item> should be used for
this purpose. The combo box saves the index DATA_ACCESS Attribute:
of the currently selected text in the variables type = "TRUE" – values that have been en-
belonging to the control (variable name). In- tered are not buffered. The dialog screen
dexing starts with the value 1. directly copies the values that have been
Syntax: entered into the reference variables.
<item>Expression</item>
Example: type = "FALSE" – the values are only copied
<control name = "button1" xpos = "10" ypos = into the reference variable when tag UP-
"10" fieldtype=‖ combobox ―> DATA_DATA type = "FALSE"
<item>text1</item>
<item>text2</item>
<item>text3</item>
<item>text4</item>
</control>
Notes :

B009
TAG Descriptions - Dialogue Screens continued Tag Function
Tag Function The tag is used to display an image/graphic at the
specified position.
The tag is used to display a text at the specified posi-
The bit maps in the BMP or PNG format should
tion on the screen. If the text is to be read from a text
be saved in the directory CF-Card/oem/
file, then the ―$$‖ character string should be placed in
sinumerik/hmi/dvm.
front of the label.
If the contents of a string variable are to be displayed,
Linux: Lower case letters should be used for all
then the ―$$$‖ character string should be located in
front of the variable. file names.
Syntax: Syntax:
<img xpos = "X position" ypos = "Y position" na-
<text xpos = "X position" ypos = "Y position"> Text </
me=―name― />
text>
Attributes:
IMG Attributes:
xpos - X position of the upper lefthand corner
xpos - X position of the upper lefthand corner
ypos – Y position of the upper lefthand corner
ypos – Y position of the upper lefthand corner
color – text color
Value: Text to be displayed name – bit map name
Example: Direct text output
Optional: If the display of an image/graphic devi-
<text xpos=―10― ypos=―20―> Hello World </text>
Example: Indirect text output with text from a file: ates from the original size then the dimensions
can be defined using the width and height attrib-
The text to be output should be set-up in the
oem_aggregate_eng.ts file, ―eng‖ specifies thst the utes.
file is the english version. The German version would
width – width in pixels
be ―deu‖. This should be changed to suit the language
of the controller. height - height in pixels
The file has to exist in the following directory:-

The tag draws a solid square at the specified po-
TEXT System CF card\oem\sinumerik\hmi\lng sition in the specified color.
Example of the file:-
<TS> Syntax:
<context> <box xpos="X position" ypos = "Y position"
<name>EASY_EXTEND</name> width=―X extension― height=―Y extension―
<message> color=―color code― />
<source>MY_TEXT_SYMBOL</source> BOX Attribute:
<translation>R2</translation> xpos – X position of the upper left hand corner
<chars>20</chars> ypos – Y position of the upper left hand corner
</message> width – extension in the X direction (in pixels)
<message> height – extension in the Y direction (in pixels)
<source>R3</source> color – color coding
<translation>RPAR3</translation>
<chars>20</chars>
</message> Dialog box message
TIMER
</context> The tag is cyclically executed.
</TS> Dialog box message
Example tag to be placed in the relevant xml file:- CLOSE This tag is executed before the dialog box is
<text xpos=―10‖ ypos=―20‖>$$MY_TEXT_SYMBOL </ closed.
text>
Example: Indirect text output with text form a vari- Using the tag, a variable is included in the cyclic
able: read utility (hotlink).
<LET name=―TextVar‖ type=―string‖> Hello World </ This tag is only valid within the INIT instruction of
text><text xpos=“10” ypos=“20“>$$$TextVar </text> a form.
REQUEST Attribute:
Name - address label
Syntax:
<REQUEST name = ―NC Variable― />
Notes :

B009
The tag synchronises data between the This tag overwrites the standard behavior
operator when a dialog box is closed using the
elements and the reference variables. "Cancel" softkey.
Attribute: The tag should be programmed in the first
type – the attribute defines the direction of sub-level of a form tag.
the data The following functions can be executed in
alignment. this tag:
TRUE – data is read out of the reference
UDATE_
variables and  Data manipulation
copied into the operator elements.
CONTROLS
FALSE – data is copied from the operator  Conditional processing
elements into the reference variables. SOFTKEY_  Loop processing
CANCEL
Syntax: Syntax:
<update_controls type="<direction>"/>
Example: Example:
<softkey_ok>
<update_controls type="false"/> <form>
</softkey_ok>
This tag overwrites the standard behavior <softkey_cancel>
when closing a dialog box using the "OK" <data name=‖plc/mb170‖>2</data>
softkey. </softkey_cancel>
The tag should be programmed in the first
sub-level of a form tag. </form>
The following functions can be executed in
this tag:
 Data manipulation
 Conditional processing
 Loop processing
Syntax:
<SOFTKEY_OK>
…
…
</SOFTKEY_OK>
SOFTKEY_OK Example:
<form>
….
….
<softkey_ok>
<update_controls type="false"/>
<let name="msgbox_result">0</let>
<MsgBox text="Execute NCK Reset!! " cap-
tion = "NCK Reset" retvalue =
"msgbox_result" type=
"BTN_OKCANCEL" />
<if>
<condition> " msgbox_result " == 1 </
condition>
<then>
<CONTROL_RESET resetnc="TRUE"/>
</then>
</if>
</softkey_ok>
</form>
B009: END
Notes :

B009 END

B020 Service Planner
Module Description:
The 828D controller has a Service Planner function which allows the user to set up maintenance
tasks. The tasks require an acknowledgement to confirm that the task has been completed, the
tasks are based on timed intervals. Each task has to be parameterised to suit the individual re-
quirements of that task.
Module Objective:
Upon completion of this module you will be able to set up maintenance tasks using the Service
Planner function.
Content:
Sinumerik
Enabling the Service Planner
Setting up the Maintenance Tasks
XML Data Files
PLC Interface Signals
Confirming/Resetting/Saving Tasks
PLC Programme Example
B020
B020

B020
Service Planner: Description Service

Planner:
START
The 828D controller has a Service Planner func-
tion which allows the user to set up maintenance
tasks. The tasks require an acknowledgement to Enabling the
confirm that the task has been completed, the Service
tasks are based on timed intervals. Each task has Planner
to be parameterised to suit the individual require-
ments of that task.
Setting up
the Mainte-
nance Tasks
XML Data
Files
PLC Interface
Signals
Confirming/
Resetting/
Saving Tasks
PLC
Programme
Example
Service
Planner:
END
Notes :

B020
Enabling the Service Planner
In order for the Service planner to function the PLC user pro-
ject must contain DB9903 and DB9904. These are created
with the PLC828 programming tool and then downloaded to
the controller.
To create the Data Blocks first open up the correct project and
open the Data Block folder.
Save the user project.

In this example the required Data
Blocks (DB9903 & DB9904) are not
present. Download the Data Blocks to the controller.
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.
Notes :

B020
Setting up the Maintenance Tasks
To set up a Maintenance task the password level needs to be

set to Manufacturer.
To locate the Service Planner screen use the following key

sequence.
To create a new task use the “New task” soft-key
Task information now needs to be entered
Input Field Explanation:- (All time values are in hours)
Maintenance Task: A brief description of the task

Interval:
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 follow-
ing:-
The Service tasks are entered by selecting the “Change”, “Interval” minus the “1st warning” divided by the “Quantity”.
“Cursor”, “Insert” & “OK” keys.
168 - 144
=3
8
To confirm the data, use the “Input” key, to navigate the dia-
logue boxes use the cursor keys. When the data required
fields have been entered press the “Enter” key.
Notes :

B020
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.
Below is the “oem_maintenance_data.xml” file containing the
data of the example used in Section 3.
The red clock symbol
Will be replaced with a green tick PLC Interface Signals
The data entered on the screen is stored in the data blocks

XML Data Files created earlier. This can be seen in the PLC diagnosis area:-
When a task is created the interval details are stored in an xml
file, the task names are stored in a language dependent ts file.
These files can be viewed and edited on the controller or off-
line.
Location of the Service Planner files:
For a task to have an effect on the controller the interface

signals have to be evaluated 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 re-
quired.
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 val-
ues to determine when the interface bits need
setting.
DB9903 uses four data words per maintenance task.
Notes :

B020
DB9903 Initial Data Table for Service Planner [r]
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 is continued up to Task 32.

252 Task 32: Quantity
254 Reserved
Data Block 9904 is used to report the status of the maintenance tasks.
DB9904 Actual Data Table for Service Planner [r]
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.
248 Task 32: Residual time (Hours)

252 Reserved
254 Reserved
Notes :

B020
User interface warning signals.

When the maintenance task is acknowledged the relevant interface bit will be set for one PLC cycle.
DB1800 Acknowledgement signals PLC -> HMI [r/w]

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. Ex-
ample: 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 HMI -> PLC [r]

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 PLC -> HMI [r/w]

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

B020
Confirming/Resetting/Saving Tasks
When a task has reached the time limit, it requires, depend-

ing on the task type, some kind of action is to be completed.
Once this is complete then the task can be acknowledged
and the time limits reset.
Only qualified personnel should reset the task after the main-
tenance action has been
completed. Simply resetting the task without completing the
task could result in
damage to the machinery. The „Reset all” soft-key will reset the remaining times
The user PLC program should trigger a PLC user alarm when for all the tasks.
a task has reached a time limit. If it is a pre-warning the mes-
sage response can usually acknowledged by the “Alarm Can-
cel” 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 Service Planner
screen, a red clock symbol should have appeared in the
“Status” column and the remaining time column will be zero.
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 time expiring.
Saving Service Tasks:

All the Service Tasks can be saved/read-in to/from an external
USB/CF memory device.
Exporting tasks:
The “Exporting tasks” soft-key is used to save the tasks.
Select the destination of the file e.g. USB and

then select the “OK” soft-key.
Once the maintenance task is complete then it can be ac-

knowledged by pressing the “Maintenance Completed” soft-
key.
The red clock symbol Enter a suitable name for the file and then select the “OK” soft
-key.
will be replaced with a green tick
This will reset the remaining 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 any time prior to
the interval time expiring.
Tasks can be changed or deleted at any time with the

“Change task” & “Delete task”
soft-keys.
Notes :

B020
Confirming/Resetting/Saving Tasks continued
A warning that existing files on the USB/CF device will be over-

written, select “OK” to
continue.
Reading in Service Tasks:

The “Importing tasks” soft-key is used to read in a task file.
The save procedure creates two files, one file is of the “xml”
type, while the second file is of the “ts” type. The “xml” has to
be selected for the import procedure, followed by the “OK” soft
-key.
The procedure will overwrite any existing tasks on the control-

ler, select the “OK” soft-key to continue.
Notes :

B020
PLC Programme Example
Below is an example of how to activate and reset messages using the Service Planner.
Setting the alarm
Setting the
message
Resetting the alarm
Resetting the mes-

sage
Deactivating the
service interval
B020: END
Notes :

B020 END

B018 Easy Messenger
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 be used to
influence the machine by means of changing PLC variables.
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.
Content:
Sinumerik
Activating the Modem
Configuring the Modem
Testing the Modem
Setting PLC variables via SMS
B018
B0018

B018
Easy Messenger: Description Easy

Messenger:
START
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 be used to
Activating
influence the machine by means of changing PLC variables.
the Modem
Configuring
the Modem
Testing the
Modem
Setting PLC
variables via
SMS
Easy
Messenger:
END
Notes :

B018
Activating the Modem To activate the modem machine data

51233 needs to be set to 1.
A SIM card is required which has to be fitted inside the Mo-
dem. To dismantle the
modem two clips have to be released.
Configuring the Modem
The modem setup screens are reached through the following

key combination:-
The SIM card slot can be seen below, once inserted the mo-
When the “Easy Msg active” soft key is selected the control
dem can be clipped back
will start to communicate with the modem.
together.
Slide the top part of the SIM

card holder in the direction of
the arrow and lift up.
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 transmis-

sion 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) The status of the connection will be displayed.
Q (Quality
C (Connection)
During normal operation:-

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

B018
Configuring the Modem continued
To identify the controller to the SMS recipient a name can be

added in the settings screen.
A limit on the number of SMS messages sent can also be A user profile must now be added.
entered. 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. Details about the recipient of the SMS messages should be
entered as well as the events which result in a message be-
ing sent.
The screen is navigated using the cursor and select keys.
The following example shows the user name of Fred Bloggs

has been entered with a phone number of +49123456789.
The User ID is a 5 digit number which is selected by the user
and is necessary for the setting of PLC variables by SMS.
The user will receive SMS messages when programmed
messages from the part program are initiated.
More information about some of the events can be seen by

pressing the “Details” soft key.
If the SIM card has a pin number active, it can be deleted with
the “Delete PIN” soft-key.
Notes :

B018
Testing the Modem
A test message can be sent to test the connection. “Send test

SMS” soft key.
The telephone number specified in the user profile will receive

a test message.
The user must now be activated, select the “User active” soft-
key and then the “OK” soft-key
The newly created user will appear on the screen.

A green tick appears before the name to indicate the user is
active.
The user profile can be edited or deleted, further profiles can Sending a message from a part program:
also be added. 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:-

A list of text messages that have been sent and received can
be seen when the “SMS Protocol” soft key is selected. MSG (“SMS: TYPE YOUR TEXT IN HERE”)
Then press “CYCLE START”
Notes :

B018
Testing the Modem continued The variable should also have changed to the requested set-
ting.
The text should then be displayed at the very top of the
screen.
A message containing the same text should then be re-
ceived by the designated phone.
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 suc-
cessful.
A record of these texts can be found in the alarm log page.
Setting PLC variables via SMS
The possibility is available to set a variable in the PLC via

SMS. 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.
B018: END
Notes :

B018 END

B011 Easy Screen
Module Description:
Easy Screen is a function of the Sinumerik 828D which allows the manufacturer to write custom
screens.
The screens are intended as an interface to the specific functions offered by the OEM
Module Objective:
Upon completion of this module the course participant will be able to
 Create Easy Screens.
Content:
Sinumerik
General Information
Basic Configuration Information.
Creating Easy Screen User Files.
Parameters and Variables Description.
B011
B011

B011
Easy Screen: Description

Easy Screen:
START
Easy Screen is a function of the Sinumerik 828D which allows
the manufacturer to write custom screens.
The screens are intended as an interface to the specific func-
tions offered by the OEM
General
Information
Basic
Configura-
tion
Information
Creating
Easy Screen
User Files
Parameters
and
Variables
Description
Easy Screen:
END
Notes :

