En 802D SL Complete Service v14

SINUMERIK 802D solution line
Service Handbook
Training Manual Edition 07.2008
Training Material
SINUMERIK 802D sl
Service Handbook
Valid for
Control Software
SINUMERIK 802D sl 1.4
This document was produced for training purposes.

Siemens assumes no responsibility for its contents.
Edition 07.2008
Service Handbook
Content
System overview C060 Install additional axis C016

Select Hardware (Sizer) C004 Optimization with Starter C055
Design of Electrical Cabinet C006 Optimization with IBN tool C055
Line modules C051 On - board optimization C056
Installation of Commissioning Tools C002 Interface signals C063
Protection levels C021 Machine data lists C064
RCS Data transfer tool C001 PLC Instruction list C065
Working with CF cards C059 Component mounting dimensions C062
Pushbutton test (MCP) C008
Profibus configuration C061
LED Diagnosis Drive C009
LED Diagnosis HMI C010
MCPA signal test C011
Save Data Backup C017
Restore Data Backup C018
External data backup and restore C019
Diagnose PLC program C028
Diagnose PLC alarm C031
Creating alarm texts C029
Alarm structure C037
Diagnosis of Cycle alarms C039
Editing of NC Machine data C041
Drive Diagnostic parameters C053
Service Displays C058
Creating the PLC program C026
Loading a PLC program C027
PLC Subroutine library C035
PLC Functions C033
Commissioning of Options C044
ISO Dialect commissioning C085
Start-up of NC parameters C040
Display options C022
Reference - encoder adjustment C084
C060 802D sl System overview
1 Brief description
Module Objective:
Upon completion of this module you will understand the system architecture.
Module Description:
The 802D sl system is built from various components, this module gives graphically an overview of
these components, so that an impression can be seen of the complete system. Also included in this
module is general component information including MLFB identification.
Module Content:
Graphic overview of 802D sl CNC system
Graphic overview of Section 2

802D sl CNC system
Common part informa-

Section 3
tion
SINUMERIK 802D sl Service, Training Manual Page 1

Siemens assumes no responsibility for its contents. C060
Section 2 Graphic overview of 802D sl CNC system
Notes
Digital I/O
(Sinamics)
Electronic
handwheel
NC full keyboard
CF Card
X20 X21
1
X30 X9
X40
DC24V Power Supply 1
2 SINUMERIK Terminal connection
802D sl
3 MCP Via MCPA
PCU Ribbon
X10
USB
X1201 X1202
Cable
X1
210.3
MCPA
X110
X5
Insert to
X2
X8 X2 X1 X6 (2x40)
Ethernet connection (Option)

X1020 X701
/X1021
MCP Direct I/O
RS232 cable connection
X1201 X1202
2
X1 X2
Terminal
X111
strip
converter
PP 72/48
Terminal
X333 X222
strip
converter
Terminal
RS232 strip
converter
Adapter
2
PC X1 X2
Machine tools
Terminal
X111
strip
electric
converter
PP 72/48
Terminal
X333 X222
strip
converter
Terminal
strip
converter
2
X1 X2
Terminal
X111
strip
converter
PP 72/48
Terminal
Machine tools
X333 X222
strip
electric
converter
Terminal
strip
converter
DP/DP Other DP
X1
X2
Coupler master
DRIVE CLiQ for ALM
DRIVE CLiQ for SLM < 16KW
SMC Encoder
Interface
3
Smart line 2 -axes

module
or Motor module
Active line (power section)
module
2 -axes 1-axis
Motor module Motor module
(power section) (power section)
Inverter Spindle motor
Mains
supply Filter
Encoder
Reactor
(Option)
SINUMERIK 802D sl Service, Training Manual Page 2 C060

Common part information Section 3
Notes
PCU
CNC central processing unit, comprising of a complete embedded system, Contain-

ing, HMI, NCK, PLC and CU. (for sinamics drives) Three variants are available, giving
different degrees of functionality. These are, Value, Plus and Pro. This must be speci-
fied at time of order as software upgrade, are not possible.
PCU210.3 6FC5370-0AA00-xAA0
1 - Value
2 - Plus
3 - Pro
Differences in functionality can be seen in the following table.
Value Plus Pro
Control structure/application
CNC main memory (buffered) for programs and data in MB 0.5 1 3
CNC main memory maximum configuration in MB 0.5 1 3
Axes / spindles yes (1) yes (2) yes (2)
Maximum configuration of axes 4 5 5
Maximum configuration of spindles 1 2 2
Maximum configuration of axes and spindles 4 5 5
Maximum configuration of axes incl, spindles 4 5 5
PLC controlled axes - 1 1
CNC Functionality: Program functions
Look ahead 20 50 100
CNC Functionality: Axis functions
Rotary axis, turning endlessly - yes yes
Acceleration with jerk limitation - yes yes
Traversing to fixed stop - yes yes
CNC Functionality: Spindle functions
Changeover to axis mode - yes yes
CNC Functionality: Interpolations
Maximum 3 4 4
Helical interpolation 2D+1 2D+2 2D+2
CNC Functionality: Transformations
TRANSMIT / peripheral surface transformations - yes yes
CNC Functionality: Measuring
Measuring stage 1, Probe (touch trigger) - yes yes

(1) 3 axes + 1 spindle
(2) 4 axes + 1 spindle or 3 axes + 1 spindle + 2nd spindle for rotating tool

Section 3 Common part information
Notes
Value Plus Pro
CNC Functionality: Motion-synchronous actions
High-speed CNC digital inputs (on-board) - 8 (1) 8 (1)
High-speed CNC digital inputs or outputs (on-board) - 8 (1) 8 (1)
CNC Programming: Language

Via H word max. programmable value range
- yes yes
REAL 3.4028 ex 38 (display: 999 999 999.9999)
+/- +/-
Program / workpiece management on network drive - - yes
Operating modes
Execute from network drive - - yes
Tools
Number of tools 32 64 128
Cutting edges in tool list 32 64 128
Monitoring of tool life and workpiece count - yes yes
Communication and data management
Ethernet connection - - yes
Save data to network drive (Ethernet) - - yes
Compensation
Feedforward control, speed dependant - - yes
PLC Area
Ladder steps memory configuration 4000 6000 6000
Bit memories, max. number 2048 3072 3072
Timers, max. number 40 40 64
Counters, max. number 32 32 64
Diagnostic functions
PLC Remote diagnostics via Ethernet - - yes (2)
RCS 802 PC License 6FC6000-6DA51-0AA0 option
(1) Software version 1.2 onwards

(2) RCS 802 required

Common part information Section 3
Interface connections Notes
X1 & X2 DRIVE-CLiQ interface (Special RJ45)
X5 Ethernet connection to external PG / PC (RJ45)
X6 Profibus DP interface to PLC I/O (12MB fixed)
X8 RS232C interface (Pin D-sub)
X9 NC Keyboard
X10 USB (Not fully supported)
X20 & X21 Drive interface, BICO connectors
X30 Handwheel / Probe connection
X40 24V supply
X110 MCPA interface connection
CF Card Compact flash interface
Machine control panel
The machine control panel can be connected to the system in two different ways. Di-
rectly to machine PLC I/O, In this case all pushbuttons and LED indicators have fixed
addresses in the PLC. The control voltage levels are 24V and must be connected to
the 1st PP72/48 (X111 & X222)
The second option for MCP, is via MCPA interface. This method involves connecting
an MCPA pcb to the option slot of the PCU (X110) and connecting the MCP to the
MCPA. (X1 & X2) the interface signals are connected directly to the NC-PLC inter-
face. The control voltages are 5V. This method allows more PLC I/O availability for
the PLC.
Via MCPA 6FC5303-0AF30-1AA0

Direct 6FC5603-0AD00-0AA2
Power supply
Supplies 24V DC to the PCU, PLC I/O & Sinamics control voltage
24V DC (Sitop / PS307) (5A) 6EP1333-3BA00

(10A) 6EP1334-3BA00
RS232
Isolation of RS232 is required to separate floating potentials between two devices
Adapter 6FX2 003-0DS00

Cable 6FX8 002-1AA01-1xx0
NC Full Keyboard
(Complete with cable) Upright 6FC5303-0DT12-1AA0
Broad 6FC5303-0DM13-1AA0
Electronic handwheel 6FC9320-5DC01

Section 3 Common part information
Notes MCPA Module
This module has several functions, It is used to interface the signals from the MCP
with the PCU, It has the facility to provide an analogue output to an external drive
(X701) Also connected to this module is the fast NC I/O. 8 x Digital inputs, and 8 x
Digital outputs.
6FC5312-0DA01-0AA0
X1 & X2 MCP interface (5V)
X110 PCU 210 interface
X701 External analogue setpoint interface
X1020 & X1021 Fast NC I/O interface

($A_IN[9...16], $A_OUT[9...16])
PLC I/O Module
Maximum of 3 modules, the addresses are fixed by the system. Diagnostic LED’s
are available for local fault identification.
X1 24V DC Supply
X2 Profibus DP interface
X111, X222 & X333 I/O Interface
S1 DIP switch
(9 - 1st module, 8 - 2nd module, 7 - 3rd module)
PP 72/48 6FC5611-0CA01-0AA0
Terminal strip converter 6EP5406-5AA00

Profibus connector 6ES7972-0BA41-1XA0
Profibus cable ( < 100m) 6XV1830-0EH10
DP – DP Coupler 6ES7158-0AD01-0XA0
Sinamics drive system
Smart line module 6SL3130-6AExx-0AA0

Active line module 6SL3130-7TExx-6AA1
Single axis motor module 6SL3120-1TExx-0AA0

Double axis motor module 6SL3120-2TExx-0AA0
Servo motor 1FK7xxx-5AF71-1xx3

Servo motor power cable 6FX5002-5xSxx-1xx0
Servo motor signal cable 6FX5002-2DC10-1xx0
Spindle motor 1PH7xxx-2QF02-0xx3

Spindle motor power cable 6FX5008-1BBxx-1xx0
Spindle motor signal cable 6FX5002-2DC10-1xx0
External encoder module SMC20 (1V pp) 6SL3055-0AA00-5BA1

External encoder cable SMC20 6FX5002-2CG00-1xx0
External encoder module SMC30 (TTL) 6SL3055-0AA00-5CA0

External encoder cable SMC30 6FX5002-2CD01-1xx0
DRIVE-CLiQ cable 6FX2002-1DC00- 1..0

C004 Hardware Configuration with SIZER
1 Brief Description
Module Objective:
Upon completion of this module you can use the program “SINAMICS MICROMASTER SIZER” and
configure a system containing Sinamics hardware components.
Module Description:
The operation of the program SINAMICS MICROMASTER SIZER is explained in more detail and an
overview of the configuration options is given by means of examples.
The following systems are supported by the software for project configuration:
Single drives with MICROMASTER 4, SIMATIC ET200S FC, SINAMICS G110, G120, G130,
G150
S150 sectional drives with SINAMICS S120 with the controller versions SINAMICS CU320,
SIMOTION (D425, D435, D445, C230-2, P350) or SINUMERIK SL (802D sl, 840D sl, 840 Di sl)
In combination with SIMOTION or SINUMERIK, it is possible to configure expansion boards. These

drive versions can be mixed within a project as desired, i.e. with SINAMICS MICROMASTER SIZER,
it is possible to implement comprehensive configurations for overall applications.
Module Content:
Basics of SINAMICS MICROMASTER SIZER
Basics of SINAMICS
MICROMASTER SI- Section 2
ZER

Section 2 Basics of SINAMICS MICROMASTER SIZER
Notes
Start the program and create an empty project via “Project” “New…”.
Then, set the project name, master data and project settings (Fig. C4-1).
Master
Project settings
Figure C4-1 - Creating a project
The user interface with the graphical wizards is displayed (Fig. C4-2).
Workflow
Project navigator
Result display
Working area
Hints
Figure C4-2 - User interface

In the project navigator, all connected objects and their status are
displayed. The workflow shows the physically required process of the drive
configuration (arrow direction). The highlighting (yellow frame) identifies
the component you are currently working on . In addition to that, the status
is indicated with a green check or a red cross. The hints area contains
notes on the current step. In the “Results” tab, the results of the
configuration are displayed (parts list, technical data, characteristics, etc).

Basics of SINAMICS MICROMASTER SIZER Section 2
Notes
For a complete configuration of the drive, all steps in the workflow have to
be executed. The current status is highlighted. Each entry in the workflow
has a structure which can be opened with “+”. To change the data, click
the respective button (Fig. C4-3). To proceed to the next step, press the
corresponding blue symbol with the text.
Button
Figure C4-3 - Workflow
Execute all steps of the workflow to create the configuration. Comfortable wizards
like the Motor wizard (Fig. C4-4) will support you.
When all steps have been executed correctly, the results can bee seen in the result
display.