B011
General Information Basic Configuration Information
The Easy Screen function is configured using ASCII files. Configuration files are used to create the screens.
These files contain the descriptions of the user interface. These configuration files are automatically interpreted by the
controller.
As standard, up to 5 screens can be configured. Further The files are not available as standard and have to be cre-
screens are available via a licensed option. ated by the user using an ASCII editor (e.g. Notepad® or
(Sinumerik Operate Runtime OA Easy Screen, order No directly on the controller).
6FC5800-0AP64-0YB0).
The “easyscreen.ini“ file is a master file which is required to
In order to create images for the screens, a graphic pro- specify which other files are to be used to create a user
gramme is required. Paint Shop Pro® and Paint® are pro- screen.
grammes which are compatible with the 828D controller. These files contain the information which determine what is
displayed on a particular screen.
Easy Screen can be used for the following functions: The screen is split into different areas:
1. Display of dialogs and provision of:
 Soft-keys
 Variables, (tables This function will be available with a
later level of implementation.)
 Text and help text
 Graphic displays and help displays
2. Calling up dialogs by means of:
 The (entry) soft-keys
 PLC selection
3. Dynamic re-structuring of dialogs:
 Changing or deleting soft-keys
 Defining and designing variable fields
 Showing, replacing and deleting (language-dependent/
independent) display texts 1 Main dialog area
 Showing, replacing and deleting display texts 2 Title bar containing screen name (Left) and
detailed variable
(Language dependent/individual)
description (Right)
4. Initiating actions when:
3 Variable input/output field
 Showing dialogs 4 Variable name-short description
 Entering values (variables) 5 Graphics related text
6 Unit text
 Pressing soft-keys
Closing dialogues Operating areas overview
5.. Exchange of data between dialogs.
6. Variables Operating area Permissible position for start softkeys
 Reading (NC, PLC, user variables)
Machine JOG HSK6
 Writing (NC, PLC, user variables)
Machine MDA HSK6
 Linking with mathematical, comparative or logic
operators Machine AUTO HSK6
7. Executing functions:
 Subroutines
Parameter HSK7
 File functions Program HSK6

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

B011
To enable custom screens in other area of the controller, the Creating Easy Screen User Files
“easyscreen.ini” file has to be modified.
There are eight areas in total:- The files required for the Easy Screen function need to be
created. This can be done directly on the controller by navigat-
Machine Area-Sub divided into:- ing to the relevant folders. Use the following key sequence to
Jog locate the “System data” area.
MDA
Auto
Parameter Area
Program Edit Area
Program Manager Area
Diagnosis Area
Start-up Area
The three Machine Areas are specified by the by “Screen”

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

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

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

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

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

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

startfile := startup.com
Notes :

B011
To create the file select the “New” soft-key and ensure that the The file needs to contain information about which soft-key is
“Any” soft-key is selected. to be used, the text for the soft-key and what is to be dis-
The any soft-key allows the file type to be determined. In the played on the screen.
dialogue box type in the name of the file and confirm with the The example will use the 7th horizontal soft-key and display
“OK” soft-key. the text “Easy Screen”. The screen will display R parameters
The file name must be in lowercase due to the LINUX operat- 0 to 3 with descriptive texts.
ing system.
Example:-
//S(START)
HS7=("Easy %nScreen")
PRESS(HS7)
LM("mask1")
END_PRESS
//END
//M(Mask1/"Workpiece Dimensions")
Def Var1=(R2///"Length of component","R0 X Length"///"$R
[0]")
Def Var2=(R2///"Width of component","R1 Y Width"///"$R[1]")
Def Var3=(R3///"Height of component","R2 Z Height"///"$R
[2]")
Def Var4=(I///"Main spindle speed","R3 Spindle speed"///"$R
The newly created file will be automatically opened in prepara-
[3]")
tion for editing.
VS8=("EXIT")
PRESS(VS8)
Example:-
EXIT
The following example will demonstrate how to place a selec-
END_PRESS
tion of R variables on a user screen accessed via a user soft-
key.
//END
The first step is to enter the header called “Startfiles” enclosed
in square brackets. Beneath this header we type the area of
To aid clarity, the file with the descriptions is shown below:
the controller where the start file is to be active
//S(START) Opens the dialogue for defining the soft-key
(AreaParameter) and the name of the startfile (param.com).
menu.
When the area in question is accessed the system will locate
HS7=("Easy %nScreen") Defining the text for horizontal soft-
the specified startfile and act upon the instructions typed within.
key 7 (HS7) as “Easy Screen” (%n = new line)
PRESS(HS7) When HS7 is pressed the load mask (LM) com-
[STARTFILES]
mand is processed.
StartFile04 = area := AreaParameter, dialog := SlParameter,
LM("mask1") In this example the system searches for
startfile := param.com
“mask1’ and acts upon the contents of this mask.
END_PRESS
Creating the “param.com” file on the controller
//END
The “param.com” file needs to be created. This can also be
//M(Mask1/"Workpiece Dimensions") Opens the dialogue for
done on the controller in the following paths/directories:-
“mask1” The name of the mask (Within the speech marks) will
“System CF card\oem\sinumerik\hmi\proj”
be displayed on the left of the title bar.
“System CF card\user\sinumerik\hmi\proj”
Def Var1=(R2///"Length of component","R0 X Length"///"$R
[0]")
“param.com” file example see next page.
Def Var3=(R3///"Height of component","R2 Z Height"///"$R
Creating the User Files on an external PC [2]")
Def Var4=(I///"Main spindle speed","R3 Spindle speed"///"$R
As mentioned previously it is possible to create the Easy [3]")
Screen files directly on the controller or offline using an ASCII
editor (e.g. Notepad®). VS8=("EXIT") Defines the text for vertical soft-key 8 as
The latter is usually a more comfortable method than stood at “EXIT”
the controller. PRESS(VS8) When VS8 is pressed, exit the screen.
These files have to be transferred to the controller and placed EXIT
in the correct folders. END_PRESS
This can be done via the USB /CF Interfaces or with the RCS //END
Commander software.
Notes :

B011
To see the results of the example we have to locate the Detailed Analysis
“parameter” area of the control.
Def Var1=(R2///"Length of component","R0 X Length"///"$R[0]")
R parameter 0 as a real number to 2 decimal places, sets the
component length:
The 7th horizontal soft-key contains the text specified in the

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

component width:
Def Var3=(R3///"Height of component","R2 Z Height"///"$R[2]")

component height:
To view the custom screen press the “Easy Screen” soft-key.
Def Var4=(I///"Main spindle speed","R3 Spindle speed"///"$R[3]")

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

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

B011
Parameters and Variables Descriptions
VS8=("EXIT") Determines the text for vertical soft-key 8 as
“EXIT”: When a variable is assigned certain properties can be set.
These properties are contained rounded brackets, each prop-
erty is separated by a forward slash (/)
If a property is not used, the slash still needs be present.
Basic description:
Checking the entered values DEF Var1=(1/2/3/4/5/6/7/8/9/10)
Values can be entered directly on the custom screen. These 1. Variable type
values are transferred directly to the variables. 2. Limit values, toggle field or table identifier
This can be checked by viewing the variables on the standard 3. Default
screen by pressing the “User variable” soft-key. 4. Texts
5. Attributes
6. Help display
7. System or user variable
8. Position of short text
9. Position of I/O field (Left, top, width, height)
10. Colours
Detailed description:
1. Variable type
R[x] Real number, “x” indicates the number of decimal
places displayed
I Integer.
S[x] String,”x” indicates the string length.
C Character (Individual character)
B Boolean number
V Variant type
2a. Limit values-

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

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

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

B011
DEF Var1=(1/2/3/4/5/6/7/8/9/10) 5. Attributes continued-
4. Texts- Font size:-
Text possibilities are- Attribute Effect
 Long text = text displayed when each element is high- fs1 8pt. font size (Default)
lighted. fs2 16pt font size
 Short text = name of the element
 Graphics text = text relating to the graphics, if used. The Clearance between lines is defined. The default font size
 Unit text = unit of the variable e.g. mm, rpm etc allows 16 lines. The graphics and unit text can only be
configured in the default font size.
The texts types are separated by commas and need enclosing
in speech marks:- /”Long”, “Short”, “Graphics”, “Unit”/ Limits:-
5. Attributes- Checking whether the value of the variable are is within the lim-
The following properties can be influenced by the attributes its specified by the limit values.
Input mode
Attribute Effect
 Access level
li0 No check.
 Alignment of short text li1 Check with respect to minimum
 Font size li2 Check with respect to maximum.
 Handling limit values li3 Check with respect to minimum and maximum.
 Response when screen is opened (Change block)
Behaviour when opening (Change block):-
The attributes are separated by commas, and are not valid for
toggle fields. Attribute Effect
cb0 The change block defined for this variable is
Input mode:- processed when the screen opens (Default)
Attribute Effect cb1 The change block defined for this variable is
wr0 I/O field invisible, short text visible. processed if there is a change in the value of the
wr1 Read only, no inputting of data, short text visible. variables
(Default setting)
wr2 Read & write possible, long and short text visible. The “cb” attributes, specified in the variables definition, take
wr3 As with wr1 but with I/O field visible, long and short precedence over the
text visible. globally specified attributes in the “screen form” definition.
wr4 All elements invisible.
wr5 As wr2 except entries are immediately active. 6. Help Display-
with wr2 the entry becomes active exiting the field
or pressing enter/input/return. The name of the PDF file containing the help text needs to be
typed in speech marks. The display appears automatically if the
Access level:- cursor is positioned on the variable.
Attribute Level Password/Key position
ac7 7 Not released 7. System or user variables-
ac6 6 SUNRISE
ac5 5 EVENING The variable to be viewed is entered here, these have to be
ac4 4 CUSTOMER contained within speech marks. The variable must be
ac3 3 Key switch pos 3 addressed in the correct way.
ac2 2 Key switch pos 2
ac1 1 Key switch pos 1 Addressing Variables.
ac0 0 Key switch pos 0
Machine Data Syntax
Alignment of short text:-
Attribute Effect Global machine data $MN_...
al0 Left justified (Default)
al1 Right justified Axis specific machine data $MA_...
al2 Centred
Channel specific machine data $MC_...
Notes :

B011
Setting Data 8. Position of short text
Global setting data $SN_... The Short Text defined in attribute No.4 positioned using
Axis specific setting data $SA_... parameter No.8.
The measurements are in pixels and relate to the top left
Channel specific setting data $SC_... corner of the main dialogue body.
System variable Three values can be entered to define the position from the left,
the position from the top and the width of the short text.
R parameter 1 $R[1] Each entry has to be separated by a comma.
PLC Data The following example would position the text “Short text” 200
pixels from the left and 100 pixels from the top with a width of
Byte y of bit z of data block x DBx.DBXy.z 250 pixels:
Byte y of data block x DBx.DBBy Def Var1=(R2///" ","Short text"///"$R[0]"/200, 100, 250//)
Word y of data block x DBx.DBWy 9. Position of I/O field
Double word y v. of data block x DBx.DBDy
The I/O field can be positioned and sized using parameter No.9.
String y with length z from data block x DBx.DBSy.z The measurements are in pixels and relate to the top left
corner of the main dialogue body.
Real y of data block x DBx.DBRy
Four values can be entered to define the position from the left,
Flag byte x bit y Mx.y the position from the top and the width and length of the I/O box.
Each entry has to be separated by a comma.
Flag byte x MBx
Flag word x MWx

The following example would position the I/O box for the
Flag double word x MDx defined variable, 600 pixels from the left and 100 pixels from the
top with a width of 100 pixels and a height of 150 pixels:
Input byte x bit y IBx.y
Def Var1=(R2///" "," "///"$R[0]"//600, 400, 100, 150/)
Input byte x IBx
Input word x IWx 10. Colours
Input double word x IDx The foreground and background colours of the I/O field can be
chosen by using parameter No.10.
Output byte x bit y QBx.y The default colours are foreground: Black, background: White.
These are determined by the “Write mode” (See parameter 5)
Output byte x QBx
Output word x QWx The following table shows index number to bused to
achieve the required colour.
Output double word QDx The foreground colour is defined first, followed by a
comma and the background colour:
Soft-key Status
Visible (Default) Se1 Index Colour

1 Black
Disabled (Grey text) Se2
2 Red/brown
Displayed(Last soft-key used) Se3 3 Dark green
4 Light grey
5 Dark grey
6 Blue
7 Red
8 Brown
9 Yellow
10 White
B011: END
Notes :

B006 Electrical Cabinet Design
Module Description:
Technological advances have resulted in the reduction in size of electronic equipment. The result
being that the equipment is more prone to heat, dust and moisture damage.
By calculating the power loss of the components and therefore ensuring the correct cooling
requirements of a particular cabinet, it is possible to reduce the failure rate of these and other compo-
nents.
It is also essential that the cabinets are designed to prevent/minimise the ingress of contaminants.
Module Objective:
 Upon completion of this module you will know the design criteria of electrical cabinets.
Content:
Sinumerik
Module Theory and Objective
Choice of Cabinet
Cabinet Cooling
Equipment Mounting.
Cables, plugs and sockets..
Cabinet Sealing.
Miscellaneous.
B006

B006
Electrical Cabinet Design: Description
Electrical Cabinet
Failure to construct an electrical cabinet to the Design:
requirements set out in this module will result in START
premature failure of electronic components.
This could be due to heat, dust moisture etc.
The following list shows the Seven Deadly Sins which Choosing a
must be avoided. Cabinet
Seven Deadly sins
The key to building a good electrical cabinet is avoiding

Arrhenius’
certain “Sins” which will cause
Law
premature equipment failure and sporadic faults.
 Sin 1 Cooling units must be able to handle the

heat generated by the electrical equipment. Cabinet
Cooling
 Sin 2 Air circulation must be controlled in a man-
ner which will prevent condensation forming and
must make use of the natural convection of warm
air.
Equipment
 Sin 3 Shielding of cables should be done with pur- Mounting
posely made clamps and not with a wire tail.
 Sin 4 Cabinets should be fully sealed including

unused cable entries.
Cables, plugs
and sockets
 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.
Cabinet
 Sin 6 Electrical cables must be routed so that Sealing
sensitive signal cables are kept separate from the
power cables.
 Sin 7 DC link bus-bar connections must be

tightened to the recommended torque. Miscellaneous
Electrical Cabinet
Design:
END
Notes :

B006
Choosing a Cabinet Cabinet Ambient Temperature
Most of the heat within an electrical control cabinet is produced The ideal ambient temperature for the cabinet is 35°C.
by the drive The cooling unit should be set to achieve this temperature.
components. If the temperature is allowed to get too high the lifetime of the
components will be reduced.
Sinamics drives are available in internally or externally cooled If the temperature is set too low there is a risk of condensation
variants. forming on the electronic components which can also be
The internally cooled drive types dissipate heat within the detrimental to the equipment.
cabinet and will usually require a cooling unit to remove this
heat.
The externally cooled drive types dissipate heat to the outside
of the cabinet and may not require cooling units.
It may be preferable to always use cooler units as this allows

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

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

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

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

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

B006
Arrhenius Law
The following graph demonstrates Arrhenius Law and shows the effects that increased temperature has on the lifetime of elec-
tronic components.
It can be seen that an increase in temperature by 10 will result a 50% increase in the failure rate (50% reduction in life time).
Expected
Life Defect
Time Rate
120% — 9.00
— 8.00
100%
— 7.00
80% — 6.00
— 5.00
60%
— 4.00
40% — 3.00
— 2.00
20%
— 1.00
0% — 0.00
-10K -5K 0K 5K 10K 15K 20K 25K 30K
Temperature Change
Notes :

B006
Cabinet Cooling. Cabinets with cooling units.
Cabinet cooling is usually accomplished using fans and filters Correct installation of cooling units.
or cooling units.
The cool air should be directed to the bottom of the drive. The
The fans and filter option would normally be used on low internal drive fans and natural convection will draw the air
power installations or where the drive units are of the through the drives.
externally cooled type.
A drawback of this method is that the fans pull air from outside The cool air from the cooling unit should not be directed
the cabinet via filters. Even if the filters are serviced regularly it straight onto/into the drives, it should be allowed to mix with
is impossible to keep all contaminants out of the cabinet. the warmer air already in the cabinet, This will minimise the
risk of condensation forming.
Cooling units allow the cabinets to be air-tight as the air within
the cabinet is re-circulated through the cooling unit. Cabinet top mounted cooling units require a method of direct-
A thermostat should be employed to regulate the temperature ing the cool air from the cooling unit to the bottom of the
to the recommended 35°C. drives.
If a higher temperature is unavoidable (max 50°C) the drive
units have to be de-regulated. In the case of a door mounted unit it may be necessary to
direct the cool air with the use of baffles.
It is important to position the cabinet and cooling devices to
ensure correct operation. Example of cabinet cooling with roof mounted cooling units:
A cabinet placed in such a position where it restricts the venti-
lation inlet/outlet can prevent the cabinet from being cooled
correctly or result in the cooling unit becoming damaged due
to excessive work cycles.
The cooling device should also be positioned to ensure the Outlet Cooling
cool air is reaching the desired areas and that the warm air is unit
extracted and not allowed to cause hot spots within the cabi- Inlet
net.
The inlets and outlets of the cooling units must have a

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

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

B006
Example of cabinet cooling with door mounted cooling units: Cabinet cooling sins.
The following diagrams are examples of cabinet cooling sins:
Outlet Cooling
unit
Inlet
Outlet
≥ 200mm Cooling
unit Air short circuit due
Drive to lack of ducting
equipment
Baffle
Temp.
Meas. Drive
point Inlet equipment
Cabinet door mounted cooling unit.
It is advisable that the cooling units are switched off

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

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

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

possible contamination such as coolant, machine waste etc.
Notes :

B006
Cabinet cooling sins continued. Cabinet cooling sins continued.
Air intake restricted due to

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

onto drive equipment will Warm air intake at the
cause condensation prob- bottom of the cooling
lems. unit.
Wrong type of cooling unit used.

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

cabinet sealing problems
Notes :

B006
Cabinets Without Cooling Units
For cabinets with externally cooled drive units it is possible that

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

B006
Equipment Mounting
Example:- Externally cooled
The correct mounting of equipment is important with respect drive module heat-sinks
to the cooling process and for Electromagnetic compatibility protruding from the rear of a
measures. cabinet with a cut-out ready to
accept another module.
Air flow to drive units:-
It is essential that the air flow to the drive units is unrestricted.

Other electrical
equipment, including cable ducting and 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.
Examples: Correct mounting methods for drive equipment.
Cable
ducting Example:- Externally cooled
drive modules with heat-sink
≥ 80mm cover and fan/filter.
The fan takes air in at the
bottom and the cover creates
a chimney effect to give a
good cooling effect.
Drive
equipment
≥ 80mm
Cable
ducting
Diagram showing minimum Photograph of correctly

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

B006
Equipment Mounting continued.
Example of a filter, reactor and line module installation.
Electromagnetic Compatibility (EMC)
To cut down on the interference effects caused by the high

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

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

Example: How shielded cable can be grounded.
Notes :

B006
Equipment mounting continued
A typical cabinet layout demonstrating the close proximity of the filter, reactor and line module in order to reduce the interference
effects of the high frequency drive current.
The use of shielded cables is also necessary to further eliminate this Interference.
Shielding plates offer the best method for grounding the shields.
The power cables and the signal cables should also be run separately from each other throughout the machine and not just in
the electrical cabinet.
It is not permissible to connect any other equipment between the line module and the filter and reactor.
Remaining
Equipment
Filter
Shielded DriveCliq
Cables
Shielded Power Cables
Comb Power Module Add.

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

≥ 100mm grounding the shields
Shielded Power Cables

Shielded Motor Cables
Notes :

B006
Cables, Plugs and Sockets. Example: An Incorrectly shielded cable
Shielding
Shielded power cables are recommended between the Sinam-

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

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

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

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

Example: Correctly shielded cables
With plugs and sockets
Notes :

B006
Cabinet Sealing
Cables, Plugs and Sockets.
A cabinet that isn’t sealed correctly can lead to a multiple of
Cabling Sins problems. Poor Sealing can be caused by cable entries, poorly
fitting doors, etc.
Encoder and power cables in close proximity: 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
Encoder and motor cables in close proximity.
Bottom
Notes :

B006
Miscellaneous
Coil Suppression
Poor Electromagnetic compatibility can also affect other

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

B006: END

Appendix A Hardware Differences
Contents:
Appendix A: PPU Differences (IDC & SOC2 Drive Controllers)

Sinumerik
Appendix A
Appendix A PPU Differences (IDC & SOC2)
Basic Information: 828D controller with integrated PPU (Panel Processing

Unit)
Sinamics Drive Controller Types:

PPU260/280 Vertical variant 10.4” TFT Colour Screen.
The IDC type drive controller has been superseded by the
SOC2 drive controller.
This has made it necessary to change the design of the 828D.
The IDC controller is for use only with software version 2.x
The SOC2 controller is for use only with software version 4.x
Version Information:
PPU26x.1 and PPU28x.1: Compatible only for version 2.x

software.
PPU24x.2, PPU26x.2 and PPU28x.2: Compatible only for

version 4.x Software.
PPU261/281 Horizontal variant 10.4” TFT Colour Screen.
Technology:
PPU26x.x and PPU28x.x: Technology is determined by the

software contained on the system CF card.
The milling and turning variants are identical when viewed
from the front and rear.
PPU24x.2 : Technology determined by the controller hardware

type and the software contained on the system CF card.
The milling and turning variants are labelled on the top right
corner of the front face of the controller (BASIC M or BASIC
T). PPU240 Horizontal variant 8.4” TFT Colour Screen:
Sinamics Drive Component Compatibility:
It is important that the drive component versions are compati-

ble with the software version.
Version 4.x can only be used with the following drive compo-
nent versions (Numbers relate to the last four digits of the Sie-
mens part number e.g. 6SL3120-2TE13-0AA3):
S120 Booksize Motor and Infeed modules: xxA3

PPU241 Vertical variant 8.4” TFT Colour Screen:
SME2x Sensor Module External: xxA3
SMC30: Sensor Module Cabinet: xxA2
All other components (e.g. SMC20) are not affected.
Notes :
Appendix A Page 2 SINUMERIK 828D

PPU Differences (IDC & SOC2) Appendix A
Interface locations: Interface locations:
Version 2.xx IDC Hardware. Version 4.xx SOC2 Hardware.

(PPU26x.1 & PPU28x.1) (PPU24x.2, PPU26x.2 & PPU28x.2)
Internal (System) CF card location. Internal (System) CF card location.
Fault
X100 Sync PN
X101 Fault PN
Sync
Rx/Tx X130
X102 Link
X140 X135
X122
X132
X242
X252
X143
X1
M T1 T2 T3
Interfaces for 828D V4.x:
Interfaces for 828D V2.x: X1 +24V DC supply
X1 +24V DC supply X100 DriveCliQ interface for line/motor modules

X100 DriveCliQ interface for line/motor modules DriveCliQ interface for Combi Dive
X101 DriveCliQ interface for DMC module
X102 DriveCliQ interface for NX10 module X101 DriveCliQ interface for DMC module
X120 Profinet interface DriveCliQ interface for Compact Motor Modules
X121 Profinet interface (When used with Combi drive)
X130 Ethernet-Factory network
X135 USB interface X102 DriveCliQ interface for NX10 module
X140 RS232 interface for modem only (Not Combi or Basic versions)
X122 Digital I/O for Sinamics DriveCliQ interface for TM54 Terminal Module for
X132 Digital I/O for Sinamics Safety Integrated signals.
X143 Interface for two Hand-wheels X130 Ethernet-Factory network
T0 Analogue output measuring socket X135 USB interface
T1 Analogue output measuring socket X140 RS232 interface
T2 Analogue output measuring socket X143 Interface for two Hand-wheels
M Electronic ground for analogue measuring sockets X122 Digital I/O for Sinamics
X132 Digital I/O for Sinamics
PN Profinet interface
PN Profinet interface (Not on 828D Basic M/T)
M Electronic ground for analogue measuring sockets
Notes :
SINUMERIK 828D Page 3 Appendix A

Appendix A PPU Differences (IDC & SOC2)
Digital I/O Interfaces
The interfaces for the digital I/O functionality has changed. The
v4.x interfaces now have 14 terminals compared with the v2.x
which have 12 pins.
An extra interface (X252) for digital NC I/O is present on V4.x
hardware.
V2.x Digital I/O Interfaces:
X122, X132 and X142
V4.x: Digital I/O Interfaces:
X122, X132, X242 and X252
Please refer to modules B010 & B030 for a detailed description

of the terminal functionality.
Notes :
Appendix A Page 4 SINUMERIK 828D

Appendix B Technology Settings
Content:
Appendix B:The Technology settings for Milling and Turning machines

Sinumerik
Appendix B
General Machine Data
MD No. Machine Data Description Old MD/GUD
51000 DISP_RES_MM Display resolution in mm
Appendix B
51001 DISP_RES_MM_FEED_PER_REV Display resolution in mm feedrate/rev
51002 DISP_RES_MM_FEED_PER_TIME Display resolution in mm feedrate/min
Appendix B
51003 DISP_RES_MM_FEED_PER_TOOTH Display resolution in mm feedrate/tooth

51004 DISP_RES_MM_CONST_CUT_RATE Display resolution constant cutting speed m/min
51010 DISP_RES_INCH Display resolution in inch 9011
51011 DISP_RES_INCH_FEED_P_REV Display resolution in inch feedrate/rev
51012 DISP_RES_INCH_FEED_P_TIME Display resolution in inch feedrate/min
51013 DISP_RES_INCH_FEED_P_TOOTH Display resolution in inch feedrate/tooth
51014 DISP_RES_INCH_CUT_RATE Display resolution constant cutting speed ft/min
51020 DISP_RES_ANGLE Display resolution of angle
51021 DISP_RES_SPINDLE Decimal places in speed entry field 9010, 9664
Page 2
51022 DISP_RES_ROT_AX_FEED Display resolution of rotary axis feedrate
51023 ACT_VALUE_SPIND_MODE Only display spindles in actual values window
This affects the display of the spindles in the axis actual values window.
0 = Spindles are always displayed
1 = Spindles are displayed only if in axis mode
((This affects the display of the spindles in the axis actual values window.
0 = all spindles are displayed
1 = only those spindles in axis mode are displayed)
51025 FRAMES_ACT_IMMEDIATELY Active data (frames) are activated immediately after change 9440
51026 AXES_SHOW_GEO_FIRST When the machine data value is 1, the geometry axes of the channel are displayed 9421
first.
51027 ONLY_MKS_DIST_TO_GO Distance-to-go display in work window 9420
51028 BLOCK_SEARCH_MODE_MASK Bit mask for available block search modes
Bit 0: Block search with calculation without approach
Bit 1: Block search with calculation with approach
Bit 2:
Bit 3: Skip EXTCALL programs
Bit 4: Block search without calculation
Bit 5:
SINUMERIK 828D

51029 MAX_SKP_LEVEL The machine data defines how many skip levels are made available for operation. 9423
SINUMERIK 828D
51030 SPIND_MAX_POWER Maximum value of the permissible spindle power rating in percent; the display bar in the 9428
machine image is shown in green within the range between 0 and the value stored in
SPIND_MAX_POWER.
51031 SPIND_POWER_RANGE Scale end value for spindle power rating in percent; value must be equal to or greater than 9429
SPIND_MAX_POWER.
The display bar in the machine image is shown in red in the range between the values of
SPIND_MAX_POWER and SPIND_POWER_RANGE.
51032 STAT_DISPLAY_BASE Number basis for display of articulated joint STAT 9042
00: no display
02: binary value display
10: decimal value display
16: hexadecimal value display
51033 TU_DISPLAY_BASE Number basis for display of rotary axis position TU 9243
00: no display
Page 3
02: binary value display
10: decimal value display
16: hexadecimal value display
51034 TEACH_MODE Teach mode to be activated 9026
Bit 0: Default teach-in
Taught-in block is transferred to the program using the Accept softkey.
Bit 1: Acceptance of teach block can be blocked by the PLC.
DB19.DBX13.0 = 0 block is accepted.
DB19.DBX13.0 = 1 block is not accepted.
Bit 2: Block selection only explicitly
Bits 16-31 Reserved for OEM.
51035 WRITE_FRAMES_FINE_LIMIT Input limit for all work offsets fine
51036 ENABLE_COORDINATE_REL Display REL coordinate system
0 = no relative coordinate system selectable
1 = REL coordinate system can be selected as an alternative of the WCS/SZS coordinate
system
51037 ENABLE_COORDINATE_ACS Activate settable coordinate system 9424
0 = WCS coordinate system is displayed.
1 = SZS coordinate system is displayed.
(SZS is WCS reduced by the offset components defined in MD24030)
Appendix B
Appendix B

51038 SET_ACT_VALUE Set actual value selection 9422
Appendix B
0 = Set actual value is not offered.
1 = If a user frame (settable work offset e.g. G54) is active, it will be used. In G500 Set ac-
tual values is not offered (system frame is no longer used).
Appendix B
51039 PROGRAM_CONTROL_MODE_MASK Options for machine - program influence:

Bit 0: Program test function available
51040 SWITCH_TO_MACHINE_MASK Automatic operating area switchover to machine
Bit 0: When selecting a program in the program manager, the operating area does not auto-
matically switch over to Machine.
Bit 1: When switching the type of operation via the MCP, the operating area is not automati-
cally switched over to Machine.
51041 ENABLE_PROGLIST_USER Activates the PLC program list of the USER area. The programs entered there can be se-
lected by the PLC for processing.
51042 ENABLE_PROGLIST_INDIVIDUAL Activates the PLC program list of the INDIVIDUAL area. The programs entered here can be
selected by the PLC for processing.
51043 ENABLE_PROGLIST_MANUFACT Activates the PLC program list of the MANUFACTURER area. The programs entered here
Page 4
can be selected by the PLC for processing.
51044 ACCESS_SHOW_SBL2 Display protection level SBL2 9227
51045 ACCESS_TEACH_IN Protection level TEACH IN 9219
51046 ACCESS_CLEAR_RPA Protection level delete R variables 9221
51047 ACCESS_READ_GUD_LUD Read user variable protection level 9211
51048 ACCESS_WRITE_GUD_LUD Write protection level of user variables
51049 ACCESS_WRITE_PRG_COND Write program control protection level 9214
51050 ACCESS_WRITE_PROGRAM Write part program protection level 9217
51051 ACCESS_WRITE_RPA Protection level write R variables 9222
51052 ACCESS_WRITE_SEA Protection level write setting data 9215
51053 ACCESS_WRITE_BASEFRAME Write basic work offset (basic frame) protection level
51054 ACCESS_WRITE_CYCFRAME Write cycle frame protection level 9186