Section 2 Basics of SINAMICS MICROMASTER SIZER
Notes
Via the object item “System components”, the specific settings for the re-
spective controller and the axis assignment can be executed in the
“Topology” menu (Fig. C4-5).
Model selection
Axis assignment
Figure C4-5 - Drive system
For the use of double motor modules, these have to be configured as sin-
gle motor modules first. They can then subsequently be combined under
the menu item “Double Motor Modules” (Fig. C4-6).
Figure C4-6 - Double motor module

Basics of SINAMICS MICROMASTER SIZER Section 2
Notes
As a result of your configuration, all required information is displayed in a

summarized form under the “Result” tab (Fig. C4-2). This is, among other
things, the characteristics of the motors, a quantity list, technical data, and
dimensioned drawings (Fig. C4-7).
Figure C4-7 - Dimensioned drawings motor
Figure C4-8 - 3D view motor
All data can be converted into Excel format (*.xls) via an export function
(“Options” menu) for further processing. The configuration is thus com-
pleted.

Notes

C006 Electrical cabinet requirements
1 Brief description
Module Objective:
Upon completion of this module you can:-
Identify the installation requirements of the various components of the 802D sl system.
Brief Description:
It is important that the hardware is correctly installed for trouble free operation. This module identifies
the key areas to help achieve this.
Module Content:
Section 2
Cabinet types.
Section 3
Cooling fans/cooling unit.
Section 4
Component mounting methods.
Section 5
Cable ducting and Din rail.
Section 6
Equipotential bonding and equipment grounding.
Section 7
Line filter and commutation reactor.
Section 8
Drive modules and supply voltages.
Section 9
Eletromagnetic compatibility (EMC).
Section 10
Auxiliary components.
Section 11
Mounting of the PCU210.3 and other operator components
Section 12
Power supply unit (+24VDC) and secondary fuse/circuit
Breaker.
Section 13
+24VDC Wiring
Section 14
Item identification and labelling
Section 15
Control element identification and warning labels
Section 16
Main switch early break contact
Section 17
Main circuit wiring
Section 18
Emergency stop and guard door monitoring
Section 19
Motor brake connections

C006 Electrical cabinet requirements
Switching the control voltage ON/OFF Section 20
Machine control panel connections (MCP & MCPA) Section 21

Terminal strip converters Section 22
Profibus cables Section 23
DRIVE-CLiQ cables
Section 24
Surge suppressing
Section 25
SMC module
Section 26

Cabinet types Section 2
Notes
2.1 Standard Rittal type cabinet for Sinamics internal heat sink.
Due to the presence of a backplane

there is no opportunity to fit drive
modules with external heat sinks
Advantages:-Closed cabinet system-

less chance of contamination
Disadvantages:-High Internal cabinet

temperature, Cooling unit required.
2.2 Special cabinet for Sinamics external heat sink.
Advantages:-External heatsinks-
Lower internal cabinet temperatures
Disadvantages:-Heatsinks exposed
to contmination, regular inspection/
cleaning required.
Note:-Individual cabinet cooling requirements depend on the heat-loss
characteristics of the installed components and the cabinet manufacturers
specifications regarding heat dissipation

Section 3 Cooling fans/cooling unit
Notes
There are several factors which influence the type of cooling required.
These range from the size and type of SLM/ALM to the type of mounting of
the drive components.
3.1 Cooling Fans
Size of fan is dependent on the

heat loss of the modules.
Example:-This method could be used for cabinets wihere external heat
sinks are used. Filters need cleaning on a regular basis.
3.2 Cooling unit
Example:-High powered systems

with internal drive heat sink system.
The internal air is cooled and recir-

culated which allows for the cabinet
to be fully sealed thus lessening the
chance of contamination.
Note:-Contact the cabinet manufacturer for heat loss characteristics of indivi-

dual cabinets.
Cooling fans/cooling unit Section 3
With the external cooling option, the heat-sinks need to be covered with a Notes
metal cover incorporating a fan. This serves two purposes, to protect the
heat-sinks and to promote good airflow for improved cooling.
heat sink cover External fan
The cover should fit close to the heat-sink. This helps produce a strong
air flow.

Section 4 Component mounting methods
Notes
4.1 Tapped hole up to M6 (M3, M4, M5, M6)
The sheet metal for the backplane is 3mm thick. Tapping the back-
plane directly is fine for screws up to M6 x 1.0mm This will give a
minimum of 3 complete threads which offers good mechanical
strength.
4.2 Rivet nut for screws greater than M6 (M8, M10)

If M8 x 1.2mm screws or larger are used, the number of complete
threads will be less than 3 and result in reduced mechanical strength.
The use of rivet nuts is reccomended for the mounting of heavier com-
ponents using screw sizes of M8 and above.
Rivet nut

Cable ducting and Din rail Section 5
Notes
Slotted cable ducting, allows the components to

be connected in a tidy and professional manner.
Din rail mounting system, allows compo-

nents to be easily clipped into place.
Allow space above and be-

low components for the
connection of larger
cables.

Section 5 Cable Ducting and Din rail
Notes
The cable ducting above the drive modules is

positioned so that it does not interfere with the
air flow, which is essential for cooling.
Cable ducting cover, restrains the

cables and gives a professional appea-
rance.

Equipotential bonding and equipment grounding conductor Section 6
Notes
A good earth bonding system is essential, not just for safety reasons but
for EMC measures. Electrical interference can cause problems with signal
voltages such as those used in encoders etc. Earth bonding can help
eliminate these problems.
The uncoated galvanised mounting plate

serves as the central earth point.
In this example there are five earth cables
which will be connected to the five
individual drive components.

Section 7 Line filter and commutation reactor
Notes 7.1 Components for a higher powered drive system.
Line filter
The line filter, commutation reac-

tor and the ALM/SLM should all
be within close proximity to each
other. This keeps the wiring
length to a minimum and helps
prevent electrical interference.
Commutation reactor.
These are large/heavy
items and are usually
floor mounted.
7.2 Components for a lower powered drive system.
Line filter
As mentioned previously, the

components should be mounted
close to the ALM/SLM.
Commutation reactor.
This smaller type can
be mounted on the
mounting plate.

Drive modules and supply voltages Section 8
This panel has a combination of Sinamics and 611 drives Notes
600V DC
24V DC busbar busbar
Drive modules and supply

voltages
Example:-Sinamics Drive component Example:-611 Si-

drive system earthing point. modrive system
Line Module Connection voltages:

Line voltage:
3-ph. 380V AC -10% (-15% < 1 min) to 480V AC +10%
Line frequency:
47 to 63Hz
Electronics power supply

24V DC (20.4 - 28.8)

Section 9 Electromagnetic compatibility (EMC)
Notes ALM and SLM modules produce high levels of electrical interference.
Measures must be taken to reduce the effects of this and comply with
Electromagnetic compatibility (EMC) measures.
9.1 Wiring behind the mounting plate
The power leads can be placed

behind the mounting plate. The
mounting plate acts as a shield.
By twisting the power lines to-
gether the interference can be
further reduced.
9.2 Wiring in front of the mounting plate

Power leads exposed in the cabi-
net need to be shielded, this can
be achieved by using steel brai-
ded cables.
The steel braiding of the drive

supply cable needs to be earthed.
This can be achieved with a sim-
ple clamp device.

Auxiliary components Section 10
Notes
No machine would be able to function without auxiliary components. Here

are a few examples of such components. These would typically be
mounted on Din rail.
All coils should be suppressed as close to the coil as possible to prevent
possible interference or damage to sensitive components.
Circuit breaker Contactor Suppressor

Section 11 Mounting of the PCU210.3 and other operator components
Notes
11.1 Door or locally mounted
Example:-Door mounted operator components-front view
11.2 Pendant or remotely mounted
Example:-Pendant mounted operator components-rear view

Power supply unit( +24VDC) and secondary fuse/circuit breaker Section 12
12.1 Power supply unit (PSU) Notes
The control voltage on modern machines is usually +24VDC, this is

obtained from power supply unit.
Example-Siemens Sitop +24VDC/20A PSU.
12.2 Secondary fuse/circuit breaker
Grounding of M
point
6EP1 961-2BA00
4 channels 2-10A
It is good practice to supply different areas of the machine via secondary

fuses/circuit breakers. This can be achieved with the Siemens Sitop Se-
lect Diagnostic Module. The Diagnostic module allows four seperate circu-
its to be protected from 2A to 10A. The module also has LED‘s for quick
diagnosis of faults and a volt free contact which can be used to signal the
PLC.

Section 13 +24V DC Wiring
Notes
The +24VDC supply is used to supply many components, here are some
Examples.
13.1 Sinumerik 802D sl
PCU210.3
+24VDC,0V
13.2 MCPA
Terminal block X201

+24VDC, 0V
For the Digital outputs
13.3 Sinamics
BLM, SLM & ALM
Terminal block X24
+24VDC, 0V
24VDC for Motor mo-

dules supplied via
bus from X24

Item identification and labelling Section 14
The correct labelling/marking of equipment is required to meet the stan- Notes
dard EN 60439 section 5.2.
Correct labelling and marking is a necessary aid for quick fault diagnosis
provided that the electrical schematic diagrams also refer to these labels/
markings.
14.1 Equipment
Label
14.2 Terminals
Terminal markings

Section 15 Control element identification and warning labels
Notes
The control elements must be clearly labelled to identify their function and
meet the standard EN60204-1 Section 17.
15.1 Main switch label
15.2 Pushbutton labels
15.3 Warning label

Main switch early break contact Section 16
Notes
To prevent possible line module damage it is essential that the line module is
disabled at least 10ms before removal of the mains supply. This is not a prob-
lem in the event of a controlled shutdown via the emergency stop sequence.
The problem arises if the main switch is operated while the machine is run-
ning. To overcome this the main switch unit must equipped with an early
break normally closed (NC) contact(t >/=10ms). This must be connected into
the Enable Pulses terminal (X21.3) of the line module.
Example:-Early break
NC contact
(t >/=10ms)

Section 17 Emergency stop and guard door monitoring
Notes In today's world, the health and safety of the operator and service
personnel is a priority. This is achieved via safety relays which monitor
safety circuits. These relays can be configured to reset automatically as in
the case of a guard door being closed, or require resetting manually e.g.
via a pushbutton, as in the case of an emergency stop.
Example:-Emergency stop safety Example:-Guard door safety re-

relay-Manually reset lay-Automatically reset.
3TK2827-1BB40 3TK2830-1CB30 Ex- 3TK2828-1BB40

pansion unit. Adds
two extra channels to
an existing safety re-
lay
Safety functions such as a stopping in an emergency and guard

door operation must conform to standard:-
EN 60204-1 section 9.4.2.1.

Main circuit wiring Section 18
To meet the standard EN 60204-1 Section 14.2, the electrical cables Notes
should be of a certain colour.
18.1 Wiring before the main switch
The cables supplying

the machine will still
be live when the main
switch is in the off
position. These
cables should be
orange.
18.2 Wiring after main switch
Cables after the main

switch are coloured
black.

Section 19 Motor brake connections
Notes
The type of brake connector depends on the size of the motor module
19.1 Motor modules 3,5,9,18,30A
The brake connections are incor-

perated in the same plug and so-
cket as the motor supply.
19.2 Motor modules from 45A
The brake connections are on a

seperate plug and socket (X11)
from the motor supply

Switching the control voltage ON/OFF Section 20
The control voltage can be initialised via different methods. Typically this Notes
would be used to reset the emergency stop safety relay (See section 17)
20.1 Control voltage ON/OFF by hardwired pushbutton
20.2 Control voltage ON/OFF by PLC
ON OFF OPM

Section 21 Machine control panel connections (MCP & MCPA)
Notes
The two types of machine control panel have different connection methods
21.1 Connection via periphery (PP72/48)
This method uses a

PP72/48 for inputs
and outputs
Connecting cable to
PP72/48.
24VDC signals
21.2 Connection via MCPA module
If an MCPA module is
used for an analogue
spindle option the
MCP is connected via
this and so does not
require a PP72/48
Connection to MCPA
5VDC signals

Terminal strip converters Section 22
22.1 Free connections available with MCP (Sec. 21.1) Notes
The unused inputs and outputs on the PP72/48 are available for general
use on the machine. The ribbon cables from the PP72/48 can be taken to
terminal strip converters to allow connection of the individual inputs and
outputs.
Connection
PP72/48 X222
16 Outputs
Connection
PP72/48 X333
24 Inputs
16 Outputs
22,2 Free available connections with MCPA (Sec. 21.2)

In the case of the MCPA, the PP72/48 has all inputs and outputs available for
general use on the machine.
Connection Connection Connection

PP72/48 X111 PP72/48 X222 PP72/48 X333
24Bit Inputs 24Bit Inputs 24Bit Inputs
16 Bit Outputs 16 Bit Outputs 16 Bit Outputs

Section 23 Profibus cables
Notes
23.1 Sinumerik 802D sl
The PCU210.3 communicates to the PP72/48 via Profibus. It is im-
portant thet the cable is terminated in the correct way.
Terminating switch
Cable
6XV1830-0EH10
Socket X5
23.2 PP72/48
Terminating switch
Socket X2