51055 ACCESS_WRITE_EXTFRAME Write external work offset protection level 9188
SINUMERIK 828D

51056 ACCESS_WRITE_PARTFRAME Write table reference protection level 9184
SINUMERIK 828D
51057 ACCESS_WRITE_SETFRAME Write basic reference protection level
51058 ACCESS_WRITE_TOOLFRAME Write basic tool reference protection level 9183
51059 ACCESS_WRITE_TRAFRAME Write transformation frame protec. level 9187
51060 ACCESS_WRITE_USERFRAME Write settable work offset (G54 ... G599) protection level
51061 ACCESS_WRITE_WPFRAME Write workpiece reference protection level 9185
51062 ACCESS_WRITE_FINE Write protection level for fine offset of all work offsets 9203
51063 ACCESS_SET_ACT_VALUE Set actual value protection level 9220
51064 ACCESS_WRITE_PROGLIST Write protection level of program list in USER area
51065 NUM_DISPLAYED_CHANNELS Number of channels displayed simultaneously 9034
51066 ORDER_DISPLAYED_CHANNELS Channel numbers of the channels displayed
Contains the numbers of the channels to be displayed under machine in the multi-
Page 5
channel view, in the desired order and separated by commas, semicolons or spaces.
51200 ACCESS_WRITE_TM_GEO Write tool offset geometry data protection level 9201
51201 ACCESS_WRITE_TM_WEAR Write tool offset wear data protection level 9202
51202 ACCESS_WRITE_TM_WEAR_DELTA Protection level for restricted writing of tool wear values 9203
S. MD 54213: TM_WRITE_DELTA_LIMIT
51203 ACCESS_WRITE_TM_SC Write tool offset sum offset protection level 9204
51204 ACCESS_WRITE_TM_EC Write tool offset use offsets protection level 9205
51205 ACCESS_WRITE_TM_SUPVIS Write tool offset monitoring data protection level 9206
One authorization applies to all limit values: quantity, service life, wear and the monitor-
ing type.
51206 ACCESS_WRITE_TM_ASSDNO Write tool offset unique D number protection level 9207
51207 ACCESS_WRITE_TM_ASSDNO Write tool offset wear groups (magazine location / magazine) protection level 9208
51208 ACCESS_WRITE_TM_ADAPT Write tool offset tool adapter geometry data protection level 9209
Appendix B
Appendix B

51209 ACCESS_WRITE_TM_NAME Write tool offset tool name and duplo data protection level 9240
Appendix B
51210 ACCESS_WRITE_TM_TYPE Write tool offset tool type protection level 9241
51211 ACCESS_READ_TM Read tool offset data protection level 9200
Appendix B
51212 TM_WRITE_WEAR_ABS_LIMIT With TM_WRITE_WEAR_ABS_LIMIT, the max. possible value of a tool wear is limited 9639
absolutely, independently of the current protection level (keyswitch position), i.e. also
independently of ACCESS_WRITE_TM_WEAR. Absolute and incremental wear limita-
tion can be combined, i.e. the wear can be changed incrementally up to the absolute
limit. S. MD 51213.
51213 TM_WRITE_WEAR_DELTA_LIMIT When entering tool offsets, the value of the change from the previous value to the new 9450
value cannot exceed the value set here.
With TM_WRITE_WEAR_DELTA_LIMIT, the change to a tool wear can be limited incre-
mentally, if the current protection level is the same as or higher than the one set in AC-
CESS_WRITE_TM_WEAR_DELTA. With the current protection level being the same or
higher than ACCESS_WRITE_TM_WEAR, an incremental limitation is no longer per-
formed. incremental wear limitation can be combined, i.e. the wear can be changed up
to the absolute limit. S. MD 51212
51214 TM_WRITE_LIMIT_MASK Validity of the restricted tool wear input
Page 6
9449
Bit 0: Use for cutting edge data, wear
Bit 1: Use for SC data, sum offsets
Bit 2: Use for EC data, use offsets
Bit 0+1+2: Use for all data, wear, SC, EC
51226 FUNCTION_MASK_SIM Function mask Simulation
Bit 0: No automatic start on simulation selection
51230 ENABLE_LADDER_DB_ADDRESSES Activation of DB addresses in PLC Ladder Viewer
51231 ENABLE_LADDER_EDITOR Activation of PLC Ladder Editor
51235 ACCESS_RESET_SERV_PLANNER Protection level for acknowledgement of maintenance tasks
51600 MEA_CAL_WP_NUM The workpiece probe calibration data refer to the workpiece coordinate system (WCS)!
In the data fields, the workpiece probe calibration data of the technologies Milling and
Turning are stored!
51601 MEA_CAL_EDGE_NUM The gauging block is exclusively used to calibrate the workpiece probe of the Turning
technology!
SINUMERIK 828D

51602 MEA_CAL_TP_NUM The geometry data and calibration data of the tool probe refer to the machine coordinate system
SINUMERIK 828D
(MCS)!
51603 MEA_CAL_TPW_NUM The geometry data and calibration data of the tool probe refer to the workpiece coordinate system
(WCS)!
51606 MEA_INPUT_PIECE_PROBE Selection of NC measuring input for measuring the workpiece 9750
$MCS_MEA_INPUT_PIECE_PROBE[0] corresponds to NC measuring input 1
$MCS_MEA_INPUT_PIECE_PROBE[1] corresponds to NC measuring input 2
This parameter must be applied in conjunction with$MCS_MEA_INPUT_TOOL_PROBE[n]!
Either a workpiece probe or a tool probe can be connected to each of the NC measuring inputs!
Value:
=0: No workpiece probe connected/active
=1: Workpiece probe connected/active
51607 MEA_INPUT_PIECE_PROBE Selection of NC measuring input for measuring the tool 9751
$MCS_MEA_INPUT_TOOL_PROBE[0] corresponds to NC measuring input 1
$MCS_MEA_INPUT_TOOL_PROBE[1] corresponds to NC measuring input 2
This parameter must be applied in conjunction with$MCS_MEA_INPUT_PIECE_PROBE[n]!
Either a workpiece probe or a tool probe can be connected to each of the NC measuring inputs!
Value:
Page 7
=0: No tool probe connected/active
=1: Tool probe connected/active
51608 MEA_WP_PROBE_INPUT_SUB Workpiece probe available/active on the counter spindle
=0: Workpiece probe not available/active on the counter spindle
=1: Workpiece probe available/active on the counter spindle
51609 MEA_T_PROBE_INPUT_SUB Tool probe available/active on the counter spindle 9828
=0: Tool probe not available/active on the counter spindle
=1: Tool probe available/active on the counter spindle
51610 MEA_TOOLCARR_ENABLE Support of orientatable tool holders
0: No support of orientatable tool holders.
1: Support of a probe or tool positioned using an orientatable tool holder (kinematics type "T")
with reference to the special tool holder positions 0°, 90°, 180° and 270°.
51612 MEA_MONO_COR_POS_ACTIVE Monoprobe position offset GUD_CBIT[8]
0: No offset
1: If the workpiece probe is a monoprobe, the orientation of its switching direction (spindle po-
sition) is offset by the angle value in _CORA.
Appendix B
Appendix B

51614 MEA_PROBE_LENGTH_RELATE Length reference of the workpiece probe, measurement technology milling GUD _CBIT14]
Appendix B
0: Tool length L1, referring to the centre of the probe sphere 9778
1: Tool length L1, referring to the sphere volume of the probe sphere
51616 MEA_CAL_MONITORING Activation of calibration status monitoring for measuring in automatic mode GUD _CBIT16]
Appendix B
0: Calibration monitoring inactive

1: Calibration monitoring active
Between calibration and measuring the status of the following states is monitored:
- Working plane (G17, 18, 19)
- Probe type (monoprobe, multiprobe)
- Length reference of the probe (centre point of the probe sphere, probe sphere volume)
- Programmed probe speed
For "Measure in JOG" these monitoring modes are always active and cannot be deactivated.
51618 MEA_CM_ROT_AX_POS_TOL Entries in parameter $MN_MEA_CM_ROT_AX_POS_TOL are effective only if
$MN_MEA_TOOLCARR_ENABLE=1
The real angle position of the rotary axes can deviate from the programmed one (exact stop fine
window).
This deviation depends on the position control features of the axis. The maximum deviation ex-
pected on the concrete axis must be entered in this parameter. When the tolerance is exceeded,
alarm 61442 "Toolholder not in parallel with the geometry axes" is displayed.
Page 8
51750 J_MEA_M_DIST This parameter defines the measuring path in front of and behind the measuring setpoint. 9752
51751 J_MEA_M_DIST_MANUELL Measuring path, manual measurement ((for "Measure in JOG")) [mm] (in front of and behind the 9753
measuring setpoint)
51752 J_MEA_M_DIST_TOOL_LENGTH Measuring path for tool length measuring. 9754
51753 J_MEA_M_DIST_TOOL_RADIUS Measuring path for tool radius measuring. 9755
51755 J_MEA_MEASURING_FEED Measuring feed for workpiece measurement and calibration of the workpiece probe, for "Measure 9756
in JOG"
51757 J_MEA_COLL_MONIT_FEED Feedrate in the working plane with active collision detection. 9757
51758 J_MEA_COLL_MONIT_POS_FEED Feedrate of the infeed axis with active collision detection, for "Measure in JOG". 9758
51770 J_MEA_CAL_RING_DIAM Calibration ring diameter, for probe sphere calibration in the plane, for "Measure in JOG"
51772 J_MEA_CAL_HEIGHT_FEEDAX Calibration height in the infeed axis for probe length calibration, for "Measure in JOG"
The calibration height must be entered with reference to the the workpiece coordinate system
(WCS)!
SINUMERIK 828D

51774 J_MEA_T_PROBE_TYPE For the "cube" tool probe type, the three-dimensional geometric dimensions of the cube probe are 9763
SINUMERIK 828D
entered in the three field elements of this parameter. Cube-shaped probes are mainly used for
turning tool measuring.
0 : Cube
101 : Wheel in XY, working plane G17
201 : Wheel in ZX, working plane G18
301 : Wheel in YZ, working plane G19
51766 J_MEA_T_PROBE_ALLOW_AX_DIR Permissible axis directions during tool probe calibration for milling tool measuring, for "Measure in 9764
JOG"
In the default setting, X and Y correspond to the plus and minus direction, Z only to the minus di-
rection.
The parameter is divided into three elements the functions of which must be assigned to calibra-
tion data records 1, 2 and 3!
The calibration data records are assigned to tool measuring in working planes G17 (1), G18 (2)
and G19 (3)!
Meaning of the parameter elements

Decimal position:
Ones: 1st geometry axis (X)
Page 9
Tens: 2nd geometry axis (Y)
Hundreds: 3rd geometry axis (Z)
Value:
=0: Axis not possible
=1: Only minus direction possible
=2: Only plus direction possible
=3: Both directions possible
51778 J_MEA_T_PROBE_DIAM_LENGTH Effective grinding wheel diameter of the tool probe for length measurement on milling tools, for 9765
"Measure in JOG"
51780 J_MEA_T_PROBE_DIAM_RAD Effective grinding wheel diameter of the tool probe for radius measurement on milling tools, for 9766
"Measure in JOG"
51782 J_MEA_T_PROBE_ALLOW_AX_DIR Distance between the upper edge of the tool probe and the lower edge of the tool for radius meas- 9767
urement on milling tools, for "Measure in JOG"
51784 J_MEA_T_PROBE_APPR_AX_DIR Approach direction in the plane on the tool probe, for "Measure in JOG" 9768
= 0 positive direction
= -1 negative direction
51786 J_MEA_T_PROBE_MEASURE_DIST Measuring path for tool probe calibration and tool measuring with stationary spindle, in front of and 9772
behind the expected switching position.
51787 J_MEA_T_PROBE_MEASURE_FEED Measuring feed for tool probe calibration and tool measuring with stationary spindle, for "Measure 9773
in JOG".
Appendix B
Appendix B
Channel Machine Data

52000 DISP_COORDINATE_SYSTEM With this MD you adapt the operator panel of the coordinate system to the machine's coordinate 9650
Appendix B
system. Depending on the selected position, all help screens, the sequence graphic, the simula-
tion and the input fields with the circular direction specified will change automatically.
Also note MD 52210 $MCS_FUNCTION_MASK_DISP, bit 1.
Appendix B
52005 DISP_PLANE_MILL Plane selection Milling 9660

0: plane selection on the operator panel
17: always G17
18: always G18
19: always G19
52006 DISP_PLANE_TURN Plane selection Turning
0: plane selection on the operator panel
17: always G17
18: always G18
19: always G19
52010 DISP_NUM_AXIS_BIG_FONT Number of actual values with large font
52200 TECHNOLOGY Technology 9020
0: no specific configuration
Page 10
1: turning
2: milling
Also note MD 52201 $MCS_TECHNOLOGY_EXTENSION.
52201 TECHNOLOGY_EXTENSION Extended technology
0: no specific configuration
1: turning
2: milling
Also note MD 52200 $MCS_TECHNOLOGY.
Example:
Turning machine with milling technology
MD 52200 $MCS_TECHNOLOGY = 1
MD 52201 $MCS_TECHNOLOGY_EXTENSION = 2
52205 NUM_AXIS_USED Number of axes used in the channel (axis gaps are also counted). 9650
SINUMERIK 828D
52206 AXIS_USAGE Meaning of the axes in the channel 9703, 9704,
SINUMERIK 828D
0 = no special meaning 9705, 9706,
1 = tool spindle (driven tool) 9707, 9708,
2 = auxiliary spindle (driven tool) 9720, 9802,
3 = main spindle (turning) 9803, 9804,
4 = C axis of the main spindle (turning) 9805, 9806,
5 = counter spindle (turning) 9807, 9808.
6 = C axis of the counter spindle (turning)
7 = linear axis of the counter spindle (turning)
8 = tailstock (turning)
9 = steady rest (turning)
10= B axis (turning)
52207 AXIS_USAGE_ATTRIB Axis attributes 9822, 9832,
Bit 0: Rotates around the 1st geometry axis (applies to rotary axes) 9824, 9825.
Bit 1: Rotates around the 2nd geometry axis (applies to rotary axes)
Bit 2: Rotates around the 3rd geometry axis (applies to rotary axes)
Bit 3: Displayed positive direction of rotation is counterclockwise (applies to rotary axes)
Bit 4: Displayed direction of rotation for M3 is counterclockwise (applies to spindles)
Bit 5: Direction of rotation M3 corresponds to rotary axis minus (applies to spindles)
Page 11
This bit must be set analog to PLC bit DBnn.DBX17.6!
(nn = 31 + machine data index)
52210 FUNCTION_MASK_DISP Function mask Display

Bit 0: Measuring system for programs always in the base system 9626 Bit 9
Bit 1: Use school coordinate system with G17 9719
Bit 2: Hide soft key T,S,M
Bit 3: Automatic generation of M30 in MDA
52212 FUNCTION_MASK_TECH Function mask Cross-technology
Bit 0: Enable Swivel 9723
Bit 1: No optimized travel along software limit switches
Bit 2: Approach logic for step drill (ShopTurn)
Bit 3: Call block search cycle for ShopMill/ShopTurn
Bit 4: Approach logic through cycle (ShopTurn)
Appendix B
Appendix B
52214 FUNCTION_MASK_MILL Function mask Milling
Appendix B
Bit 0: Reserved
Bit 1: High Speed Settings cycle (CYCLE832) Unhide input field Technology
Bit 2: High Speed Settings cycle (CYCLE832) Tolerance input field or table
Appendix B
[0 = Tolerance input field (values 0 ... 0.999 real value)]

[1 = Selection field (toggle) Tolerance table (values 1,2,3 .. 9 or higher)
The tolerance table is stored in the CYC_832T manufacturer cycle.
Bit 3: Enable inside/rear machining
Bit 4: Enable spindle clamping (C axis) 9843
Developers’ documentation:
Bit 0: Enable cylinder surface transformation for milling 9721
52216 FUNCTION_MASK_DRILL Function mask Drilling
Bit 0: CYCLE84 Unhide input fields Technology
Bit 1: CYCLE840 Unhide input fields Technology
52218 FUNCTION_MASK_TURN Function mask Turning
Bit 0: Enable zoom under manual for tool measurement 9840
Bit 1: Enable parts gripper for cut-off 9841
Bit 2: Enable tailstock 9842
Bit 3: Reserved
Page 12
Bit 4: Enable spindle control of main spindle above surface 9897Bit 0
Bit 5: Enable spindle control of tool spindle above surface 9897Bit 1
Developers’ documentation:
Bit 6: Enable mask Taper angle 9897Bit 2
52229 ENABLE_QUICK_M_CODES Enable fast M functions
Bit 0: Coolant OFF

Bit 1: Coolant 1 ON
Bit 2: Coolant 2 ON
Bit 3: Coolant 1 and 2 ON
52230 M_CODE_ALL_COOLANTS_OFF M code for all coolants OFF 9686
52231 M_CODE_COOLANT_1_ON M code for coolant 1 ON 9680
52232 M_CODE_COOLANT_2_ON M code for coolant 2 ON 9681
52233 M_CODE_COOLANT_1_AND_2_ON M code for coolant 1 + 2 ON 9668
52240 NAME_TOOL_CHANGE_PRO Tool change program for G code steps
SINUMERIK 828D

52241 SPINDLE_CHUCK_TYPES Spindle jaw type 9829
SINUMERIK 828D
0 = Clamp from outside
1 = Clamp from inside
Elements:
[0]: Main spindle
[1]: Counter spindle
52242 MAIN_SPINDLE_PARAMETER Parameters for main spindle
[1]: Chuck dimension
52243 NUM_AXIS_USED Parameters for counter spindle
[0]: Chuck dimension

[1]: Stop dimension
[2]: Jaw dimension
52244 SUB_SPINDLE_PARK_POS_Y Parking position of the Y axis with counter spindle 9849
52246 TAILSTOCK_DIAMETER Tailstock diameter 9836
52247 TAILSTOCK_LENGTH Tailstock length 9837
Page 13
52248 REV_2_BORDER_TOOL_LENGTH Limit value of tool length X for 2nd revolver: 9838
Limit value = 0: There is only one revolver
Tool length < limit value: Tool belongs to 1st revolver/multifix
Tool length >= limit value: Tool belongs to 2nd revolver/multifix
52250 M_CODE_CHUCK_OPEN M code for Open chuck with non-rotating spindle.

Example: "M34" or "M1=34"
Elements:
[0]: Main spindle
52251 M_CODE_CHUCK_CLOSE_OPEN_ROT M code for Open chuck with rotating spindle.
Elements:
[0]: Main spindle
52252 M_CODE_CHUCK_CLOSE M code for Close chuck
Elements:
[0]: Main spindle
Appendix B
Appendix B
52270 TM_FUNCTION_MASK Function mask Tool management
Appendix B
Bit 0: Create tool on magazine location not allowed. Tools can only be created outside the 9478 Bit 3
magazine.
Bit 1: Load/unload disable, if machine is in reset. Tools can only be loaded/unloaded, if the ap- 9478 Bit 9
Appendix B
propriate channel is in reset state.

Bit 2: Load/unload disable on Emergency stop. Tools can only be loaded/unloaded, if Emer- 9478 Bit 12
gency stop is not active.
Bit 3: Load/unload tool to/from spindle is disabled. Tools cannot be loaded to or unloaded from 9478 Bit 15
the spindle.
Bit 4: Loading is executed directly in the spindle. Tools are loaded exclusively directly in the 9478 Bit 20
spindle.
Bit 5: Reserved
Bit 6: Reserved
Bit 7: Create tool using the tool number. Specify the tool's T number when creating the tool.
Bit 8: Fade out Relocate tool. The function 'Relocate tool" is faded out on the user interface.
Bit 9: Fade out Position magazine. The function 'Position magazine' is faded out on the user
interface.
Bit 10: Reactivate tool using Position magazine. Prior to reactivating the tool is positioned on the
loading position.
Bit 11: Reactivate tool in all monitoring modes. When reactivating a tool, all monitoring modes
Page 14
enabled in the NC are reactivated for this tool, even the monitoring modes, which have
not been set for the relevant tool, but are available in the background only.
Bit 12: Fade out Reactivate tool. The function 'Reactivate tool' is faded out on the user interface.
52271 TM_MAG_PLACE_DISTANCE Distance between individual magazine locations. 9479

Is used for graphical display of magazine and tools in tool management.
52272 TM_TOOL_LOAD_DEFAULT_MAG Default magazine for tool loading 9671

0 = No default magazine
52273 TM_TOOL_MOVE_DEFAULT_MAG Default magazine for tool relocation 9687

0 = No default magazine
52281 TOOL_MCODE_FUNC_ON M code for tool-specific function ON 9739, 9741,
Value -1 means that the M function is not output. If both M commands of a function equal -1, the 9743, 9745.
corresponding field will not be displayed in the user interface.
52282 TOOL_MCODE_FUNC_OFF M code for tool-specific function OFF 9740, 9742,
Value -1 means that the M function is not output. If both M commands of a function equal -1, the 9743, 9745.
corresponding field will not be displayed in the user interface.
SINUMERIK 828D

52480 MILL_PARALLEL_AX1_NAME Channel axis name of first parallel axis (tool axis) for CYCLE69.
SINUMERIK 828D
The first parallel axis is the third geometry axis, if geometry axis interchange is not active (e.g.
axis ZZ with G17)
The channel axis name must be different from the name of the geometry axis (e.g. channel axis
name ZZ, name of geometry axis Z)
52481 MILL_PARALLEL_AX2_NAME Channel axis name of the second parallel axis (in tool direction) for CYCLE69
52482 MILL_PARALLEL_AX3_NAME Channel axis name of the third parallel axis (in tool direction) for CYCLE69
52483 MILL_ROUND_AX_NAME Channel axis name of the rotary axis for CYCLE69
During positioning, the Parallel axes cycle (CYCLE69) can also support a rotary axis (e.g. rotary
table B).
52485 FUNCTION_MASK_MILL_PARAXES Function mask Parallel axes CYCLE69
Bit 0: Always move parallel axes individually, (e.g. with M command in case of parallel axes
clamping)
Bit 1:
Bit 2: Value of the workpiece reference (compensation value) still active after Reset
In CYCLE69, the value is transferred globally to data management
52605 MEA_TURN_CYC_SPECIAL_MODE Functional behavior of a third geometry axis (Y axis) in the turning technology based on the G18
Page 15
working plane!
=0: an existing third geometry axis (Y axis; applicate); is not supported by the measuring cycles!
=1: specified setpoint and parameterization (SETVAL, _TUL, _TLL, SZO) refer to the third geome-
try axis (Y axis).
However, tool length offset or work offset are performed in the components active in the second
geometry axis (X axis, ordinate) (i.e. measurement in Y and offset in X). The offset target can be
influenced using the _KNUM parameter!
52750 J_MEA_FIXPOINT Z value for measuring against fixed point 9748
52715 J_MEA_MAGN_GLAS_POS Zoom position for tool measurement: 9820, 9821
[0] = Position in 1st axis
[1] = Position in 2nd axis
52800 ISO_M_ENABLE_POLAR_COORD Polar coordinates
0: OFF
1: ON
52802 ISO_ENABLE_INTERRUPTS Interrupt process
0: OFF
1: ON
Appendix B
Appendix B

52804 ISO_ENABLE_DRYRUN Machining skipped during tapping G74/G84 at DRY RUN
Appendix B
0: OFF
1: ON
52806 ISO_SCALING_SYSTEM Basic system:
Appendix B
0: not defined
1: METRIC
2: INCH
52808 ISO_SIMULTAN_AXES_START Simultaneous approach to the boring position on all programmed axes
0: OFF
1: ON
52810 ISO_T_DEEPHOLE_DRILL_MODE Select the type of deep hole drilling
0: deep hole drilling with chip breaking
1: deep hole drilling with stock removal
Axis Machine Data
Page 16
53230 SIM_START_POSITION Axis position for simulation
SINUMERIK 828D
General Setting Data

54215 TM_FUNCTION_MASK_SET_ Function mask Tool management
SINUMERIK 828D
Bit 0: Diameter display for rotating tools. For rotating tools the diameter is displayed instead of 9663
the radius value.
Bit 1: Default direction of rotation for all turning tools is M4. When creating turning tools the di- 9826
rection of rotation is defaulted with M4.
Bit 2: Create tool without name suggestion. 9478 Bit 4
Bit 3: Input disable for tool name and tool type in loaded tools. When tools are loaded, the tool 9478 Bit 7
name and tool type can no longer be changed.
Bit 4: Input disable for loaded tools, if the channel is not in Reset. 9478 Bit 6
Bit 5: Clear tool wear input additively. Wear data are input additively to the already existing wear 9478 Bit 10
value.
Bit 6: Numerical input of the tool ident. Only numbers are permissible for tool ident input. 9478 Bit 11
Bit 7: Fade out tool monitoring parameters. The tool monitoring parameters are faded out on the
user interface.
Bit 8: Diameter display for transverse axis - Geometry. The geometry value of the transverse
axis is displayed as diameter value.
Bit 9: Diameter display for transverse axis - Wear. The wear value of the transverse axis is dis-
played as diameter value.
Bit 10: Enable load/relocate tool on buffer locations. In the load dialog the magazine number can 9478 Bit 25
be entered. Thus it is possible to access the buffer using magazine number 9998.
Page 17
Bit 11: Creating tool in gripper disabled.
54600 MEA_WP_BALL_DIAM Effective sphere diameter of the probe sphere for the workpiece probe. GUD =_WP[x,0]
The value of this parameter is created by the operation "Calibrate workpiece probe"!
54601 MEA_WP_TRIG_MINUS_DIR_AX1 Trigger point of the 1st measuring axis (abscissa) in negative traversing direction (X at G17) of the GUD =_WP[x,1]
workpiece probe.
The term "negative traversing direction" refers to the currently active workpiece zero point refer-
ence!
54602 MEA_WP_TRIG_PLUS_DIR_AX1 Trigger point of the 1st measuring axis (abscissa) in positive traversing direction (X at G17) of the GUD =_WP[x,2]
workpiece probe.
The term "positive traversing direction" refers to the currently active workpiece zero point refer-
ence!
54603 MEA_WP_TRIG_MINUS_DIR_AX2 Trigger point of the 2nd measuring axis (ordinate) in negative traversing direction (Y at G17) of the GUD =_WP[x,3]
workpiece probe.
ence!
Appendix B
Appendix B

54604 MEA_WP_TRIG_PLUS_DIR_AX2 Trigger point of the 2nd measuring axis (ordinate) in positive traversing direction (Y at G17) of the GUD =_WP[x,4
Appendix B
workpiece probe.
ence!
Appendix B
54605 MEA_WP_TRIG_MINUS_DIR_AX3 Trigger point of the 3rd measuring axis (applicate) in negative traversing direction (Z at G17) of GUD =_WP[x,5]
the workpiece probe.
ence!
54606 MEA_WP_TRIG_PLUS_DIR_AX3 Trigger point of the 3rd measuring axis (applicate) in positive traversing direction (Z at G17) of the GUD =_WP[x,6]
workpiece probe.
ence!
54607 MEA_WP_POS_DEV_AX1 The position deviation in the 1st measuring axis represents a geometrical offset of the centre point GUD =_WP[x,7]
of the probe sphere related to the electrical centre point of the probe in this axis!
Page 18
54608 MEA_WP_POS_DEV_AX2 The position deviation in the 2nd measuring axis represents a geometrical offset of the centre GUD =_WP[x,8]
point of the probe sphere related to the electrical centre point of the probe in this axis!
54609 MEA_WP_STATUS_RT Calibration status of the axis positions reserved for internal use! GUD =_WP[x,9]
54610 MEA_WP_STATUS_GEN Calibration status in general reserved for internal use! GUD =_WP[x,10]
54615 MEA_CAL_EDGE_BASE_AX1 Calibration groove base of the 1st measuring axis (abscissa, Z at G18) GUD =_KB[x,2]
This parameter is a geometrical component of the calibration groove and must be supplied by the
user!
54617 MEA_CAL_EDGE_PLUS_DIR_AX1 Calibration groove edge in positive direction of the 1st measuring axis (abscissa, Z at G18) GUD =_KB[x,3]
user!
54618 MEA_CAL_EDGE_MINUS_DIR_AX1 Calibration groove edge in negative direction of the 1st measuring axis (abscissa, Z at G18) GUD =_KB[x,4]
user!
SINUMERIK 828D

54619 MEA_CAL_EDGE_BASE_AX2 Calibration groove base of the 2nd measuring axis (ordinate, X at G18) GUD =_KB[x,6]
SINUMERIK 828D
user!
54620 MEA_CAL_EDGE_UPPER_AX2 Calibration groove upper edge of the 2nd measuring axis (ordinate, X at G18) GUD =_KB[x,5]
user!
54621 MEA_CAL_EDGE_PLUS_DIR_AX2 Calibration groove edge in positive direction of the 2nd measuring axis (ordinate, X at G18) GUD =_KB[x,0]
user!
54622 MEA_CAL_EDGE_MINUS_DIR_AX2 Calibration groove edge in negative direction of the 2nd measuring axis (ordinate, X at G18) GUD =_WP
This parameter is a geometrical component of the calibration groove and must be supplied by the [x,10]
user!
54625 MEA_TP_TRIG_MINUS_DIR_AX1 Trigger point of the 1st measuring axis in negative direction (abscissa, X at G17, Z at G18) GUD =_TP[x,0]
The trigger point refers to the machine coordinate system (MCS).
Prior to calibration the approximate trigger point must be entered in the machine coordinate sys-
tem!
The exact value of this parameter is created by the operation "Calibrate tool probe"!
Page 19
54626 MEA_CAL_EDGE_PLUS_DIR_AX1 Trigger point of the 1st measuring axis in positive direction (abscissa, X at G17, Z at G18) GUD =_TP[x,1]
tem!
54627 MEA_TP_TRIG_MINUS_DIR_AX2 Trigger point of the 2nd measuring axis in negative direction (ordinate, Y at G17, X at G18) GUD =_TP[x,2]
tem!
54628 MEA_TP_TRIG_PLUS_DIR_AX2 Trigger point of the 2nd measuring axis in positive direction (ordinate, Y at G17, X at G18) GUD =_TP[x,3]
tem!
54629 MEA_TP_TRIG_MINUS_DIR_AX3 Trigger point of the 3rd measuring axis in negative direction (applicate, Z at G17, Y at G18) GUD =_TP[x,4]
tem!
Appendix B
Appendix B
New MD No. Machine Data Description Old MD/GUD