Drive CLiQ cables Section 24
Special cables are required to connect the various hardware together, these Notes
are called Drive-CLiQ cables. These look similar to standard ethernet
cables, but the encoder cables have two extra pins for the +24VDC. The
cables linking the PCU210.3 and the drive modules do not have the extra
pins.
24.1 Internal
DRIVE-CLiQ encoder
cable With 24VDC
(Degree of protection:-
IP20)
Standard DRIVE-CLiQ
Cable Without DC 24V
wires (IP20)
24.2 Cabinet glands
The encoder cables

need to be taken outside
the cabinet to reach the
encoders. This is done
using a DRIVE-CLiQ
Cabinet gland (6SL3066
-2DA00-0AAx)
Degrees of protection
Internal:-IP20
External:-IP54
24.3 External
External Drive-CLiQ
encoder cable (Degree
of protection:-IP54)

Section 25 Surge suppressing
Notes
All devices (AC or DC) such as valves, contactors, motors (Except servo
motors) etc must be interference suppressed.
Example:-3 phase motor

suppressor

SMC Module Section 26
Notes
Where the encoder is not Drive-CLiQ compatible an SMC30 module is
used. This module is then connected to a spare Drive-CLiQ interface on
the drive via a standard Drive CLiQ cable.
SMC30 part number:-6SL3055-0AA00-5CA0
DRIVE-CLiQ cable from

drive
Encoder cable
Eg 6FX5008-1BD41-2AA0

Notes

C051 Smart Line Module / Active Line Module
1 Brief Description
Module Objective:
Upon completion of this module you can locate and understand the functionality of the Smart Line
Module (SLM) and Active Line Module (ALM) connections.
Module Description:
SLM and ALM are two variants of the energy regeneration for the SINAMICS drive family. Depending
on the requirements of an application, there are Smart Line Modules available for the temporary gen-
erator operation and Active Line Modules for especially high plant availability and network quality.
The design and functions of the modules are described.
Module Content:
Functions
Hardware description
Interfaces
Smart Line Modules

Section 2
Active Line Modules

Section 3

Section 2 Smart Line Modules
Notes
In the case of SINAMICS with a Smart Line Module, the line-commutated

units in IGBT technology (Insulated Gale Bipolar Transistor) feed the brak-
ing energy back into the network. Thus, braking resistors and complex
measures for heat dissipation can be omitted.
Smart Line Module
The SLM provides the motor with a non-stabilized DC voltage at the DC

output. In the regenerative feedback mode, the current is in block format.
The feedback can be deactivated via a terminal since the SLM has no
DRIVE-CliQ connection bellow 16 KW.
The pre-loading of the DC link starts immediately after the application of
the supply voltage and is independent of its rotating field direction. Loading
the DC link is possible after the release of the module. Voltage activation
requires an optional main contactor.

Smart Line Modules Section 2
Notes
Terminal block X1 Smart Line Module 5 and 10 kW network connection
Terminal block X21 Smart Line Module
Terminal block X22 Smart Line Module
If disabling of regeneration is required, 24V should be supplied to terminal 2 and

0V to terminal 4, Caution should be exercised. Adequate braking modules / resis-
tors should be fitted to stop premature component failure.
Terminal block X24 Smart Line Module - 24 V terminal adapter

Section 3 Active Line Modules
Notes
Active Line Modules in IGBT technology supply the connected drives with
a constant voltage. With a fast vector control, a sinusoidal current is gener-
ated.
ALMs are used when, apart from being capable of energy regeneration,
the compensation of supply voltage dips is required for drives or high de-
mands are made on the quality of the fed-back current. The constantly
controlled DC link voltage which decouples the motor from the supply volt-
age brings highest failure safety.
...
Active Line Module
The capability of energy regeneration of the module can be deactivated via

parameters. The pre-loading of the DC link starts immediately after the ap-
plication of the supply voltage and is independent of its rotating field direc-
tion. Loading the DC link is possible after the release of the module. Volt-
age activation requires an optional main contactor.
If disabling of regeneration is required (Sinamics parameter p3533), Cau-

tion should be exercised. Adequate braking modules / resistors should be
fitted to stop premature component failure.

Active Line Modules Section 3
Terminal block X1 Active Line Module 16 kW network connection Notes
Terminal block X1 Active Line Module 26 to 120 kW network connection
X200-X202 - Drive-CliQ interface
Terminal block X21 - EP terminal
Terminal block X24 - 24 V terminal adapter

Notes

C002 Installation of commissioning tools
1 Brief description
Module Objective:
Upon completion of this module you can install the commissioning software.
Module Description:
To ensure the necessary level of compatibility and consistency between machines configured with
the SINUMERIK 802D sl controller , a defined set of commissioning tools are required. How to install
the tools, is described in this document. The procedure used to install these tools is described here.
Module Content:
Software installation
Software:
Commissioning Software Section 2
User Software

SINUMERIK 802D sl 1st Service, Training Manual Page 1 Siemens assumes no responsibility for its contents. C002
Section 2 Commissioning Software
Notes
Software tools are required to commission the 802D SL Controller. These
tools are delivered on CD with each controller.
These tools have to be installed on the commissioning engineers PC or
laptop computer
.
Example of CD:
The following software is contained on the CD:
1. Adobe Reader
2. Automation License Manager Installation optional RCS Viewer
3. Licenses
4. PLC Library PLC Example files
5. Programming tool PLC 802
6. RCS 802 Data transfer tool
7. Toolbox Configuration files
The software contained on the CD should be installed on the commission-

ing PC as follows:
SINUMERIK 802D sl 1st Service, Training Manual Page 2 C002

Commissioning Software Section 2
Notes
All the software packages are installed by running the “setup.exe” file on
the root of the CD.
In some cases, later versions of software are available than is contained

on the CD. Example:- Abode Reader. Individual software packages can be
selected/deselected where necessary.

Section 2 Commissioning Software
Notes
During the installation various dialogue boxes will appear. The dialogue
boxes should be acknowledged and where necessary installation data
should be entered and confirmed.
To install all the software packages will take approximately 45 minutes.

C021 Protection Levels
1 Brief Description
Module Objective:
Upon completion of this module you are able to change protection levels.
Module Description:
The SINUMERIK 802D sl provides a protection level concept for the release of data areas.
Access to programs, data and functions is user-oriented.
There are protection levels 0 to 7, 0 being the highest and 7 the lowest level.
Module Content:
Setting the protection level
Setting the protection

Section 2
level

Section 2 Setting the protection level
Notes
The SINUMERIK 802D provides a protection level concept for the release
of data areas.
The default passwords for the protection levels 1 to 3 are the following:
Attention:
During a system startup during which the standard machine data is loaded,
the passwords are set to their default values. For a safe access protection,
the default passwords should be changed.
The protection levels used with passwords can be influenced via softkeys
as follows: “Set Password”, “Change Password”, “Delete Password”.
Set / change /
delete password
The passwords for the four possible password levels with their respective
access rights can be entered in the SYSTEM operating area via the soft-
key “Set Password”

Setting the protection level Section 2
Notes
Protection levels 1 ... 3
The protection levels 1 to 3 require the entry of a password. The pass-
words can be changed after their activation. If the passwords are, for ex-
ample, no longer known, a new initialization (startup with standard ma-
chine data) has to be carried out. During that, all passwords are set to the
standard of this software version.
Protection levels 4 ... 7

The protection level 7 is set if no password and no protection level inter-
face signal is set. The protection levels 4 to 7 can be set without a pass-
word by the PLC user program by setting bits in the user interface.
Please bear in mind that a password remains valid until the access right is
reset again with the softkey “Delete Password”. The access right is thus
not deleted automatically by POWER ON!

Notes

C001 RCS802 Data Transfer Tool
1 Brief description
Module Objective:
Connect to the controller and transfer data using The RCS802 Data Transfer Tool.
Understand the use of licences
Use Sinumerik 802D Snapshot.
Module Description:
Data resident on the controller can be saved to an external Laptop/PC for backup purposes. This
data can be transferred back to the controller as and when required.
Alternatively, data created off-line such as part programs can be transferred to the controller in the
same way.
This module describes the three methods of connecting to the controller and shows an example of
how the RCS802 Data Transfer Tool can be used to save/restore data.
Module Content:
Description of
RCS802
Section 2
RS232C-
Online Section 3
connection
Ethernet-
Peer to Peer online Section 4
connection
Ethernet-
Network online Section 5
connection
Data transfer with

802D sl Section 6
Sinumerik 802D
Snapshot Section 7

Section 2 Description of RCS802
Notes
The RCS802 program is available as part of the toolbox supplied with the
controller.
The software can be used in several ways:-commissioning/service work,
data transfer and remote diagnosis.
Connection is via Ethernet or RS232.
There are two Ethernet connection methods:-Peer to Peer & Network.
The following pages will describe how to make a connection with each of
the above protocols.
Section 3 RS232C online connection
The following sequence of operations should be carried out to obtain an

online serial connection to the controller.
The PG/PC should be connected to the 802D sl controller (Socket X8) with
a standard RS232 cable.
The communication port on the controller must be activated.

Access the System area with the following simultaneous key presses:-
+
Now select the “PLC” softkey
This opens the page where the communication parameters are set up.
When the parameters have been set, the connection is activated with the
“Connect. ON” softkey.

RS232C online connection Section 3
Notes
When the connection is activated the “Connect. ON” softkey changes to
“Connect. OFF”.
Also a connection icon appears at the bottom right of the screen.
The RCS802 program should now be opened.
Choose the “RS232[V24]” option from the “Connect via” drop down menu.
Then select the “connect” button
Now the relevant communication port of

the PG/PC can be selected and then
configured.

Section 3 RS232C online connection
Notes
The settings should be changed to match the controller settings set on
page 2.
Now select the “OK” button (Twice)
The connection should now be complete. This is confirmed by the

appearance of the 802D sl drives in the bottom of the left hand window
Another indication of a successful connection is the appearance of the

following icon in the bottom right hand of the controller screen.

Ethernet-Peer to Peer online connection Section 4
To use the Peer to Peer method of connection first connect the PG/PC to Notes
socket X5 on the controller using a crossover Ethernet cable.
The connection on the controller is activated first. This is done from the
“System” area.
+
The following sequence of softkey presses is then followed.
The following page is then shown as the port is activated.
The IP Address and subnet mask are default and are independent of the
settings in in the “Service network” area which are disabled when the
“Peer to Peer” mode is selected.

Section 4 Ethernet-Peer to Peer online connection
Notes The RCS802 software is now opened and the “Ethernet [peer to peer]”
option selected from the drop down menu.
The “Connect” button is then selected.
The dialogue box is for information only and shows the default IP settings
of the controller. No changes can be made.
The procedure is completed with the “OK” button.
If the connection is successful, the drives of the

controller can be seen in the left hand window of
the RCS802 Software, also the following icon
appears in the bottom right of the controller
screen.

Ethernet-Network online connection Section 5
Licences Notes
This method of connection is primarily for “Remote Diagnostics” use.
To function correctly a licence is required.
To check whether a licence is Installed the “Automatic Licence Manager”
software is opened from the Start Menu.
The example above shows that the RCS802 Licence is stored on the C Drive
along with the licences of other software applications.
The licences can be transferred to/from other media such as floppy drives,
memory sticks etc via the “Licence Key” Menu.
Making a connection
To set the controller up to communicate, enter the “System” Area:-
+
The password needs to be active to a minimum of level 3 (Customer).
Module C21 explains the various protection levels
A user must also be logged in. There are three default users, SIEMENS,
SERVICE and PEERTOPEER.
The SIEMENS user is not available for general use.
The PEERTOPEER user is automatically logged in when the
“Ethernet-PeertoPeer” connection described in section 4 is selected.
The SERVICE user is available for use and will be used for this module.
The password for this user is:-$SERVICE$.
To log into an existing account the “RCS log-in” softkey is used

Section 5 Ethernet-Network online connection
Notes The user name and password are entered followed by the “Log in”
Softkey.
Use the “Back” softkey to return to the “System” page.
If a new user is to be added, follow the following softkey sequence:-
A user name and password can now be entered followed by the “OK”
softkey.

Notes
The newly created user now appears in the list.
To continue setting up the contol select the “Back” softkey
This page is used for entering network settings. These settings will depend
on the type of remote access required. For a simple connection between
the controller and a PC/PG we are interested in the IP address and Subnet
mask. More detailed information will be required for connection via factory
networks etc.

Notes
Any changes to the network settings are activated with the “Save” then
“OK” softkeys.
Now that the controller is setup the RCS802 program is opened. From the
drop down menu the option “Ethernet [network]” is selected.
When the “Connect” button is selected a dialogue box will appear. Then
the “Configure” button must be selected

Notes
This is where the connection can be named and the IP address of the
controller we are connecting to entered.
Select the “Add” button and enter the Station name and IP address followed
by the “Save” button and the “OK” button.

Notes
In the dialogue box, enter the log on name and password of the user which
is currently logged in on the controller. Then select “OK”
A successful connection is shown by the 802D sl drives appearing in the

left hand window of the RCS802 program.
Another indication of a successful connection is the appearance of the

following icon in the bottom right hand of the controller screen.

Data Transfer with RCS802 Section 6
Saving data to external PG/PC Notes
Data such as programs can be transferred to and from the controller using
the RCS802 software.
The directory structure and functionality of the software is similar to
Windows Explorer.
Example:-To create an NC/PLC/DRIVES series start up file, right click on
the folder named “Start-up archive (NC/PLC/Drive)” and select the copy
option. Now select a destination on the PC/PG, right click and paste the
file.
If you need to change the name of the archive from default you can do this
here by selecting “Yes”. Enter the desired file name followed by “Save”

Section 6 Data Transfer with RCS802
Notes
The progress of the data transfer is displayed
Once the transfer is complete a logfile of the transferred files can be

viewed.
Restoring Data with external PG/PC
The control can be restored using the same method. The Archive file is
copied from the PG/PC to the “Start-up archive (NC/PLC/Drive)” folder of
Drive A on the controller.

Data Transfer with RCS802 Section 6
Notes
Allow data transfer to complete then view the logfile if required
After the “OK” button is selected the controller will reboot
Certain dialogue boxes will be shown on the controller which are quite
normal. The procedure finishes with an NCK reset and resets the password
as well as the RCS802 losing connection with the controller.

Section 6 Data Transfer with RCS802
Notes
In this example an NCK archive was created and restored. Individual data
such as Tool Offsets, Part Programs etc can be copied and pasted to and
from the controller. The screen below shows the contents of the MPF
directory. This is reached by expanding the menu tree in the left hand
Window. Other data is found in the same way.
As well as the three drives on the controller (Drives A, N & F), data can be
transferred to and from the other drives (Drives D & G) Provided that the
media has been inserted i.e. CF card in drive D and USB memory device
in drive G
Section 7 Sinumerik 802D Snapshot
The RCS802 software package also has a function called “Snapshot”

Like the “Ethernet [Network]” option, this is dependant on a license (See
page 7)
If a licence is detected the “Sinumerik 802D Snapshot” button is available
on the toolbar. No licence and the button will be greyed out.
Selecting this button will open up a window which will show exactly the
same screen that the controller is showing.
When the mouse pointer is on the Snapshot screen and right click is se-
lected, a list is displayed which can be used to replicate key board func-
tions.
Changing a screen via Snapshot will result in the screen changing on the
controller.
This is very useful for Remote Diagnosis and service/commissioning work.

Sinumerik 802D Snapshot Section 7
Click the “Sinumerik 802D Snapshot” button to show a real-time display of the Notes
controller screen
Right click the mouse over the Snapshot screen to get a list of keyboard
functions.
End of Module C1
Notes

C059 Working with CF cards
1 Brief description
Module Objective:
Upon completion of this module you can copy and paste programs between the CF card and the
CNC controller.
Module Description:
It is possible to use a CF (Compact Flash) card in the controller as additional storage for part pro-
grams or for storing backups of the machines commissioning data. This module describes the usage
of the card in the control.
Module Content:
Copying data to and from the card
Copying data to and

from the card Section 2

Section 2 Copying data to and from the card
Notes
2.1 Copying data to and from the card
All data can be saved to a CF card using copy and paste functionality. To
use the feature a CF card should be inserted into the controller, as can be
seen below:
Data can be transferred to the card in the “Program Manager” area of the
control, also in the “System area”.
Keyboard (u
Keyboard
Program Manager
File functions
CF Card

Copying data to and from the card Section 2
Notes
To copy data to the card in the program manager perform the following,
reverse the process to copy from card to NC.
Highlight the file

which should be
copied
With the COPY

softkey, the file is
copied to the buffer
of the control.
With paste the file

is copied to the
destination.

Notes

C008 Pushbutton Tests
1 Brief description
Module Objective:
Upon completion of this module you can identify which Machine Control Panel (MCP) is installed and
perform a pushbutton test
Module Description:
There are two possibilities currently existing to connect a Machine control panel to the 802D SL CNC.
1. The first variant is to connect an MCP to the (additionally required) MCPA board, section 2.2.
2. The second variant is to connect the MCP to the PLC periphery, section 2.2
The hardware differs between the two variants, the part numbers (MLFB) are given in the respective
sections.
In certain cases it may become necessary to perform a pushbutton test. The objective of the test, is
to determine whether or not a pushbutton / LED on the machine control is defect.
Module Content:
Hardware identification
Hardware interface
MCP and MCPA:-

General information. Section 2
MCPA:-
Hardware identification Section 3
Interface signals
MCP:-
Hardware identification Section 4
Interface signals
MCP and MCPA

LED testing Section 5

Section 2 MCP and MCPA versions
Notes 2.1 General information

The following diagram shows the layout of the 802D machine control
panel.
The layout is the same for both of the MCP types.
The CNC functionality is the same for both of the MCP types.
The addressing of the inputs of the MCP differs between MCP types.
The addressing of the customer LED's differs between MCP types.
The input voltage differs between the MCP types.

(MCPA = 5V DC, MCP = 24V DC)
Each pushbutton is assigned a mnemonic identifier.
Example: NC START key is given mnemonic #27

+X key is given mnemonic #17
2.2 MCP/MCPA layout
[VAR]
Jog
Ref Point
Auto
Single Block
MDA
Spindle Left
Spindle Stop
Spindle Right
Reset
Rapid
Cycle Stop
After performing a pushbutton test, it may be found that all pushbuttons

are defective and not just one key or lamp.
In the case where all keys and lamps are not working the MCPA board or
the PP72/48 could be faulty and not necessarily the MCP.
MCPA - Hardware identification Section 3
To carry out a pushbutton test, it is necessary to differentiate between the Notes
two MCP variants. When viewed from the front, both MCP’s are identical in
appearance.
3.1 Identification of MCP connected to MCPA interface card.
Identification can be done visually by simply examining the hardware of the

from the reverse side. The following photograph shows the MCPA
(Machine Control Panel Analogue) version. This method comprises of two
parts, the MCP and the MCPA interface card.
The MCPA interface card is mounted directly on the PCU210.3.
The MCP connects into the MCPA interface card by way of two 37-way
ribbon cables..
The second method of identification is to check the status of PLC Variable

V18001000.7 (P_H_MCPA)-MCPA exists. The control detects the physical
presence of the MCPA and sets this bit=1.
Note:-Plc variable V18001000.7 can be made to change status via the

“PLC status” screen, even when the MCPA is present. This will be reset on
power Off/On of the control.
Any attempt to write to the variable in the PLC program will result in a
“PLC stop” alarm.
Apart from interfacing between the MCP and the PCU210.3, the MCPA
also offers extra functionality such as the controlling of a single analogue
axis and digital I/O. Module C11 explains this in more detail.

Section 3 MCPA - Hardware identification
Notes The following table contains product information for the MCPA.
3.2 Interface signals
Machine control panel Machine control panel I/F
X1202
X1201
X2 X1
It is important to correctly connect the ribbon cables between the MCP and
the MCPA interface board.
MCP connector X1201 to MCPA Interface board connector X1.
MCP connector X1202 to MCPA Interface board connector X2.

MCPA - Interface signals Section 3
The MCPA uses PLC variables for the interface signals. These are shown Notes
in the table below. To carry out a pushbutton test these variables are
monitored via the PLC status function of the control or the PLC802
programming tool. Each pushbutton (Key) has been given an mnemonic
identifier ranging from #1 to #27
Pushbutton testing examples based on the above diagram:

NC START Pushbutton.
NC START = mnemonic #27
#27 = V10001003.2
NC STOP Pushbutton
NC STOP = mnemonic #26
#26 = V10001003.1
Due to the update time of the HMI software you should keep the key
pressed in order for the change to register on the screen.
Example:How the signals are tested using “PLC Status” on the control.
Here the “NC Start” variable V10001003.2=1 indicating that the button is
activated.

Section 4 MCP - Hardware identification
Notes 4.1 Identification of MCP connected to a PP72/48 periphery board.

The MCP variant uses a PP72/48 periphery board to interface to the
control.
Due to both variants of MCP looking identical from the front, Identification
is done by visual inspection of the hardware and checking of part numbers.
Variable V18001000.7 can be checked in the PLC status area.
If V18001000.7 = 0, MCP is in use. If V18001000.7 = 1, MCPA is in use.
It must be noted that the variable can be set in the PLC status area
regardless of which type of MCP is fitted. This variable reverts to the
correct status on power Off/ON of the control.
Attempting to change the state of the variable in the PLC program will
Result in a PLC stop alarm.
Periphery board PP72/48
6FC5603-0AD00-0AA1
X111 X1201
X222 X1202
X333
The location of the PP72/48 connectors can be seen above.
The following table contains product information for the MCP.

MCP - Interface signals Section 4
4.2 Interface signals Notes
A maximum of three PP modules can be fitted to the 802D sl.
Compatibility must be taken into account before deciding where to connect
the MCP. The following table shows the I/O assignment of an MCP
connected to the first PP module. (PP72/48 plug X111 to MCP plug
X1201and PP72/48 plug X222 to MCP plug X1202)
In this case the I/O addressing will start at 0 (Zero).
4.3 Pushbutton testing examples based on the above diagram

NC START Pushbutton.
NC START = mnemonic #27
#27 = I3.2
NC STOP Pushbutton
NC STOP = mnemonic #26
#26 = I3.1
Due to the update time of the HMI software you should keep the key
pressed in order for the change to register on the screen.
The state of the inputs can be checked via “The PLC status” area of the
control. The above example shows that the “NC start” button is activated.

Section 5 MCPA and MCP LED testing
Notes
Note:- Care must be taken when testing the 6 LED’s.
The user PLC program must be consulted to ensure that artificially
changing the state of an output does not result in any unwanted machine
movement.
The “Change” function in the “PLC status” area of the control will not allow
the changing of an output that is assigned in the PLC program. The PLC
program itself will have to be edited to test the output.
Many machine tool builders have a special test function for the purpose of
safely testing the LED’s and lamps of a machine.
Other methods of testing the status of a pushbutton are “Status list” on the
control and Programming Tool PLC802 software with the functions “Chart
status” and “Program status.
Module C28 offers more information of these methods.

C061 Profibus configuration
1 Brief description
Module Objective:
Upon completion of this module you can connect the periphery modules to the control.
Module Description:
Up to three periphery modules can be connected to the 802D sl controller, this modules shows how
to address the modules and where they can be found in the controls addressable range.
Module Content:
Profibus configuration
Connecting the Profibus
Profibus configuration Section 2
Connecting the
Section 3
Profibus

Section 2 Profibus configuration
Notes
2.1 The profibus addressing is fixed in the PLC architecture. The first
module assigned in the system is always addressed as “9” as this is usu-
ally for the MCP (when a MCPA board is not connected) The other two are
addressed “8” and “7” This ensures commonality in all systems.

Profibus configuration Section 2
Notes

Section 3 Connecting the Profibus
Notes
3.1 Connecting the Profibus

C009 LED Diagnosis Drive
1 Brief description
Module Objective:
Upon completion of this module you can locate the status LED's and determine the module status.
Module Description:
The 802D sl controller has extensive diagnostic possibilities, one of which is the LED diagnostic on
the drive modules.
It is possible using the LED status to determine quickly the hardware status of the drive boards.
Before investigating faults using external diagnostic tools (HMI alarm, Starter etc) a status should first
be taken of the drive LED's.
Module Content:
Locating the status LED's

Status of Motor Module LED's
Status of Active Line Module LED's
Status of Smart Line Module LED's
Status of Smart Line Module ≥ 16kW LED's
Locating the status

LED's
Section 2
Status of LED's:-
Motor Modules, Section 3
ALM & SLM (> 16 Kw)
Status of LED's:-
SLM (< 16Kw) Section 4

Section 2 Locating the status LED's
Notes 2.1 Locating the status LED’s
As can be seen from the picture below, the status LED´s are always
located in the same place on the drive modules.
Ready
DC Link
Status of LED’s:-Motor Modules, ALM &

Section 3 SLM > 16Kw.
3.1 MM LED's, ALM LED´s, SLM LED´s ≥ 16kW
LED´s for:
Motor Module
Active Line Module
Smart Line Module ≥ 16kW
The above modules share identical LED functions, therefore the table
below can be used for these module types.
In the case where a fault diagnosis is not possible a status of the LED´s
should be given to the OEM or to Siemens service personnel.
(Only when module is ready)

Status of LEDs:- SLM < 16kW Section 4
Notes
4.1 SLM LED´s < 16kW
LED´s for:-
Smart Line Module < 16 Kw
The above module does not have DriveCliq capability, therefore the LED
functionality is different. The table below decribes the meaning of the
status LED’s.
In the case where a fault diagnosis is not possible a status of the LED´s
in the case where a fault diagnosis is not possible a status of the LED´s

Notes

C010 LED Diagnosis HMI
1 Brief description
Module Objective:
Upon completion of this module you can locate the status LED's and determine the status of the CNC
controller.
Module Description:
The 802D sl controller has extensive diagnostic possibilities, one of which is the LED diagnostic on
the CNC Controller.
It is possible using the LED status to determine quickly the hardware status of the CNC controller.
Before investigating faults using external diagnostic tools (HMI alarm, Starter etc) a status should first
be taken of the controller LED's.
Module Content:
Locating the Status LED's

Status of CNC Controller LED's
Locating the Status

LED's.
Section 2
Status of CNC
Controller LED's. Section 3

Section 2 Locating the Status LED's
Notes
2.1 Locating the Status LED's
As can bee seen from the picture below, the status LED´s are located
above the LCD display on the right hand side, behind the plastic cover.
Section 3 Status of CNC Controller LED's
3.1 Status of CNC Controller LED's
In normal run condition:- The green “RDY” LED is lit constantly.