54630 MEA_TP_TRIG_PLUS_DIR_AX3 Trigger point of the 3rd measuring axis in positive direction (applicate, Z at G17, Y at G18) GUD =_TP[x,5]
Appendix B
tem!
Appendix B
54631 MEA_TP_EDGE_DISK_SIZE Effective edge length or grinding wheel diameter of the tool probe. GUD =_TP[x,6]
Milling tools are normally measured with wheel-shaped probes while turning tools are measured
with square probes.
54632 MEA_TP_AX_DIR_AUTO_CAL Enabling axes and traversing directions for "Automatic calibration" of milling tool probes. GUD =_TP[x,7]
The default setting refers in X and Y to the plus and minus direction respectively, in Z only to the
minus direction.
The parameter is divided into three components the functions of which are to be assigned to cali-
bration data records 1, 2 or 3!
The calibration data records are firmly assigned to tool measuring in the working planes G17 (1),
G18 (2) and G19 (3)!
Meaning of the parameter components

Decimal position:
Page 20
Value:
= 0: Axis not enabled
54633 MEA_TP_TYPE Tool probe type GUD =_TP[x,8]
0: Cube
101: Wheel in XY, working plane G17
201: Wheel in ZX, working plane G18
301: Wheel in YZ, working plane G19
54634 MEA_TP_CAL_MEASURE_DEPTH Distance between the upper tool probe edge and the lower milling tool edge. GUD =_TP[x,9]
For tool probe calibration this distance defines the calibration depth and for milling tool measuring
the measuring depth!
This parameter does not apply to turning tool measuring!
SINUMERIK 828D
54640 MEA_TPW_TRIG_MINUS_DIR_AX1 Trigger point of the 1st measuring axis in negative direction (abscissa, X at G17, Z at G18) GUD =_TPW[x,0]
SINUMERIK 828D
The trigger point refers to the workpiece coordinate system (WCS).
Prior to calibration the approximate trigger point must be entered in the workpiece coordinate sys-
tem!
54641 MEA_TPW_TRIG_PLUS_DIR_AX1 Trigger point of the 1st measuring axis in positive direction (abscissa, X at G17, Z at G18) GUD =_TPW[x,1]
tem!
54642 MEA_TPW_TRIG_MINUS_DIR_AX2 Trigger point of the 2nd measuring axis in negative direction (ordinate, Y at G17, X at G18) GUD =_TPW[x,2]
tem!
54643 MEA_TPW_TRIG_PLUS_DIR_AX2 Trigger point of the 2nd measuring axis in positive direction (ordinate, Y at G17, X at G18) GUD =_TPW[x,3]
Page 21
tem!
54644 MEA_TPW_TRIG_MINUS_DIR_AX3 Trigger point of the 3rd measuring axis in negative direction (applicate, Z at G17, Y at G18) GUD =_TPW[x,4]
tem!
54645 MEA_TPW_TRIG_PLUS_DIR_AX3 Trigger point of the 3rd measuring axis in positive direction (applicate, Z at G17, Y at G18) GUD =_TPW[x,5]
tem!
54646 MEA_TPW_EDGE_DISK_SIZE Effective edge length or grinding wheel diameter of the tool probe. GUD =_TPW[x,6]
Milling tools are normally measured with wheel-shaped probes while turning tools are measured
with square probes.
Appendix B
Appendix B

54647 MEA_TPW_AX_DIR_AUTO_CAL Enabling axes and traversing directions for "Automatic calibration" of milling tool probes. GUD=_TPW[x,7]
Appendix B
The default setting refers in X and Y to the plus and minus direction respectively, in Z only to the
minus direction.
The parameter is divided into three components the functions of which are to be assigned to cali-
bration data records 1, 2 or 3!
Appendix B
The calibration data records are firmly assigned to tool measuring in the working planes G17 (1),
G18 (2) and G19 (3)!
Meaning of the parameter components
Decimal position:
Value:
= 0: Axis not enabled
54648 MEA_TPW_TYPE Tool probe type GUD =_TPW[x,8]
0: Cube
Page 22
101: Wheel in XY, working plane G17
201: Wheel in ZX, working plane G18
301: Wheel in YZ, working plane G19
54649 MEA_TPW_CAL_MEASURE_DEPTH Distance between the upper tool probe edge and the lower milling tool edge. GUD =_TPW[x,9]
For tool probe calibration this distance defines the calibration depth and for milling tool measuring
the measuring depth!
This parameter does not apply to turning tool measuring!
54655 MEA_REPEAT_ACTIVE Measurement repetitions after exceeding of the dimensional difference (parameter _TDIF) and/or GUD =_CBIT[0]
the safety margin (parameter _TSA)
=0: When the dimensional difference and/or safety margin is exceeded, the measurement is not
repeated. A corresponding alarm is displayed that can be acknowledged with "RESET".
=1: When the dimensional difference and/or safety margin is exceeded, the measurement is
repeated 4 times max.
54656 MEA_REPEAT_WITH_M0 This parameter refers to SD54655 $SNS_MEA_REPEAT_ACTIVE, provided that it is set to "1"! GUD =_CBIT[1]
In this case one of the following behaviors can be selected:
=0: No alarm, no M0 in the measurement repetitions
=1: NC command "M0" is generated in all measurement repetitions; the repetition must be started
with NC-START.
The corresponding alarm that can be acknowledged with "NC-START" is displayed for
each measurement repetition, [default = 0]
SINUMERIK 828D

54657 MEA_TOL_ALARM_SET_M0 M0 with tolerance alarms 62304 Allowance, 62305 Undersize, 62306 Permissible dimensional GUD =_CBIT[2]
SINUMERIK 828D
difference exceeded
=0: No M0 is generated when alarms 62304 "Allowance", 62305 "Undersize" or 62306
"Permissible dimensional difference exceeded" are output.
These alarms are merely displayed, but do not cause program execution to be interrupted!
=1: NC command "M0" is generated when these alarms are displayed.
54659 MEA_TOOL_MEASURE_RELATE Tool measuring and calibration in the machine workpiece coordinate system. GUD =_CBIT[5]
The function of this parameter only refers to CYCLE982.
=0: Tool probe calibration and tool measuring are performed in the machine coordinate system
(MCS).
Tool probe calibration data are stored in the $SNS_MEA_TP_..... parameter fields.
=1: Tool probe calibration and tool measuring are performed in the active workpiece coordinate
system (WCS).
Calibration and measurement must be performed under the same environmental conditions
(frames). Thus, tools can be measured even at active transformations, e.g. TRAANG.
Notice: the $SNS_MEA_TP_..... parameter fields are used for calibration and measure-
ment here, too.
54660 MEA_PROBE_BALL_RAD_IN_TOA Accept the calibrated workpiece probe radius in the tool data. GUD =_CBIT[15]
Page 23
The function of this parameter only refers to CYCLE976.
0: Calibrated workpiece probe radius is not accepted in the tool data

1: For the calibration type "with probe sphere calculation" the determined "effective probe
sphere diameter" (54600 $SNS_MEA_WP_BALL_DIAM), is converted into a radius value and
entered in the tool radius geometry memory of the active workpiece probe.
54670 MEA_CM_MAX_PERI_SPEED Max. permissible peripheral speed of the tool to be measured when the spindle rotates. GUD =_CM[0]
9759
Monitoring parameter for tool measuring with rotating spindle only effective with
SD54749 $SNS_MEA_FUNCTION_MASK_TOOL, Bit 10 = 0!
54671 MEA_CM_MAX_REVOLUTIONS Max. permissible tool speed for tool measuring with rotating spindle. GUD =_CM[1]
The speed is automatically reduced when this value is exceeded. 9760
54672 MEA_CM_MAX_FEEDRATE Max. permissible feed for contact of the tool to be measured with the probe when the spindle ro- GUD =_CM[4]
tates. 9771
Appendix B
Appendix B

54673 MEA_CM_MIN_FEEDRATE Min. feed for first contact of the tool to be measured with the probe when the spindle rotates. GUD =_CM[4]
Appendix B
Too small feeds for large tool radii are thus avoided! 9761
Appendix B
54674 MEA_CM_SPIND_ROT_DIR Direction of spindle rotation for tool measuring with rotating spindle (default: 4 = M4) GUD =_CM[5]
Notice: If the spindle is already rotating when the measuring cycle is called, the direction of rota-
tion is maintained independently of $SNS_MEA_CM_SPIND_ROT_DIR!
54675 MEA_CM_FEEDFACTOR_1 Feedrate factor 1, for tool measuring with rotating spindle GUD =_CM[6]
=0: Single probing with the feedrate calculated by the cycle (but at least with the value of 9769
$SNS_MEA_CM_MIN_FEEDRATE)
>=1: First probing with calculated feedrate (but at least with the value of
$SNS_MEA_CM_MIN_FEEDRATE).
54676 MEA_CM_FEEDFACTOR_2 Feedrate factor 2, for tool measuring with rotating spindle GUD =_CM[7]
=0:Second probing with the feedrate calculated by the cycle (only effective with 9770
Page 24
MEA_CM_FEEDFACTOR_1 > 0)
>=1: Second probing with calculated feedrate, feedrate factor 2
Third probing with calculated feedrate (tool speed is influenced by SD54749
$SNS_MEA_FUNCTION_MASK_TOOL, Bit 12)
Notice: - Feedrate factor 2 should be smaller than feedrate factor 1!

- If the value of feedrate factor 2 is 0, a third probing will not be not performed!
54677 MEA_CM_MEASURING_ACCURACY Required measuring accuracy for tool measuring GUD =_CM[3]
The value of this parameter always refers to the last contact of the tool with the probe! 9762
54689 MEA_T_PROBE_MANUFACTURER Tool probe type (manufacturer) GUD =_TP_CF
These indications are required for tool measuring with rotating spindle. 9774
=0: No indication
=1: TT130 (Heidenhain)
=2: TS27R (Renishaw)
SINUMERIK 828D
New MD No. Machine Data Description Old MD/GUD

54691 MEA_T_PROBE_OFFSET Measurement result offset for tool measuring with rotating spindle. GUD=_MT_COM
SINUMERIK 828D
P
=0: No offset
=1: Cycle-internal offset (only effective with SD54690 9775
$SNS_MEA_T_PROBE_MANUFACTURER<>0)
=2: Offset through user-defined offset table
54695 MEA_RESULT_OFFSET_TAB_RAD1 Parameter for user-defined measurement result offset for tool measuring with rotating spindle,
$SNS_MEA_RESULT_OFFSET_TAB_RAD1[0] ... this element always has value ZERO
$SNS_MEA_RESULT_OFFSET_TAB_RAD1[1] ... 1st tool radius
$SNS_MEA_RESULT_OFFSET_TAB_RAD1[2] ... 2nd tool radius
$SNS_MEA_RESULT_OFFSET_TAB_RAD1[3] ... 3rd tool radius
$SNS_MEA_RESULT_OFFSET_TAB_RAD1[4] ... 4th tool radius
$SNS_MEA_RESULT_OFFSET_TAB_RAD2[0] ... 1st peripheral speed
$SNS_MEA_RESULT_OFFSET_TAB_RAD2[1] ... offset value for radius regarding 1st radius
and 1st peripheral speed
$SNS_MEA_RESULT_OFFSET_TAB_RAD2[2] ... offset value for radius regarding 2nd radius
Page 25
$SNS_MEA_RESULT_OFFSET_TAB_RAD2[3] ... offset value for radius regarding 3rd radius
$SNS_MEA_RESULT_OFFSET_TAB_RAD2[4] ... offset value for radius regarding 4th radius
$SNS_MEA_RESULT_OFFSET_TAB_RAD3[0] ... 2nd peripheral speed
and 2nd peripheral speed
Appendix B
Appendix B

Appendix B
$SNS_MEA_RESULT_OFFSET_TAB_RAD4[0] ... 3rd peripheral speed
and 3rd peripheral speed
Appendix B

$SNS_MEA_RESULT_OFFSET_TAB_RAD5[0] ... 4th peripheral speed
and 4th peripheral speed
Page 26
$SNS_MEA_RESULT_OFFSET_TAB_RAD6[0] ... 5th peripheral speed
54705 MEA_RESULT_OFFSET_TAB_LEN1 Parameter for user-defined measurement result offset for tool measuring with rotating spindle,
$SNS_MEA_RESULT_OFFSET_TAB_LEN1[0] ... this element always has value ZERO
$SNS_MEA_RESULT_OFFSET_TAB_LEN1[1] ... 1st tool radius
$SNS_MEA_RESULT_OFFSET_TAB_LEN1[2] ... 2nd tool radius
$SNS_MEA_RESULT_OFFSET_TAB_LEN1[3] ... 3rd tool radius
$SNS_MEA_RESULT_OFFSET_TAB_LEN1[4] ... 4th tool radius
SINUMERIK 828D

SINUMERIK 828D
$SNS_MEA_RESULT_OFFSET_TAB_LEN2[0] ... 1st peripheral speed
$SNS_MEA_RESULT_OFFSET_TAB_LEN2[1] ... offset value for radius regarding 1st radius
$SNS_MEA_RESULT_OFFSET_TAB_LEN2[2] ... offset value for radius regarding 2nd radius
$SNS_MEA_RESULT_OFFSET_TAB_LEN2[3] ... offset value for radius regarding 3rd radius
$SNS_MEA_RESULT_OFFSET_TAB_LEN2[4] ... offset value for radius regarding 4th radius
$SNS_MEA_RESULT_OFFSET_TAB_LEN3[0] ... 2nd peripheral speed
Page 27
$SNS_MEA_RESULT_OFFSET_TAB_LEN4[0] ... 3rd peripheral speed
Appendix B
Appendix B

54709 MEA_RESULT_OFFSET_TAB_LE Parameter for user-defined measurement result offset for tool measuring with rotating spindle,
Appendix B
$SNS_MEA_RESULT_OFFSET_TAB_LEN5[0] ... 4th peripheral speed
Appendix B

$SNS_MEA_RESULT_OFFSET_TAB_LEN6[0] ... 5th peripheral speed
Page 28
SINUMERIK 828D

54748 MEA_FUNCTION_MASK_PIECE Setting for input screen, measuring cycles in Automatic mode, workpiece measurement
SINUMERIK 828D
Bit 0 Measuring plane G17 (XY), G18 (ZX), G19 (YZ)
Bit 1 Multiprobe / monoprobe
Bit 2 Log (standard protocol)
Bit 3 Measurement result display
Bit 4 Measuring feedrate input (VMS)
Bit 5 Calibration data (probe number/field)
Bit 6 Calibrate to unknown centre point
Bit 7 Zero offset TZL for calibration
Bit 8 WO compensation coarse / fine
Bit 9 WO compensation basis reference
Bit 10 WO compensation channel-spec. basis
Bit 11 WO compensation global basis
Bit 12 Tool offset geometry / wear
Bit 13 Tool offset not inverted / inverted
Bit 14 Tool offset L1, L2, R
Bit 15 Tool offset zero offset TZL
Bit 16 Tool offset TDIF
Bit 17 Total offset
Bit 18 Offset into tool environment
Page 29
Bit 19 Empirical values
Bit 20 Mean values
54749 MEA_FUNCTION_MASK_TOOL Setting for input screen, measuring cycles in Automatic mode, tool measurement
Bit 1 Measure in WCS, MCS
Bit 2 Log (standard protocol)
Bit 3 Measurement result display
Bit 5 Measure absolute / incremental
Bit 6 Tool offset geometry / wear
Bit 7 Zero offset TZL for calibration
Bit 8 Dimensional difference check TDIF
Bit 9 Number of measurements
Bit 10 Specification of feedrate/spindle speeds
Bit 11 Empirical values
Bit 12 No spindle speed reduction for last touch during tool measurement
54750 MEA_ALARM_MASK Bit 0 - 7 Workpiece measurement
Bit 0 =1 Alarms with cycle-internal states and coding are displayed (expert mode)!
Bit 1 - 7 Reserved
Bit 8 -16 Tool measuring
Bit 0 - 7 Reserved
Appendix B
Appendix B
54798 Setting for input screen, measuring cycles in JOG, workpiece measurement
Appendix B
Bit 1 Reserved
Bit 2 Activation of functionality “Measure with electronic workpiece probe” 9747
Appendix B