The yellow “NC” LED flashes at approx. 1Hz
The yellow “CF” LED will flash when the CF card
(Internal or external) is accessed.
In the case of ERR (red) a further investigation is required, using internal

and external diagnostic tools in general.
Example:- Alarm “400000 PLC stop 2” can be caused by addressing a
non-existent input. In this case the “ERR” LED would be permanently lit.
The cause of the error would need to be investigated with the
Programming tool “PLC802”

C011 MCPA interface board
1 Brief description
Module Objective:

Locate the MCPA board in the system
Perform a hardware diagnosis of the analogue spindle speed setpoint.
Test the digital inputs and outputs.
Module Description:
The MCPA board can be used to drive an analogue spindle and also to connect an MCP. Diagnosing
MCP signals can be carried out with the help of module C8 (pushbutton test).
When hardware is not correctly commissioned it can result in damage to hardware, in this case the
MCPA board itself.
Module Content:
Identification of MCPA in the system.

Analogue spindle interface test.
Digital Input and output tests.
Identification of MCPA
in the system Section 2
Analogue spindle
Interface test Section 3
Digital input and output

signal tests. Section 4

Section 2 Identification of MCPA in the system
Notes
3.1 Identification of MCPA interface card.
Identification can be done visually by simply examining the hardware of the
from the reverse side. The following photograph shows the MCPA
(Machine Control Panel Analogue) version. This method comprises of two
parts, the MCP and the MCPA interface card.
The MCPA interface card is mounted directly on the PCU210.3.
The MCP connects into the MCPA interface card by way of two 37-way
ribbon cables.
MCPA interface
Board.
3.2 Location and description of connectors.
MCPA interface board brief

description of connectors:-
X1-MCP I/O signals (X1201 of MCP)

X2-MCP I/O signals (X1202 of MCP)
X1020-Digital NC inputs
X1021-Digital NC outputs
X701
X701-Analogue spindle control
(Speed set-point, enables &
direction)
X1020 X1021
The MCPA requires a 24V DC
supply. This is done via connectors:-
X1021:- Pin 1 = +24V, Pin 10 = 0V
X1020:- Pin 10 = 0V
X2 X1

Analogue spindle signal test Section 3
3.1 Machine Data Notes
The operation of the analogue spindle is dependant on various machine
data.
One machine data in particular will determine the correct method of
proceeding to test the signals on the analogue spindle connector X701.
The machine data in question is Axis Machine Data 30134-
IS_UNIPOLAR_OUTPUT[0].
To find this machine data select the “System” area with the following
simultaneous key presses:-
+
The machine data screen is located with the following softkey selection:-
The correct axis must be selected.
In this example the Spindle (SP) axis is selected.
The “find” function is available to locate the desired machine data.

Section 3 Analogue spindle signal test
Notes The value of the machine data 30134 can now be seen.
There are 3 possible options for Machine Data 30134, these options and
the effect they have on the analogue spindle out put are described in the
following pages.
3.2 Analogue spindle connector (X701).

The MCPA interface board has a 9-pin male D type connector for the
outputting of the spindle signals. This connector is labeled as X701.
The following table shows the functionality of the pins of connector X701.
Pin Name Function/Description
1 Analogue +/-10v Analogue output reference signal.

OUT Example:-T56 of Simodrive system.
2 Not used
3 Uni-Dir2 +24v Digital output for Unipolar direction 1
4 Uni-Dir1 +24v Digital output for Unipolar direction 2
5 Enable 1 Normally open, volt free drive enable contact.

Example:-T65 of Simodrive system. (Used with Enable 2)
6 Analogue 0v Analogue output reference signal.
OUT Example:-T14 of Simodrive system.
7 Not used
8 Not used
9 Enable 2 Normally open, volt free drive enable contact.

Example:-T9 of Simodrive system. (Used with Enable 1)

Analogue spindle signal test Section 3
3.3 Testing the signals:-Machine Data 30134=0. Notes
Example:-Select “MDA” mode on the controller and type in a spindle
direction and speed.
MDA MDA
In our example M3 S50 (Spindle clockwise at 50 rpm)

G4 F20 (Dwell for 20 seconds)
M30 (Program end)
Press “NC Start” he spindle will run clockwise at 50 rpm for 20 seconds
then halt.
NC Start
Due to the type of connector, it is more convenient to measure the signals

at the drive.
The expected signals for this situation will be:-

A positive voltage at X701 pin 1 with respect to pin 6.
The normally open contact between X701 pins 5 & 9
to be closed.
Note 1:- The polarity of the reference voltage between pins 1 & 6 can be
reversed by Axis Machine Data 32100 AX_MOTION_DIR. If the default
value of 1 is entered, the polarity of X701 pin 1 will be positive for a
clockwise spindle command (M3). A value of –1 for machine data 32100
would cause X701 pin 1 to be negative for a clockwise spindle command.
Note 2:-The voltage level of pins 1 & 6 is determined by the commanded

speed and Axis Machine Data 32250 RATED_OUTVAL[0] & 32260
RATED_VELO[0].
Machine Data 32250 is a percentage of the maximum analogue output
value of 10V (100%=10V, 50%=5V etc)
Machine Data 32260 is the maximum speed of the spindle. At this speed
the reference output on pins 1 & 6 will be at the level set in Machine Data
32250. At other commanded speeds the reference voltage will be
Proportionate to this.
Section 3 Analogue spindle signal test
Notes In our example with the following machine data:-
30134 = 0
32100 = 1
32250 = 100
32260 = 500
The voltage at X701 pins 1 & 6 would be +1 Volt.

This is because the value of machine data 32250 = 100, this sets the
reference voltage to 10V at the speed in machine data 32260 (500 RPM)
The commanded speed (50 RPM) is 10% of the max speed set in machine
data 32260 (500 RPM). Therefore 10% of the reference value (1 Volt) is
output.
If a spindle counter-clockwise (M04) command was programmed the
Polarity of the voltage at X701 pins 1 & 6 would be reversed.
3.4 Testing the signals:-Machine Data 30134=1
This setting only outputs a positive voltage (0 to 10v) on X701 pins 1 & 6
regardless of the programmed direction (M03 or M04).
To facilitate a change in direction:-

X701 pin 3 outputs +24V with the M04 command.
This signal can be utilised to reverse the spindle via relays or contactors
which is necessary on certain types of drives.
X701 pin 4 will output +24V for both directions and can be used for enable
purposes.
These tests assume Machine Data 32100 AX_MOTION_DIR = 1.

Changing 32100 = -1 will invert the behaviour of X701 pin 3
The signals on pins 3 & 4 should be measured to the 0V of MCPA

Connector X1021 pin 10.
3.5 Testing the signals:-Machine Data 30134=2
This setting only outputs a positive voltage (0 to 10v) on X701 pins 1 & 6
regardless of the programmed direction (M03 or M04).
To facilitate a change in direction:-

These signals can be utilised to reverse the spindle via relays or

contactors which is necessary on certain types of drives.
The signals output on pins 3 & 4 should be measured to the 0V of MCPA

These tests assume Machine Data 32100 AX_MOTION_DIR = 1.

Changing 32100 = -1 will invert the behaviour of X701 pins 3 & 4
The signals on pins 3 & 4 should be measured to the 0V of MCPA


Digital input and output signal tests Section 4
4.1 Digital input testing. Notes
Before testing can proceed the physical location of the inputs needs to be
known.
These are via connector X1020 on the MCPA board. (See page 2 section 3.2)
Connector X1020 pin assignment

Pin Description Designation
1 +24V DC
2 Digital input 0 $A_IN[9]
10 0V DC
There are eight inputs available, each one has a variable assigned to it. The
first variable starts at number 9. The variables 1 to 8 are reserved for the
PCU210.3/Sinamics (Connectors X20 and X21)
The operation of the Inputs depends on the setting of certain General
Machine Data. Locate the machine data screen by referring to Section 3.1
machine data, page 3. The required machine data are accessed with the
“General MD” softkey.
Cursor to or use the “Find” function to locate the correct machine data:-
10350 FAST_NUM_DIG_INPUTS = 2
The number of bytes available for use with fast digital inputs, this is set to 2
by default. The first byte is used for the PCU210.3/Sinamics.
Attempting to use digital inputs outside of the range set will result in alarm:-
“017100 Channel 1 block 2 digital input/comparator no. xx not activated”
Where “xx” = the digital input number.
10366 HW_ASSIGN_DIG_FASTIN[0] = 00010101H
The hardware (MCPA) has to be assigned to the local bus by entering the
above value. (Default value = 00H).
To test an Input, select “MDA” mode and type the following:-

(Not he text in brackets)
MDA
PG: (Label)
R1=$A_IN[9] (Read the state of the digital input on X1020 pin 2 to R1)
GOTOB PG (Search backwards through the program to the label “PG”)
Press the “NC Start” button.

Section 4 Digital input and output signal tests
Notes The program will loop continuously allowing the state of the digital input to
be monitored via R parameter R1.
Checking the state of the input on the “R variable” screen
The value of R1 = 1 which indicates that X1020 pin 2 should be +24V

when measured to X1020 pin 10.
If the voltage was not present it would suggest a faulty MCPA board.

4.2 Digital output testing. Notes
Before testing can proceed the physical location of the outputs needs to be
known.
These are via connector X1021 on the MCPA board. (See page 2 section 3.2)
Connector X1021 pin assignment

Pin Description Designation
1
2 Digital output 0 $A_OUT[9]
10 0V DC
There are eight outputs available, each one has a variable assigned to it.
The first variable starts at number 9. The variables 1 to 8 are reserved for
the PCU210.3/Sinamics (Connectors X20 and X21)
The operation of the outputs depends on the setting of certain General
Machine Data. Locate the machine data screen by referring to Section 3.1
machine data, page 3. The required machine data are accessed with the
“General MD” softkey.
Cursor to or use the “Find” function to locate the correct machine data:-
10360 FAST_NUM_DIG_OUTPUTS = 2
The number of bytes available for use with fast digital outputs, this is set to
2 by default. The first byte is used for the PCU210.3/Sinamics.
Attempting to use digital outputs outside of the range set will result in alarm:
-
“017110 Channel 1 block 2 digital output no. xx not activated”
Where “xx” = the digital output number.
10368 HW_ASSIGN_DIG_FASTOUT[0] = 00010101H
The hardware (MCPA) has to be assigned to the local bus by entering the
above value. (Default value = 00H).
To test the state of an output, select “MDA” mode and type the following:-
(Not the text in brackets!)
MDA
PG: (Label)
R1=$A_OUT[9] (Read the state of the digital output on X1021 pin 2 to R1)
GOTOB PG (Search backwards through the program to the label “PG”)
Press the “NC Start” button

Section 4 Digital input and output signal tests
Notes
The program will loop continuously allowing the state of the digital output to
be monitored via R parameter R1.
Checking the state of the output on the “R variable” screen:-
The value of R1 = 1 which indicates that X1021 pin 2 should be +24V

when measured to X1021 pin 10.
If the voltage was not present it would suggest a faulty MCPA board.

The state of a digital output can be set with “MDA” mode. Notes
The above program will switch the digital output on X1021 pin 2 on and off
every five seconds (G4F5 = 5 second dwell).
This can be checked with a meter.
Note:-Care should be taken on machinery when switching outputs in

this fashion, unwanted movements may occur which can cause
damage to the machinery and personnel.

Notes

C017 Save Data
1 Brief description
Module Objective:
Upon completion of this module you can Save Data which is stored in the volatile data to the internal
Flash memory of the CNC Controller.
Module Description:
The 802D SL controller executes with data which is stored in volatile memory. This volatile memory is
retained using a GoldCap capacitor. If the machine is powered off for more than 50 hours, the data
which is stored in the volatile memory can be lost. It is therefore necessary to Save this data to Flash
memory when the machine is switched off for periods which are longer than 50 hours. When neces-
sary this previously saved data can be reloaded to the volatile memory from the Flash memory.
All data excluding the PLC program are saved, the PLC is stored always in non-volatile memory
(Flash memory) and will not be lost upon dissipation of the GoldCap.
Module Content:
Performing a Data Save
Performing a Data
Save
Section 2

Section 2 Performing a Save Data
Notes
2.1 Performing a Save Data
To perform a Saving of data, you have to enter the “System Area”. To en-
ter the “System Area” proceed as follows:
On NC Keyboard — Press the key SHIFT + ALARM
Keyboard (upright)
Keyboard (broad)
To perform a “Save Data” the password “CUSTOMER” has to be set.
Password
CUSTOMER
To Save Data

Performing a Save Data Section 2
Notes
Confirm with OK to save data..
To Save Data
Confirm with OK
It is also possible to see in the above picture, which data will be saved.

Notes

C018 Restore Saved Data
1 Brief description
Module Objective:
Upon completion of this module you can restore the data which is stored in the flash memory to the
internal SRAM (active, volatile) memory of the CNC controller.
See hand book module C17 Save data
Module Description:
The 802D sl controller executes with data which is stored in volatile memory. This volatile memory is
retained using a GoldCap capacitor. If the machine is powered off for more than 50 hours, the data
which is stored in the volatile memory can be lost. It is therefore necessary to Save this data to Flash
memory when the machine is switched off for periods which are longer than 50 hours. When neces-
sary this previously saved data can be reloaded to the volatile memory from the Flash memory.
All data excluding the PLC program are saved, the PLC is stored always in non-volatile memory
(Flash memory) and will not be lost upon dissipation of the GoldCap.
This module describes the methods of restoring the previously saved data.
See hand book module C17 Save data
Module Content:
Performing a Restore of saved data
Performing a Restore
of saved data
Section 2

Section 2 Restoring Saved Data
Notes 2.1 Restoring Saved Data
The “Saved data ” can be restored in several ways:
SELECT picture at Startup

Automatic (in case of data loss)
The system can detect loss of data, upon data loss the saved data will be
loaded into the volatile memory automatically.
Saved data can be restored by the user at any time by pressing the SE-
LECT key when prompted at Startup time of the control.
The following picture then appears—one of the two will appear dependant
upon which password is activated.
The alarm 004062 indicates to the operator that “saved data” has been
loaded, this alarm can be acknowledged with the reset key.
CUSTOMER Password set
Startup Menu
Normal Startup
Reload saved user data
Software update
EVENING—SUNRISE Password set
Startup Menu
Normal Startup
Startup with default data
PLC Stop
PLC overall reset / default PLC program
HMI Startup with default data
Remove drive data
Remove drive data/default data
Software update

C019 External data Backup and Restore
with CF card
1 Brief description
Module Objective:
Upon completion of this module you can save to a Compact flash card, a complete backup of the
control.
Module Description:
Due to component defect, it may become necessary to exchange the CNC system. In such a case
the “Saved data” function is not of any use. It becomes necessary to previously store a complete
backup of the controls machine specific data. Saving the data is described in this module and also
loading the data back to a replacement control.
Module Content:
Saving all data to CF Card

Automatic save of all data to CF card
Restoring data from CF card
Saving all data to CF

Card Section 2
Automatic save of all

data to CF card Section 3
Restoring data from

CF card Section 4

Section 2 Saving All data to Compact Flash card
Notes
2.1 Saving All data to Compact Flash card
All data can be saved to a CF card using Copy and Paste functionality. To
use the feature a CF card should be inserted into the controller, as can be
seen below:
The CF card can be up to 2GB, and should be formatted using the FAT16
or FAT32 file system.
To make a backup of the machine configuration, that the controller can be

restored to it's original state requires that two archives should be saved to
the CF card. These two files can be saved to the card in the SYSTEM area
of the control. i.e. NC/PLC archive and HMI archive
The SYSTEM area of the control is reached by pressing the key : SHIFT +
ALARM.
The entry point for saving data is through softkey Start-up files, see picture
below:

Saving all data to compact flash card Section 2
Notes
The following display can then be seen:
The two files previously mentioned can be saved by copying the contents
of the HMI and the NC/PLC directories into two archives.
The following picture describes this process:
Move cursor to NC/

PLC directory and
press SK Copy
The destination should now be selected and the Paste function can be
used to save the files to the respective card. The destination is the
“Customer CF card”

Section 2 Saving All data to Compact Flash card
Notes
After pressing Paste

softkey change file
name to
e.g. NC_PLC.ARC and
confirm with OK softkey
The above should be repeated for the HMI archive.

The two archives should be now visible on the CF card. The CF card
should now be removed from the system and stored safely.
To reflect the newest changes this process should be carried out on a
regular basis.
Both archives saved to

CF, card can now be re-
moved and stored safely.

Automatic save of all data to CF card Section 3
Notes
3.1 Automatic save of all data to CF card
Complete save of all system data can also be implemented by pressing

[CTRL] + [S] at any time. This will automatically create a complete archive of
all NC & PLC data, and HMI data in two archive files and write these files
onto the CF Card. The archives are created with default names.
802dslibnhmi.arc
802dslibnnc.arc
The file creation will overwrite any existing files of that name without requir-
ing confirmation.
The only pre-requisite for this procedure is that the protection level password
must be set to a minimum of level 3 (User level)
After the file creation procedure is complete, an NCK reset is performed.
DO NOT remove the CF card until this is completed, otherwise system data
corruption will occur.

Section 4 Restoring All data from Compact flash card
Notes
4.1 Restoring All data from Compact flash card
In the case of component exchange it will be necessary to reload the previ-

ously saved archives to achieve a functional machine.
The following steps should be carried out in order to reload the data previ-
ously stored on the CF card.
The controller should first be switched on and the password for the SER-
VICE should be set: The password for a new CNC component is always
the default “EVENING”, this should be changed after new installation to
prevent mishandling of the system in the future.
Once the password is set the system should be switched OFF and ON and
the Startup menu entered with the SELECT key when prompted.
See picture below:
Startup Menu
Normal Startup
Startup with default data
PLC Stop
PLC overall reset / default PLC program
HMI Startup with default data
Remove drive data
Remove drive data/default data
Software update
Choose menu option “Startup with default data” and confirm with the
ENTER key.
The control will now re-start, wait until the control is finished starting up
and once again enter the SERVICE password.
You should see the message “004060 Standard machine data is loaded”.
Using copy from CF card and paste to CNC the backup data can be re-
stored to the control. See the following diagrams:

Restoring All data from Compact flash card Section 4
Notes
Select HMI archive and

with COPY softkey pre-
pare for paste operation
to CNC
Select HMI directory

and press “paste”
softkey

Section 4 Restoring All data from Compact flash card
Notes
Confirm the dialog box with the OK softkey, the HMI archive will now be
read into the controller.
During this reading in process the controller will reboot once, the process
will take approximately 1 minute to complete.
This procedure should be repeated for the NC/PLC archive, the CNC will
reboot more times and the process takes approximately 4 minutes to com-
plete. The NC_PLC archive should be copied to the NC PLC directory and
not the HMI.
Upon completion of this process the machine should be functional again.
Note: The HMI archive should be read in first because the specific PLC
alarms are in the NC/PLC archive.

C028 Diagnose PLC Program
1 Brief description
Module Objective:
Upon completion of this module you can use the built-in PLC program displays to diagnose faults.
Module Description:
The 802D sl controller has extensive diagnostic possibilities, one of which is the online display of the
PLC program.
It is possible using this function to quickly evaluate logic faults or external switching faults on the ma-
chine. To use this function effectively previous knowledge of PLC programming is advantageous.
Module Content:
Locating the PLC Program displays

Navigating the displays
Program status ON/OFF
Searching
Cross referencing
Locating the PLC Pro-

gram displays
Section 2
Navigating the displays

Section 3
Program status ON/

OFF Section 4
Searching
Section 5
Cross referencing
Section 6
SINUMERIK 802D sl Service, Training Manual Page 1 This document was produced for training purposes.
C028
Section 2 Locating the PLC Program displays
Notes 2.1 Locating the PLC Program displays

The PLC Program display can be found in the “SYSTEM area”. The dis-
plays are only available when the “SERVICE” password is set or higher.
To enter the “SYSTEM” area press the key “SHIFT + ALARM”.
In the system area you will see the softkey PLC, upon pressing the softkey
PLC the following picture is displayed:
When entering the PLC area, the default for the control is to open the
“Program list” picture. This function is explained in the hand book module
C33.
The PLC Program displays can be found by pressing the softkey “PLC
Program”
The following picture can be seen:

Navigating the displays Section 3
3.1 Navigating the displays Notes
Project name, Version , Cycle time, Processing time.

Section 3 Navigating the displays
Notes
Status >> Bits, Bytes, Words, DWords with the possi-
bility to change
Overview Input, Output, Marker area with the possibil-

ity to change

Navigating the displays Section 3
Notes
Status >> logic online/offline
Define which block

with softkey
“Program block”
Status >> logic online/offline as Window 1

Define which block with softkey “Program block”

Section 3 Navigating the displays
Notes
Locator >> Where is it used? And as what?
Program status ON/OFF

Section 4
4.1 Program status ON/OFF
With Program status ON, a real-time picture can be seen of the logic con-
trolling the machine.
switch OFF to
conserve proces-
sor resources

Searching Section 5
Notes
5.1 Searching
Search / Find: the function can be used context sensitive to find operands
or symbols located in the body of the PLC program or cross reference
table.
Section 6 Cross referencing
6.1 Cross referencing
Find all occurrences of operands in the PLC program

Notes

C031 Diagnose PLC alarm
1 Brief description
Module Objective:
Upon completion of this module you can use the built-in PLC program displays to diagnose a PLC
generated fault.
Module Description:
The 802D sl controller has extensive diagnostic possibilities, one of which is the online display of the
PLC program.
It is possible using this function to quickly find the source of a PLC generated fault, and quickly re-
solve an external fault on the machine. e.g. faulty sensor.
Module Content:
Structure of an alarm
Function of alarm
Cross referencing
Structure of an alarm
Section 2
Function of alarm
Section 3
Cross referencing
Section 4

Section 2 Structure of an alarm
Notes 2.1 Structure of an alarm
To identify external faults from the generated PLC fault, it is necessary to

understand the structure of the alarm.
Structure:
700000 Hydraulic pressure low
700001 Tailstock not in position
700002 Axis %d in parked position ——- Axis 1 in parked position
Axis 2 in parked position
Alarm Num- Variable = 1 Alarm Text
Alarm Number PLC Signal PLC variable NC MD alarm Text File

configuration
700000 16000000.0 16001000 14516[0] Alarm 1
700001 16000000.1 16001004 14516[1] Alarm 2
700002 16000000.2 16001008 14516[2] Alarm 3
700003 16000000.3 16001012 14516[3] Alarm 4
700004 16000000.4 16001016 14516[4] Alarm 5
700005 16000000.5 16001020 14516[5] Alarm 6
700006 16000000.6 16001024 14516[6] Alarm 7
700007 16000000.7 16001028 14516[7] Alarm 8
700008 16000001.0 16001032 14516[8] Alarm 9
700009 16000001.1 16001036 14516[9] Alarm 10
700010 16000001.1 16001040 14516[10] Alarm 11
700011 16000001.1 16001044 14516[11] Alarm 12
700012 16000001.1 16001048 14516[12] Alarm 13
.. .. .. .. ..
.. .. .. .. ..
.. .. .. .. ..
.. .. .. .. ..
700063 16000007.7 16001252 14516[63] Alarm 63
Variable definition
%d Decimal value displayed

%x Hexadecimal value displayed
%b Binary value displayed
%o Octal value is displayed
%u Unsigned integer is displayed
%f Floating point number is displayed
PLC Signal
The alarm 700000 is generated with the corresponding PLC signal, the
reaction from the NC is defined in the NC machine data 14516[index].

Function of alarm Section 3
3.1 Function of alarm Notes
Alarms are generated for a purpose, the purpose is primarily to protect the
machine operator in the case of a dangerous situation and secondly to
protect the machine from damage.
To cater for the above two cases we can react in two ways:
1) Pure PLC reaction

2) PLC >> NC reaction
The first is to use the alarm to warn the operator of a problem, e.g. coolant
is low in the machine. In such a case the axis can be prevented from mov-
ing by various disable signals in the PLC interface.
The second case is to configure the alarm in such a way that the NC can
react itself. e.g. in the case of an alarm NC start can be automatically in-
hibited.
The possibilities are listed below:
MD 14516[index] Meaning
Bit 0 NC Start inhibit
Bit 1 Read-in disable
Bit 2 Feed disable for all axis
Bit 3 Emergency stop
Bit 4 PLC Stop
Bit 5
Bit 6 Cancel with Delete key
Bit 7 Power on

Section 4 Cross reference
Notes 4.1 Cross reference
It may become necessary to track an alarm to it's source.