Bit 4 Measuring feedrate input (VMS)
Bit 5 Reserved
Bit 6 WO compensation basis reference
Bit 7 WO compensation channel-spec. basis
Bit 8 WO compensation global basis
Bit 9 WO compensation in settable frame
Bit 10 WO compensation in active frame
54799 J_MEA_FUNCTION_MASK_TOOL Setting for input screen, measuring cycles in JOG, tool measurement

Bit 1 Reserved
Bit 2 Activation of functionality “Measure with electronic tool probe” 9749
Bit 3 Specification of feedrate/spindle speeds
Bit 4 No spindle speed reduction for last touch during tool measurement
Page 30
User documentation
Bit 0 Not used
Bit 1 Not used
Bit 2 Activate calibration of electronic tool probe
Bit 3 Enable selection of tool probe calibration data field
Bit 4 Not used
Bit 5 Not used
Channel Setting Data

55200 MAX_INP_FEED_PER_REV Feedrate input upper limit for mm/rev 9665
55201 MAX_INP_FEED_PER_TIME Feedrate input upper limit for mm/min 9664
55202 MAX_INP_FEED_PER_TOOTH Feedrate input upper limit for mm/tooth 9666
55212 FUNCTION_MASK_TECH_SET Function mask Cross-technology
Bit 0: Tool pre-selection active 9667
Bit 1: Automatic calculation of thread depth 9640
Bit 2: New
SINUMERIK 828D

55214 FUNCTION_MASK_MILL_SET Function mask Milling
SINUMERIK 828D
Bit 0: Default setting - milling cycles with synchronous operation 9827
Bit 1: Angle of rotation in relation to the centre with POCKET3 GUD _ZSD[9]
Bit 1 = 0 When the rectangular pocket is dimensioned over a corner point, the angle of rotation
relates to this reference point
Bit 1 = 1 When the rectangular pocket is dimensioned over a corner point, the angle of rotation
relates to the pocket centre point
Bit 2: Depth calculation in milling cycles without parameter SC GUD _ZSD[1]
Bit 2 = 0 Depth calculation in milling cycles is carried out between reference plane + safety clear-
ance and depth
Bit 2 = 1 Depth calculation in milling cycles is carried out without inclusion of the safety clearance
Note: Bit 2 is active with the following milling cycles: CYCLE61, CYCLE71, CYCLE76, CYCLE77,
CYCLE79, CYCLE899, LONGHOLE, SLOT1, SLOT2, POCKET3, POCKET4
55216 FUNCTION_MASK_DRILL_SET Function mask Drilling
Bit 0: Tapping CYCLE84: reverse the direction of spindle rotation in the cycle
Bit 1: -
Bit 2: -
Bit 3: Tapping CYCLE84: monitoring machine data 31050 and 31060 of the spindle
Bit 4: Tapping CYCLE840: monitoring machine data 31050 and 31060 of the spindle
Page 31
Bit 5: Tapping CYCLE84: calculation of the brake point at G33
55218 FUNCTION_MASK_TURN_SET Function mask Turning
Bit 0: New thread table during thread cutting
Bit 1: Reserved (CYCLE93)
Bit 2: Reserved (CYCLE93)
55220 FUNCTION_MASK_MILL_TOL_SET Function mask High Speed Settings CYCLE832
Bit 0: Display input fields technology
Bit 1: Settings as agreed in the following setting data:
$SCS_MILL_TOL_TECHNO_NORM
$SCS_MILL_TOL_TECHNO_ROUGH
$SCS_MILL_TOL_TECHNO_SEMIFIN
$SCS_MILL_TOL_TECHNO_FINISH
$SCS_MILL_TOL_VALUE_NORM
$SCS_MILL_TOL_VALUE_ROUGH
$SCS_MILL_TOL_VALUE_SEMIFIN
$SCS_MILL_TOL_VALUE_FINISH
Appendix B
Appendix B

55221 FUNCTION_MASK_SWIVEL_SET Function mask Swivel CYCLE800
Appendix B
Bit 0: Display input field "No swivel"
Bit 1: =0: Retract Z or retract Z XY
=1: Retract to fixed position 1 or
Bit 2: Allow selection "Deselection" of the swivel data block
Appendix B
Bit 3: Show active swivel plane under Swivel in JOG

The settings of the Swivel function mask affect all swivel data records.
55230 CIRCLE_RAPID_FEED Rapid traverse feedrate in mm/min for positioning on circle path between circumferential grooves 9724
and contour elements
55231 MAX_INP_RANGE_GAMMA Maximum input area alignment angle gamma 9863
55232 SUB_SPINDLE_REL_POS Z retraction position for the counter spindle 9851
55405 MILL_TRAORI_USERCYCLE_NAME Program name of manufacturer cycle, if 5-axis machining (TRAORI) is called by means of the
High Speed Settings cycle. .
55410 MILL_SWIVEL_ALARM_MASK Hide and unhide cycle alarms CYCLE800
Bit 0: Error analysis 62186 - active work offset G%4 and base (base relation) include rotations
Bit 1: Error analysis 62187 - active base and base relation (G500) include rotations
Page 32
55440 MILL_TOL_TECHNO_NORM Settings at deselection of High Speed Settings cycle CYCLE832 of G group 59 GUD TOLT[0]
55441 MILL_TOL_TECHNO_ROUGH Settings for roughing High Speed Settings cycle CYCLE832 of G group 59 GUD _TOLT[1]
55442 MILL_TOL_TECHNO_SEMIFIN Settings for pre-finishing High Speed Settings cycle CYCLE832 of G group 59 GUD _TOLT[2]
55443 MILL_TOL_TECHNO_FINISH Settings for finishing High Speed Settings cycle CYCLE832 of G group 59 GUD _TOLT[3]
55445 MILL_TOL_VALUE_NORM Tolerance value on deselecting High Speed Settings cycle CYCLE832 GUD _TOLV[0]
55446 MILL_TOL_VALUE_ROUGH Tolerance value for roughing High Speed Settings cycle CYCLE832 GUD _TOLV[1]
55447 MILL_TOL_VALUE_SEMIFIN Tolerance value for pre-finishing High Speed Settings cycle CYCLE832 GUD _TOLV[2]
55448 MILL_TOL_VALUE_FINISH Tolerance value for finishing High Speed Settings cycle CYCLE832 GUD _TOLV[3]
55460 MILL_CONT_INITIAL_RAD_FIN This data affects the radius of the approach circle during contour pocket finishing. 9670
-1: The radius is selected to maintain a safety clearance to the finishing allowance in the start-
ing point.
>0: The radius is selected to maintain the value of this setting data to the finishing allowance in
the starting point.
SINUMERIK 828D

55461 MILL_CONT_DIFF_TOOLRAD_MIN This data is required for contour pocket milling. This data defines the percentage by which the 9657
SINUMERIK 828D
radius of an operating cutter can be smaller than the radius with which the contour program was
generated.
55462 MILL_CONT_DIFF_TOOLRAD_MAX This setting data is required for contour pocket milling. It defines the amount by which the radius 9658
of an operating cutter can be larger than the radius with which the program was generated.
55480 DRILLING_AXIS_IS_Z Drilling axis depends on plane (G17, G18, G19) or always Z
55481 DRILL_TAPPING_SET_GG12 Settings for tapping G group 12 cycle CYCLE84 and CYCLE840: 9855 - Index [0]
G group 12: Block change behavior at exact stop (G60) 9856 - Index [1]
0 = Exact stop behavior, same as before the cycle call
1 = G601
2 = G602
3 = G603
Index[0]: for tool spindle
Index[1]: for main spindle - for drilling in centre
55482 MILL_TOL_TECHNO_FINISH Settings for tapping G group 21 cycle CYCLE84: 9855 - Index [0]
G group 21: Acceleration profile (SOFT, BRISK, ..) 9856 - Index [1]
0 = Acceleration behavior, same as before the cycle call
1 = SOFT
Page 33
2 = BRISK
3 = DRIVE
55483 DRILL_TAPPING_SET_GG24 Settings for tapping G group 24 cycle CYCLE84 and CYCLE840: 9855 - Index [0]
G group 24: Feedforward control (FFWON, FFWOF ) 9856 - Index [1]
0 = Feedforward control, same as before the cycle call
1 = FFWON
2 = FFWOF
55484 DRILL_TAPPING_SET_MC Setting for tapping cycle CYCLE84 spindle operation at MCALL 9855 - Index [0]
0= Reactivate spindle operation at MCALL 9856 - Index [1]
1= Maintain position-controlled spindle operation at MCALL
55489 DRILL_MID_MAX_ECCENT Maximum centre offset for centre drilling 9862
55490 DRILL_SPOT_DIST Rough drilling depth for drill and thread milling 9682
Appendix B
Appendix B

55500 TURN_FIN_FEED_PERCENT When selecting Complete machining (roughing and finishing), the percentage of the entered 9630
Appendix B
feedrate F as specified in this setting data is used for finishing.
55505 TURN_ROUGH_O_RELEASE_DIST This setting data defines the distance by which the tool is returned from the contour during stock 9648
removal of an outer corner. This does not apply to stock removal of a contour.
Appendix B
-1: The distance is specified internally.

55506 TURN_ROUGH_I_RELEASE_DIST This setting data defines the distance by which the tool is returned from the contour during stock 9649
removal of an inner corner. This does not apply to stock removal of a contour.
-1: The distance is specified internally.
55510 TURN_GROOVE_DWELL_TIME If a tool clearance time occurs in a cycle, e.g. deep hole drilling, grooving, the value of this setting 9621
data is used
- Negative value in spindle revolutions
- Positive value in seconds
55515 TURN_THREAD_RELEASE_DIST In this setting data you specify the distance to the workpiece, by which the tool is retracted be- 9850
tween the infeed motions during thread cutting.
55540 TURN_PART_OFF_CTRL_DIST Path for cut-off check 9859
55541 TURN_PART_OFF_CTRL_FEED Feedrate for cut-off check 9860
Page 34
55542 TURN_PART_OFF_CTRL_FORCE Force in percent for cut-off check 9861
55543 TURN_PART_OFF_RETRACTION Retraction path prior to cut-off with counter spindle 9858
55550 TURN_FIXED_STOP_DIST In this setting data you specify the distance to the programmed target position, after which the 9852
counter spindle travels with a special feedrate during travel to fixed stop (see 55551
$SCS_TURN_FIXED_STOP_FEED).
55551 TURN_FIXED_STOP_FEED In this setting data you specify the feedrate with which the counter spindle travels to a fixed stop. 9853
In setting data 55550 $SCS_TURN_FIXED_STOP_DIST you specify the distance after which the
tool travels in this feedrate.
55552 TURN_FIXED_STOP_FORCE In this setting data you specify at which percentage of the driving force the counter spindle is to 9854
stop during travel to fixed stop.
55553 TURN_FIXED_STOP_RETRACTION Retraction path prior to chucking after travel to fixed stop 9857
55580 TURN_CONT_RELEASE_ANGLE This setting data defines the angle by which the tool is retracted from the contour during contour
turning roughing.
55581 TURN_CONT_RELEASE_DIST This setting data defines the value by which the tool is retracted in both axes during contour turn- 9550
ing roughing. This applies to cutting, plunge-cutting and plunge turning.
55582 TURN_CONT_TRACE_ANGLE This setting data specifies the angle between the cutting edge and the contour, at which the con- 9553
tour is rounded in order to remove residual material.
SINUMERIK 828D

55583 TURN_CONT_VARIABLE_DEPTH Percentage for variable cutting depth during contour turning 9556
SINUMERIK 828D
55584 TURN_CONT_BLANK_OFFSET This setting data specifies the distance to the blank, after which contour turning is switched from 9552
G0 to G1 in order to adjust any possible blank allowances. This applies to cutting, plunge cutting
and plunge turning.
55585 TURN_CONT_INTERRUPT_TIME Feed interrupt time during contour turning, contour grooving and plunge turning 9557
- Negative value in spindle revolutions
- Positive value in seconds
This setting data is effective only if setting data 55586 is 55586
$SCS_TURN_CONT_INTER_RETRACTION = 0.
55586 TURN_CONT_INTER_RETRACTION Retraction path feed interrupt during contour turning, contour grooving and plunge turning: 9558
>0: Retraction path after feed interrupt (setting data 55585
$SCS_TURN_CONT_INTERRUPT_TIME is ineffective!)
=0: No retraction path
55587 TURN_CONT_MIN_REST_MAT_AX1 This MD defines the limit value for stock removal of residual material in the direction of the 1st 9554
axis.
Example:
If this MD is set to 50% and if the finishing allowance is 0.5 mm, the residual material which is
thinner than 0.25 mm is not removed in a separate machining step, but during finishing.
Page 35
55588 TURN_CONT_MIN_REST_MAT_AX2 This MD defines the limit value for stock removal of residual material in the direction of the 2nd 9555
axis.
Example:
If this MD is set to 50% and if the finishing allowance is 0.5 mm, the residual material which is
thinner than 0.25 mm is not removed in a separate machining step, but during finishing.
55595 TURN_CONT_TOOL_BEND_RETR Retraction due to tool bending during plunge turning. In this setting data you specify the lateral 9560
distance to the last cut, by which each next cut will be shortened.
55596 TURN_CONT_TURN_RETRACTION Retraction depth prior to plunge turning 9561
55600 MEA_COLLISION_MONITORING Collision detection with tool probe for intermediate positioning GUD =_CHBIT
[2]
=0: no collision detection
=1: the movement of positioning operations calculated by the measuring cycles and performed
between the measuring points is stopped as soon as the probe provides a switching signal. A cor-
responding alarm message is displayed.
Appendix B
Appendix B

55602 MEA_COLLISION_MONITORING Coupling of spindle orientation and coordinate rotation in the active plane, in the case of workpiece GUD =_CHBIT
Appendix B
measurement with multiprobe in Automatic mode [13]
=0: No coupling of spindle orientation and coordinate rotation in the plane.

=1: When multiprobes are used, the spindle is oriented depending on the active coordinate rota-
Appendix B
tion in the plane (rotations around the infeed axis (applicate)).