A logic condition generates the alarm, the logic condition has to be found
in the PLC program and diagnosed using status.
To find the logic, the cross reference function should be used.
See the following picture:
Result

C029 Creating Alarm Texts
1 Brief Description
Module Objective:
Upon completion of this module you will be able to create user-specific alarm texts.
Module Description:
The machine builder has two options for defining his alarm texts.
The configuration process is described here.
Module Content:
Alarm texts
Alarm texts
Section 2

Section 2 Alarm texts
Notes
The user has two options for defining own alarm texts:
directly in the controller

via the toolbox
In the 802D, the menu can be opened via “System” “PLC” “Edit
Alarm Text“.
Own texts
Alarm text
With the arrow keys, the respective alarm text is selected in the editor. The
corresponding message can be edited with the tabulator key . The
changed text is saved with the softkey “Save”.
If the user does not assign a user alarm text, only the alarm number is dis-
played.

Alarm texts Section 2
Notes
Changing the OEM text via the toolbox:
user cycle alarm : alc.txt

user PLC alarm : alcu.txt
user cycle messages and mask text : aluc.txt
From software version 1.4 it is possible for the user PLC alarm text to be created
and modified using the RCS802 tool.
Creation of user PLC alarm text file (RCS802)
Select “Select OEM” and the following box is displayed
Expand the file structure until the file “alcu.txt” is visible for the chosen language
Then click The user PLC alarm file is then opened for
editing.

Notes
The highlighted user alarm can be edited in the lower pane. When complete, click
“SAVE” and close the editor
The completed text file can now be transferred to the controller
By clicking
Confirmation that the task is complete, is displayed at the bottom of the dialogue
box.

Alarm texts Section 2
Modification of user PLC alarm text file (RCS802) Notes
Before any modifications can be made to an existing machine, The user text file
must be imported from the controller to a project on the PG/PC. If the original pro-
ject is not on the PG/PC, Then a new one must be created.
The project is then accessed as above. And the following dialogue box is dis-
played.
The text file for user PLC messages can now be read into the controller by clicking
the following button

Notes
The following dialogue box will be displayed confirming you wish to overwrite the
existing file on your PG/PC
The file is imported to the project and the following is displayed
The file editor can now be used to modify the alcu.txt file
When modifications are complete, The file can be saved and transferred back to
the controller as discussed in the previous pages.

C037 Alarm Structure NC
1 Brief description
Module Objective:
Upon completion of this module you will be able to identify an NC alarm.
Module Description:
The 802D sl controller has extensive diagnostic possibilities, one of which is the display of the active
NC alarm.
With this knowledge you can find in the diagnostic guide, and interpret the fault.
Module Content:
Locate the alarm display

Find the alarm description in the diagnostic guide
Locate the alarm dis-

play
Section 2
Find the alarm descrip-

tion in the diagnostic Section 3
guide
C037
Section 2 Locate the alarm display
Notes
2.1 Locate the alarm display
The alarm display has to be selected in order to interpret the active alarm.
The display can be selected with the ALARM key on the NC keyboard. The
following display will be seen :
The alarm number determines whether an alarm is an NC alarm, the num-

ber range can be seen in the following table:
Find the description in the diagnostic guide

Section 3
3.1 Find the description in the diagnostic guide
A description of the alarm can be found in the 802D sl Diagnostic Guide.

C039 Diagnosis of Cycle Alarms
1 Brief Description
Module Objective:
Upon completion of this module you are able to find and diagnose alarms from the standard cycles.
Module Description:
Faulty or missing parameter assignments in cycles lead to a program abort.

Furthermore, messages which do not interrupt operation are displayed.
Module Content:
Available cycles
Troubleshooting
Available cycles
Section 2
Troubleshooting Section 3

Section 2 Available cycles
Notes
Cycles are technology subroutines with which certain process sequences

can be implemented universally. The adaptation of the cycles to the con-
crete problem is done via geometry and machining parameters.
The following standard cycles are available:

Drilling cycles
CYCLE81 Drilling, centering
CYCLE82 Drilling, counterboring
CYCLE83 Deep-hole drilling
CYCLE84 Tapping without compensating chuck
CYCLE840 Tapping with compensating chuck
CYCLE85 Reaming 1 (boring 1)
CYCLE86 Hollowing (boring 2)
CYCLE87 Drilling with stop 1 (boring 3)
CYCLE88 Drilling with stop 2 (boring 4)
CYCLE89 Reaming 2 (boring 5)
Hole pattern cycles

HOLES1 Row of holes
HOLES2 Circle of holes
Milling cycles
CYCLE71 Face milling
CYCLE72 Contour milling
CYCLE76 Rectangular spigot milling
CYCLE77 Circular spigot milling
LONGHOLE Elongated hole
SLOT1 Milling pattern grooves located on a circle
SLOT2 Milling pattern circular grooves
POCKET3 Milling rectangular pocket (with any milling tool)
POCKET4 Milling circular pocket (with any milling tool)
CYCLE90 Thread milling
Turning cycles
CYCLE93 Groove
CYCLE94 Undercut (form E and F in accordance with DIN)
CYCLE95 Cutting with relief cuts
CYCLE96 Thread undercut
CYCLE97 Thread cutting
CYCLE98 Thread chain
The cycles are stored on the controller in the path \CST (Siemens cycles)
when the technology package (milling or turning) is generated.

Notes
An alarm is released and thus the machining aborted when faulty condi-
tions are detected in a cycle.
Moreover, the cycles issue messages in the message line of the controller.
Messages do not interrupt the machining .
In the cycles, alarms are generated with numbers from 61000 to 62299.
The range of numbers is subdivided with respect to alarm response and
cancel criterion
Cancel criteria and alarm responses

Alarm number Cancel criterion Alarm response
61000 ... 61999 NC_RESET Block preparation in the NC is

canceled.
62000 ... 62999 Cancel key Block preparation is interrupted,
the cycle can be continued with NC start
after having canceled the alarm.
The error codes are classified as follows:
6 _ X _ _
X=0 General cycle alarms

X=1 Alarms of the drilling, hole pattern and milling cycles
X=6 Alarms of the turning cycles

Section 3 Troubleshooting
Notes
Alarms
Alarm Alarm text Source Explanation, remedy
number
61000 “No tool offset ac- SLOT1 D-correction has to be programmed before
tive” SLOT2 the cycle call.
POCKET3
POCKET4
CYCLE71
CYCLE72
61001 ”Thread pitch CYCLE84 Check the parameter for thread size or
wrong“ CYCLE840 pitch value (might be contradictory).
61002 ”Machining type SLOT1 The VARI parameter value for the machin-
defined incorrectly” SLOT2 ing type is wrong and has to be changed.
POCKET3
POCKET4
CYCLE71
CYCLE72
61003 “No feedrate pro-

CYCLE71 The parameter for the feedrate is wrong
grammed in the
CYCLE72 and has to be changed.
cycle“
61009 “Active tool number CYCLE71 No tool (T) has been programmed before
= 0“ CYCLE72 the cycle call.
61010 “Finishing allowance CYCLE72 The finishing allowance on the base is lar-
too large“ ger than the total depth, it has to be dimin-
ished.
61011 “Scaling not permit- CYCLE71 A scaling factor which is impermissible for
ted“ CYCLE72 this cycle is active.
61101 ”Reference level CYCLE71 With a relative value for the depth, either
defined incorrectly” CYCLE72 the values for the reference and retraction
CYCLE81 plane have to be selected differently or an
up to CY- absolute value has to be entered for the
CLE89 depth.
CYCLE840
SLOT1
SLOT2
POCKET3
POCKET4
61102 ”No spindle direction CYCLE86 The parameter SDIR (or SDR in CY-
programmed” CYCLE88 CLE840) has to be programmed.
CYCLE840
POCKET3
POCKET4
61103 ”Number of holes is HOLES1 No value for the number of holes has been
zero” HOLES2 programmed.
61104 ”Contour violation of SLOT1 Faulty parameterization of the milling pat-
the slots / elongated SLOT2 tern in the parameters defining the position
holes” of the slots / elongated holes on the circle
and their form.
61105 ”Cutter radius too SLOT1 The diameter of the used cutter is too large
large” SLOT2 for the shape to be made; either a tool with
POCKET3 a smaller radius has to be used or the con-
POCKET4 tour has to be changed.
61106 ”Number or distance HOLES2 Faulty parameterization of NUM or INDA,

of the circle ele- SLOT1 the arrangement of the circle elements
ments” SLOT2 within a full circle is impossible.

Notes
Alarms (continued)
Alarm Alarm text Source Explanation, remedy

number
61107 ”First drilling depth CYCLE83 First drilling depth opposite to the total
defined incorrectly” drilling depth.
61108 POCKET3 The parameters _RAD1 and _DP for

“No permissible val-
POCKET4 the determination of the path for the
ues for parameter
depth infeed have been specified incor-
_RAD1 and _DP1“
rectly.
61109 The value of the parameter for the mill
“Parameter _CDIR POCKET3
direction _CDIR has been specified
defined incorrectly“ POCKET4
incorrectly and has to be changed.
61110 “Finishing allowance POCKET3 The finishing allowance on the base
on the base > depth POCKET4 has been specified larger than the
infeed“ maximum depth infeed; either diminish
the finishing allowance or increase the
depth infeed.
61111 “Infeed width > tool CYCLE71 The programmed infeed width is larger
diameter“ POCKET3 than the diameter of the active tool; it
POCKET4 has to be diminished.
61112 “Tool radius negative” CYCLE72 The radius of the active tool is nega-
tive, which is impermissible.
61113 “Parameter _CRAD POCKET3 The parameter for the corner radius
too large for corner _CRAD has been specified too large, it
radius“ has to be diminished.
61114 “Machining direction CYCLE72 The machining direction of the cutter
G41/G42 defined in- radius compensation G41/G42 has
correctly“ been selected incorrectly.
61115 “Approach or retract CYCLE72 The approach or retract mode for the
mode (straight line/ contour has been defined incorrectly;
circle/plane/space) check parameter _AS1 or _AS2.
defined incorrectly“
61116 “Approach or retract CYCLE72 The approach or retract path has been
path = 0“ specified with zero, it has to be in-
creased; check parameter _LP1 or
_LP2.
61117 “Active tool radius <= CYCLE71 The radius of the active tool is negative
0“ POCKET3 or zero, which is impermissible.
POCKET4
61118 “Length or width = 0“ CYCLE71 The length or width of the milling sur-
face is impermissible; check the pa-
rameters _LENG and _WID.
61124 CYCLE71 For active simulation without tool, it is
“Infeed width not pro-
always necessary to program a value
grammed“
for the infeed width _MIDA.
62100 ”No drilling cycle ac- No drilling cycle has been called
HOLES1
tive” modally before calling the hole pattern
HOLES2
cycle.

Section 3 Troubleshooting
Notes
Alarms (continued)
Alarm Alarm text Source Explanation remedy

number
61601 ”Machined part CYCLE94 The programmed machined part diameter is too
diameter too CYCLE96 small.
small”
61602 ”Tool width CYCLE93 The grooving steel is larger than the programmed
defined incor- groove width.
rectly”
61603 ”Groove form CYCLE93 The radii/chamfers on the groove base do not match
defined incor- the groove width. A face groove on a contour ele-
rectly“ ment running in parallel to the longitudinal axis is
impossible.
61604 ”Active tool CYCLE95 Contour violation in relief cut elements caused by
violates pro- the
grammed con- clearance angle of the used tool, i.e. use a different
tour” tool or check the contour subroutine.
61605 ”Contour pro- CYCLE95 Impermissible relief cut element detected.

grammed in-
correctly”
61606 ”Fault during CYCLE95 A fault has been detected during the preparation of
contour prepa- the contour; this alarm is always connected to a
ration” NCK alarm 10930 ... 10934, 15800 or 15810
61607 ”Starting point CYCLE95 The starting point reached before the cycle call is
programmed not outside the rectangle described by the contour
incorrectly” subroutine.
61608 ”Wrong cutting CYCLE94 A cutting edge position 1...4, matching the undercut
edge position CYCLE96 form, has to be programmed.
programmed”
61609 ”Form defined CYCLE94 Check the parameter for the undercut form.
incorrectly” CYCLE96
61611 “No intersec- CYCLE95 No calculation of the intersection possible with the
tion found“ contour. Check the contour programming or change
the infeed depth.

Notes
The picture shows a cycle alarm. Apart from the alarm number and alarm
text, there are also measures for canceling the alarms (RESET) and notes
given.