Thus, the axis-parallel orientation of the probe sphere contact points (calibrated trigger points) is
maintained with regard to the geometry axis.
The direction of spindle rotation is defined by SD55604 $SCS_MEA_SPIND_MOVE_DIR!
Note:
Coordinate rotation in the active plane means: - Rotation around the Z axis at G17,
- Rotation around the Y axis at G18
- Rotation around the X axis at G19.
Notice:
The coupling is annulled by the measuring cycle, if :
- Rotations around the 1st or 2nd measuring axis (abscissa or ordinate at G17) between calibra-
tion and actual measuring are not identical!!!
- The working spindle is not position-controlled (no SPOS possible)
- A monoprobe is used (_PRNUM=x1xx)!
- When the coupling is annulled by the measuring cycle, no alarm or message is displayed!
Page 36
55604 MEA_SPIND_MOVE_DIR Direction of rotation of spindle positioning with regard to active coupling of spindle orientation and GUD =_CHBIT
coordinate rotation in the active plane. [14]
=0: The spindle is positioned as specified by the default.
- Coordinate rotation angle in the plane 0°: spindle positioning 0°
=1: The spindle is positioned in the opposite direction (adjusted angle values).
55606 MEA_NUM_OF_MEASURE Number of measurement repetitions, if the probe does not switch GUD =_CHBIT
=0: Max. 5 measuring attempts are performed before measuring cycle alarm "Probe does not [15]
switch" is output.
=1: After the first unsuccessful measuring attempt measuring cycle alarm "Probe does not switch"
is generated.
55608 MEA_RETRACTION_FEED Retraction velocity from the measuring point
=0: Retraction of the measuring point is performed with the same velocity as in intermediate posi-
tioning (SD55631 $SCS_MEA_FEED_PLANE_VALUE.
=1: The retraction velocity depends on the rapid traverse velocity in percent as specified in
SD55630 $SCS_MEA_FEED_RAPID_IN_PERCENT and is only effective with active collision
detection (SD55600 $SCS_MEA_COLLISION_MONITORING=1).
SINUMERIK 828D
55610 MEA_FEED_TYP Measuring feed GUD =_CHBIT
SINUMERIK 828D
=0: For the measuring travel the feedrate generated in the cycle or the feedrate programmed in [17]
parameter _VMS is used.
=1: Travel is first performed with "rapid measuring feed" SD55633
$SCS_MEA_FEED_FAST_MEASURE; after contact of the probe with the measuring object a
retraction of 2 mm from the measuring point is performed. Now the measuring travel itself
with the feedrate from _VMS is performed.
The function "Rapid measuring feed" is realized only if the value in parameter is _FA >=1!
55613 MEA_RESULT_DISPLAY Measurement result display GUD =_CHBIT

=0: No measurement result display [10]
=1: The measurement result is displayed until cycle end GUD =_CHBIT
=2: The measurement result is displayed until the start/call of the next cycle [11]GUD
=3: With the measurement result display, the cycle is stopped by an internal M0, =_CHBIT[18]
with NC start, the measuring cycle is continued and the measurement result display is
deselected
=4: The measurement result display is only shown for cycle alarms 61303, 61304, 61305,
61306. Same behavior as with setting 3!
55618 MEA_SIM_ENABLE Selection of measuring cycle response in an environment simulated in HMI Advanced or in Shop-
Mill / ShopTurn
Page 37
= 0: Measuring cycles are not executed (measuring cycle is skipped internally)
= 1: Measuring cycles are executed; real axes are required!
During calibration no values are entered in the probe data fields,
no measurement result is displayed,
the measuring cycle is not logged,
the travel is performed without collision detection.
555619 MEA_SIM_MEASURE_DIFF With this parameter simulated measurement errors can be specified on the measuring points. GUD=_MC_SIM
DIFF
Provided that SD55618 $SCS_MEA_SIM_ENABLE=1 is used and that the measuring cycles are
executed in a simulated environment of HMI Advanced or ShopMill / ShopTurn, a measurement
difference can be entered in this parameter. The value of the measurement difference must be
smaller than the measuring path in parameter _FA!
Otherwise cycle alarm 61301 "Probe does not switch" is output during active simulation.
55622 MEA_EMPIRIC_VALUE_NUM Number of empirical values GUD=_EVMVNU
M[0]
Appendix B
Appendix B

55623 MEA_EMPIRIC_VALUE In its default setting the empirical value memory consists of 20 memory elements. GUD=_EV[n
Appendix B
Using parameter $SCS_MEA_EMPIRIC_VALUE_NUM the number of memory elements can be
defined! Currently, however, these 20 memory elements can-not be changed!
In the empirical value memory, empirical values can be stored which are cleared with the currently
calculated difference between the setpoint and the actual value.
Appendix B
Using parameter _EVNUM the empirical value element to be cleared is addressed!

55624 MEA_AVERAGE_VALUE_NUM Number of mean values GUD=_EVMVNU
M[1]
555625 MEA_AVERAGE_VALUE In its default setting the mean value memory consists of 20 memory elements. GUD=_MV[n
Using parameter $SCS_MEA_AVERAGE_VALUE_NUM the number of memory elements can be
defined! Currently, however, these 20 memory elements can-not be changed!
In the mean value memory, the mean values calculated in connection with functionality "Automatic
tool offset with mean value creation" are stored.
Using parameter _EVNUM the mean value element to be used is addressed!
55630 MEA_FEED_RAPID_IN_PERCENT Traverse velocities for positioning in the measuring cycle between the measuring positions, GUD =_SPEED[0]
with rapid traverse velocity in per cent, with collision detection not active
Note:
Page 38
If necessary, adapt the value of the rapid traverse velocity in per cent to the probe type used and
to the machine characteristics! This means that the maximum deflection of the actual probe type
must be considered!!
Explanations:
In the measuring cycles any intermediate positions are calculated prior to the actual set of meas-
urements. These positions can be approached
- with collision detection (SD55600 $SCS_MEA_COLLISION_MONITORING=1 or
- without collision detection (SD55600 $SCS_MEA_COLLISION_MONITORING=0).
Depending on this setting different velocities are used for the approach:
- with collision detection (SD55600 $SCS_MEA_COLLISION_MONITORING=1):
With SD55631 $SCS_MEA_FEED_PLAN_VALUE the traversing feed is performed in the
plane and
with SD55632 $SCS_MEA_FEED_FEEDAX_VALUE during traversing in the feed axis
(applicate).
If the probe switches when these intermediate positions are approached, the movement is
stopped and the alarm "Probe collision" is output.
- without collision detection (SD55600 $SCS_MEA_COLLISION_MONITORING=0):
The intermediate positions are approached with the maximum axis velocity (rapid trav-
erse) in percent as specified in SD55630 $SCS_MEA_FEED_RAPID_IN_PERCENT.
With SD55630 $SCS_MEA_FEED_RAPID_IN_PERCENT=0 and SD55630
$SCS_MEA_FEED_RAPID_IN_PERCENT=100 the maximum axis velocity is effective.
SINUMERIK 828D

55631 MEA_FEED_PLANE_VALUE Traverse velocities for intermediate positioning in the measuring cycle in the plane, with and with- GUD =_SPEED[1]
SINUMERIK 828D
out collision detection
Note:
If necessary, adapt the value of the velocity for the plane to the probe type used and to the ma-
chine characteristics! This means that the maximum deflection of the actual probe type must be
considered!!
Explanations:
With SD55631 $SCS_MEA_FEED_PLAN_VALUE the traversing feed is performed in the
plane.
Page 39
Appendix B
Appendix B

55632 MEA_FEED_FEEDAX_VALUE Traverse velocities for intermediate positioning in the measuring cycle in the infeed axis, with and GUD =_SPEED[2]
Appendix B
without collision detection
Note:
If necessary, adapt the value of the velocity in the infeed axis to the probe type used and to the
Appendix B
machine characteristics! This means that the maximum deflection of the actual probe type must be
considered!!
Explanations:
With SD55632 $SCS_MEA_FEED_FEEDAX_VALUE the traversing feed is performed in
the infeed axis (applicate).
Page 40
55633 MEA_FEED_FAST_MEASURE Rapid measuring feed GUD =_SPEED[3]
Note:
If necessary, adjust the value of the velocity to the probe type used and to the machine character-
istics!
This means that the maximum deflection of the actual probe type must be considered!!
The use of "Rapid measuring feed" depends of SD55610 $SCS_MEA_FEED_TYP!
55760 J_MEA_SET_TOOL_OFFSET_MODE Selection of the offset target during tool measurement, in “Measure in JOG” GUD =_JM_B[0]
=0: Offset into the geometry of the tool component to be corrected
=1: Offset into the wear of the tool component to be corrected
55761 J_MEA_SET_NUM_OF_ATTEMPTS Number of measuring attempts, if the probe does not switch, in "Measure in JOG" GUD =_JM_B[1]
=0: 5 measuring attempts, then alarm "Probe does not switch" is output
=1: 1 measuring attempt, then alarm "Probe does not switch" is output
55762 J_MEA_SET_RETRAC_MODE Selection of the velocity of retraction from the measuring point, in "Measure in JOG" GUD =_JM_B[2]
=0: Retraction is performed at the same velocity as that of intermediate positioning
=1: Retraction is performed with rapid traverse
SINUMERIK 828D
55763 J_MEA_SET_FEED_MODE Measuring with rapid or normal measuring feed, in "Measure in JOG" GUD =_JM_B[3]
SINUMERIK 828D
=0: Measuring with measuring feed
=1: First probing is performed with "Rapid measuring feed" from SD55633
$SCS_MEA_FEED_FAST_MEASURE; the second probing represents the measurement itself
performed with measuring feed.
55764 J_MEA_SELECT_CORR_FRAME Selection of the channel frame to be corrected, in “Measure in JOG” GUD =_JM_B[4]
=0: If basic frame is selected as offset target in the parameterization mask, the offset is carried out
into the last channel-specific basic frame
=1: If basic frame is selected as offset target in the parameterization mask, the offset is carried out
into the system frame "Set zero point" ($P_SETFRAME)
55770 J_MEA_SET_COUPL_SP_COOR Coupling of spindle orientation and coordinate rotation around the active plane, in the case of GUD
D workpiece measurement with multiprobe in "Measure in JOG" mode =E_MESS_SET
=0: When multiprobes are used, the spindle is oriented as a function of the active coordinate rota- T[0]
tion in the plane (rotation around the infeed axis (applicate)).
Thus, the axis-parallel orientation of the probe sphere contact points (calibrated trigger
points) is maintained in relation to the geometry axis.
The direction of spindle rotation is defined by SD55604 $SCS_MEA_SPIND_MOVE_DIR!
=1: The current spindle orientation with NC-START of the measuring task for "Measure in JOG"
Page 41
is used as the starting position for the following procedure!
Note:
Coordinate rotation in the active plane means: - Rotation around the Z axis at G17,
- Rotation around the Y axis at G18
- Rotation around the X axis at G19.
Notice:
The coupling is annulled by the measuring cycle, if
- Rotations around the 1st or 2nd measuring axis (abscissa or ordinate at G17) between calibra-
tion and actual measuring are not identical !!!
- The working spindle is not position-controlled (SPOS is not possible)
- A monoprobe is used.
- When the coupling is annulled by the measuring cycle, no alarm or message is displayed.
Appendix B
Appendix B
55771 J_MEA_SET_CAL_MODE Calibration in the hole with known or unknown centre point, in "Measure in JOG" GUD=E_MESS_
Appendix B
SETT[1]
=0: Calibration in a hole with unknown centre point
=1: Calibration in a hole with known centre point
Appendix B
55772 J_MEA_SET_PROBE_MONO Selection of the probe type, in "Measure in JOG" GUD=E_MESS_

MS_MONO
=0 probe type is multiprobe
=1 probe type is monoprobe 9779
55800 ISO_M_DRILLING_AXIS_IS_Z Selection of the drilling axis
0: Drilling axis is vertical to the active plane
1: Drilling axis is always "Z", independently of the active plane
55802 ISO_M_DRILLING_TYPE Tapping type
0: Tapping without compensating chuck
1: Tapping with compensating chuck
2: Deep hole tapping with chip breakage
3: Deep hole tapping with stock removal
55804 ISO_M_RETRACTION_FACTOR Factor for retraction speed (0...200%)
Page 42
55806 ISO_M_RETRACTION_DIR Retraction direction for precision drilling and reverse counter-sinking G76/G87
0: G17(-X) G18(-Z) G19(-Y)
1: G17(+X) G18(+Z) G19(+Y)
2: G17(-X) G18(-Z) G19(-Y)
3: G17(+Y) G18(+X) G19(+Z)
4: G17(-Y) G18(-X) G19(-Z)
55808 ISO_T_RETRACTION_FACTOR Factor (1-200%) for retraction speed at tapping G84/G88
55810 ISO_T_DWELL_TIME_UNIT Dwell time evaluation for deep hole drilling G83/G87
0: Seconds
1: Revolutions
SINUMERIK 828D

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SINUMERIK 828D

This document was produced for training purposes.

Service Manual for

Sinumerik 828D Software 4.3

Appendix B Appendix A B006

828D & PPU Information

Machine Control Panels

Drive-CLiQ Hub & Sensor Modules

PLC Periphery Modules

B060 Page 2 SINUMERIK 828D

System overview: Description

828D & PPU

SINUMERIK 828D Page 3 B060

PP72/48 PN PLC I/O

Filter NX10 S120

B060 Page 4 SINUMERIK 828D

PP72/48 PN PLC I/O

X100 to X102 DriveCLiQ Interfaces

SINUMERIK 828D Page 5 B060

828D controller with integrated PPU (Panel Processing General Information

PPU Horizontal layout:

PPU241 Software- (Current system software delivered on CF

6FC5832-2GY00-0YA0 Basic for PPU240/PPU251

6FC5832-1GY00-0YA0 Basic for PPU PPU240/PPU241

Blank Compact Flash Card 1GB:

B060 Page 6 SINUMERIK 828D

Specifications PPU interfaces and status LEDs (Rear):

Input voltage- 24V DC +20% /-15% X1-24V DC supply

General information X122 & X132-Digital I/O for Sinamics

PPU interfaces and status LEDs (Front): LED Indicators:

LED indicators: Rx/Tx Yellow Network activity (1 each for PN1,

Name Colour Description Link Green Network connected (1 each for

SINUMERIK 828D Page 7 B060

B060 Page 8 SINUMERIK 828D

PPU240.1/241.1 PPU260/261 PPU280/281

Easy Extend management of machine components      

Easy Archive data archiving      

SINUMERIK 828D Page 9 B060

Machine Control Panels Interfaces:-

Machine Control Panel MCP483C PN

The MCP483 is recommended for use with the horizontal

6FC5247-0AF13-1AA0-Feed override, rotary switch incl. cap,

6FC5247-0AF12-1AA0-Spindle override rotary switch incl.

B060 Page 10 SINUMERIK 828D

SLM (16Kw and above) & ALM (all variants)

Smart Line Module Active Line Module

SINUMERIK 828D Page 11

Motor Modules (MM)

Part Numbers-single modules

Part Numbers-double modules

B060 Page 12 SINUMERIK 828D

SINUMERIK 828D Page 13

Braking Modules & Resistors Part Numbers-

Braking modules and resistors can also facilitate the controlled

Connector X21 on the braking module is used for enable/fault/

Connector X1 is for connecting the external resistor.

B060 Page 14 SINUMERIK 828D

NX10 Module Drive-CLiQ Hub & Sensor Modules

NX10 Module (Numerical Control Extension) DMC20 Drive-CLiQ Hub

SINUMERIK 828D Page 15

Sensor modules are required to convert non-DriveCliq encoder

B060 Page 16 SINUMERIK 828D

Sensor Modules (SMC & SME)-continued PLC Periphery Modules