Notes

C041 Editing of NC Machine data
1 Brief description
Module Objective:
Upon completion of this module you can locate the NC machine data, set the password and make
changes.
Module Description:
During the life of a machine it may become necessary to change the values of certain NC machine
data. The necessity arises e.g. due to wear on mechanical components, the axis performance can
therefore deteriorate. In some case, further mechanical damage can be prevented with the help of
the NC machine data.
A change should only be carried out in conjunction with recommendations from the machine tool
builder.
Module Content:
Location of NC machine data

Setting password
Changing machine data + data save
Location of NC ma-
chine data
Section 2
Setting password
Section 3
Changing machine
data + data save Section 4
C041
Section 2 Location of NC machine data
Notes 2.1 Location of NC machine data
The NC machine data is located in the System area. The system area can
be entered with the key combination “SHIFT + ALARM”. The following de-
scribes graphically how to enter the Machine data area:
Machine data
entry point
General MD
10000-19800
Channel MD
20050-29000
Note:
Axis MD Drive machine data should
30100-38000 only be changed under
supervision from experts

Setting password Section 3
Notes
3.1 Setting password
In order to make changes to the NC machine data, the corresponding

password must be set. Certain machine data can only be changed with the
SERVICE or MANUFACTURER password, in this case, contact the builder
of the machine.
The following sequence shows graphically how to change/activate the
password.
Enter new
password
level
Change stan-
dard password
Password cancelled
Keyswitch active
Section 4 Changing machine data + data save
4.1 Changing machine data + data save
When the necessary password is activated the machine data can be

changed.
Machine data’s are each having an activation criteria, this criteria deter-
mines when the new machine data value will become active. This criteria
is written in the machine data list next to the respective data.
Po = after powering on
Re = after pressing Reset key on machine control panel
Cf = after pressing Refresh soft-key
Im = immediately
After making changes to the machine data, it is important to make a

new backup see hand book modules C19 and C17.

Notes

C053 Drive diagnostic parameters
1 Brief description
Module Objective:
Upon completion of this module you can locate the Drive machine data, set the password and locate
the diagnostic parameters.
Module Description:
In the case of a fault, it is useful to have an overview of the fault conditions which may be existing in
other areas of the control. It is often in the case of an axis alarm that a fault in the drive may be the
cause.
Module Content:
Location of drive diagnostic parameters

Setting password
Location of drive diag-

nostic parameters
Section 2
Setting password
Section 3
C053
Section 2 Location of drive diagnostic parameters
Notes 2.1 Location of drive diagnostic parameters
The NC machine data is located in the System area. The system area can
be entered with the key combination “SHIFT + ALARM”. The following de-
scribes graphically how to enter the Machine data area and how to navi-
gate to the drive diagnostic area:
Status 0 =
ok
No drive error
existing

Location of drive diagnostic parameters Section 2
Notes
Status ≠ 0
not ok
Operational
status
Further important diagnostic parameters can be found under the softkey

“Parameter displays”. The most important parameters can be seen in the
following table, and the values can be passed to the relevant service
personnel upon request:

Section 3 Setting password
Notes
3.1 Setting password
In order to see the data, the correct password should be set.
Enter new
password
level
Change stan-
dard password
Password cancelled
Keyswitch active

C058 Service displays
1 Brief description
Module Objective:
Upon completion of this module you will be able to locate the service displays and use the informa-
tion to diagnose faults on the machine.
Module Description:
The 802D sl controller offers in the SYSTEM area tools, which can be used to diagnose problems
existing on the machine. These tools can be used to optimize or to diagnose faults in the NC and
drive parts of the system.
Module Content:
Locating the Service displays

Content of service displays
Locating the service

displays
Section 2
Content of service dis-

plays Section 3

Section 2 Locating the service displays
Notes
The service displays can be found in the SYSTEM area of the control. To enter
the SYSTEM are the key combination SHIFT + ALARM should be used:

Content of service displays Section 3
Notes
The areas which are interesting for service:
Service axis
Service drives
Service axis. Service drives.
The following information is available in The following information is available in

the service axis area: the service drives area:
Following error Pulse enable PLC

Control deviation Speed controller enable NC
Contour deviation (axial) DC Link voltage
Servo gain factor (calculated) Ramp-function generator rapid stop
Active measuring system Enable pulses
Position act. Val. Meas. system 1 Drive ready
Position setpoint Booting phase
Abs. comps. Value meas. system 1 Speed setpoint
Compensation sag + temperature Speed actual value
Speed actual value (to max speed) Smoothed current actual value
Spindle speed setpoint prog. Motor temperature
Spindle speed setpoint actual Setpoint speed filter 1
Pos. offset referred to LA/LS act val Integrator inhibit
Pos. offset referred to LA/LS setpt Actual parameter set
Feed override Parking axis
Spindle override Setpoint parameter set (drive)
Actual gear stage Heatsink temperature warning
Parameter set (axis) Motor temperature warning
Controller mode Booting completed
Status display (referenced) Threshold torque not reached
QEC learning active Minimum speed not reached
Fixed stop reached Threshold speed not reached
Torque limitation value Actual speed = setpoint speed
Variable message 1

Notes

C026 Creating a PLC Program
1 Brief Description
Module Objective:
Upon completion of this module you will know what is required in order to create a PLC program.
Module Description:
The programming tool PLC802 describes the creation of a PLC program.
Module Content:
Creating a PLC program
Creation of a
Section 2
PLC program

Section 2 Creating a PLC program
Notes The PLC is created using the Programming Tool PLC802 software
package which was installed earlier as part of the toolbox.
To start the software, locate the program icon in the start menu of the
PC\PG
A blank project will open where the program can be written.
The software includes example projects found in the folder shown below
These can be used to reduce development time of the machine.
It is important that some consideration is given to compatibility issues
especially if commissioning a machine at a customer with existing machines.

Creating a PLC program Section 2
When a sample project is opened by double clicking, the program can be Notes
seen. This example shows the Milling program.
It is recommended that the program be saved under a different name to
keep the original intact.
By using a minimal number of blocks the MCP is easily configured.

The following example is using the MCPA variant, this is because the
block “MCP_802D” is parameterized using variables. The standard MCP
would be parameterised with Input bytes.

Section 2 Creating a PLC program
Notes To be able to run the axes, enable signals need to be set. This can be done
at this stage. The example shows network 4 with Q4.0. This is the OFF3
enable signal for this particular equipment only.
Networks 5 & 6 are setting axis 1 & 2 drive and pulse enables respectively.
Remember:- on a customers machine this would be different.
Loading the PLC program to the controller is described in Module C27

C027 Loading a PLC Program
1 Brief Description
Module Objective:
Upon completion of this module you are able to establish a connection to the PLC and load a new
PLC program to the controller.
Module Description:
This module describes the establishment of a communication connection and the download of the
PLC program to the controller. The function is checked via the program status.
Module Content:
Establishing RS232 Connection

Establishing Ethernet Connection
Loading a PLC Program
Establishing RS232 Connection Section 2
Establishing Ethernet Connection Section 3
Loading a PLC Program Section 4

Section 2 Establishing RS232 connection
Notes
Establishing the communication connection
The connection between the controller and the PG is established via the
serial RS232 COM interface X8 or the Ethernet interface X5
When the “communications” option is selected in the “User” area, you are
presented with a dialogue box where you can set up/activate the
communication type.

Establishing RS232 connection Section 2
The adapter type (TCP/IP NdisWanlp or PLC 802 PPI) is opened by Notes
double clicking the icon on the right hand side of the window.
This then opens up a dialogue box where the required adapter is selected
For connecting with RS232 the adapter PLC 802 (PPI) must be selected.
Baud rate, Port number etc can be changed with the properties button.
The connection has to be started on the control in the PLC area. A serial
cable is required between the PG/PC and the control (Plug X8) The RS232
port has to be activated on the control with the “Connect on” button below.

Section 2 Establishing RS232 connection
Notes When the control connection has been started, the connection is finalized
by double clicking on the “Refresh” icon, a search is carried out for any
active online partners. The PLC address is set by default to 2. Once this
has been found, the “Refresh” icon changes to show the control details
and it’s address
The connection is successful-Below
Section 3 Establishing Ethernet Connection
The connection via Ethernet is done in the same area as with RS232.
When the adapter selection entered, the “TCP/IP NdisWlanp” option is
chosen. The properties tab allows the IP address to be setup. The IP
range and subnet mask be similar to that of the control. The default
address for the 802D sl are 169.254.11.22 with subnet mask 255.255.0.0
An example for the PC/PG setting would be 169.254.11.23 with the same
subnet as the control. A cross over Ethernet cable is required to connect
between the PG/PC and the control (Plug X5)

Establishing Ethernet Connection Section 3
Ensure the default IP address is set for the control (169.254.11.22) then refresh Notes
the
“communications setup” window. The
following should then be shown.
Section 4 Loading a PLC program
Loading a program to the CPU
For safety reasons the drives should be in some way disabled so as

to prevent unwanted movement when the PLC is loaded
Once a connection is made the project can be loaded to the control. Be-
fore this the PLC type needs to be identified. This is done via the PLC drop
down menu, then select the “Type” option
The correct control can be selected from the list and a memory range test
can be carried out with the “Read PLC” button

Section 4 Loading a PLC program
Notes The program can now be loaded to the control. A “Download” button is
available on the task bar for this function. The project to be loaded needs
to be open and the download button selected.
Acknowledge the dialogue boxes with “OK” as they appear.

Loading a PLC program Section 4
Notes
The PLC program is now in the controller but the the PLC itself is not
running and the control displays the following alarms.
003000 Emergency stop
002000 PLC sign of life monitoring
400000 PLC STOP 2
The PLC can be started with an NCK reset on the controller or via the
“Run” button on the PLC802 software task bar
After pressing the “Run” button the dialogue box should be acknowledged
with “Yes”
After approximately 20 seconds the control alarms will clear and the
machine functionality can be checked

Notes

C035 PLC Subroutine Library
1 Brief Description
Module Objective:
Upon completion of this module you can write a PLC program using Subroutines from the Library.
Module Description:
The SINUMERIK 802D sl is a compact NC system, ideally suited for turning or milling machines.
This module describes the PLC Subroutine Library, its use and the resources it uses.
Module Content:
PLC subroutine library
PLC subroutine library

Section 2

Section 2 PLC subroutine library
Notes
To use the library, Programming Tool PLC802 is required, and can be
found on the toolbox CD which is delivered to the OEM with each control-
ler.
In order to acquaint users with the 802 PLC programming, four PLC exam-
ple projects are made available with the programming tool.
SUBR_LIBRARY.PTP
Library program with all provided subroutines
SIMULATION.PTP
Simulation program
SAMPLE_TURN.PTP
Program example for a turning machine
SAMPLE_MILL.PTP
Program example for a milling machine
In the project SUBR_LIBRARY.PTP, a number of subroutines for basic

functions such as Emergency Stop or axis and coolant control are made
available, this should be used as a template. The project SIMULA-
TION.PTP is a user PLC program for testing the 802D without a control
panel.
The two other projects can be used as examples to clarify the principle of
operation of subroutines. The library and the example programs are de-
signed for a standard axis configuration, but they can be adapted.
For further information, please refer to the pdf file “PLC_appl_Program.pdf”

(path: ..\Siemens\Programming Tool PLC802\Lib802Dsl\).
The functions of all subroutines are described in detail:
PLC_INI (PLC Initializing)

EMG_STOP (Emergency Stop)
MCP_802D (802D MCP signal transferring)
SPD_OVR (Spindle override with toggle keys)
MCP_SIMU (MCP simulation)
MCP_NCK (MCP signal processing)
HANDWHL (Handwheel selection)
AXES_CTL (Feed axes and Spindle control )
MEAS_JOG (Measuring in Jog mode)
COOLING (Coolant control)
LUBRICAT (Lubricating control)
TURRET1 (Turret with Hall Effect Device position sensor)
TURRET2 (Control of a turret with binary encoder)
TOOL_DIR (Tool change direction)
MGZ_INI (Initialization on tool magazine table)
MGZ_SRCH (Search tool from magazine)
MGZ_RNEW (Refresh magazine table)
TOGGLE
The programs are loaded to the CPU as described in Module C27.

PLC subroutine library Section 2
Notes

Description of PLC Subroutine Library V02.00.00 for
SINUMERIK 802D sl
SINUMERIK 802D sl Page: 1 / 53 All right reserved

PLC Subroutine library Date: 09.04.2006
Change Log 4
1. GENERAL DESCRIPTION 6
1.1. Purpose of the library PLC application programs 6
1.2. Pre-condition 7
1.3. Arrangement of symbol table 10
1.4. Arrangement of subroutine library 10
1.5. MCP Interface Description (refer to Chapter 18.2.1 and 18.2.2 in
Functional Description) 11
2. ASSIGNMENT OF THE SYMBOL TABLES 12

2.1. Symbol table 1 12
2.2. Symbol table 2 13
2.3. Symbol table 3 - Symbol table15 13
2.4. Symbol table 16: IS_MCP 13
2.5. Symbol table 17: IS_HMI 13
2.6. Symbol table 18: IS_AUX 14
2.7. Symbol table 19: IS_NCK 14
2.8. Symbol table 20: IS_CHA 14
2.9. Symbol table 21, 22, 23, 24, 25: IS_AX1, IS_AX2, IS_AX3, IS_AX4, IS_AX5 14
2.10. Symbol table 26: MD_PLC 14
2.11. Symbol table 27: ALARM 14
2.12. Symbol table 28: NV_MEM 14
2.13. Symbol table 29: SPC_MEM 15
2.14. Symbol table 30: SBR_MEM 15
2.15. Symbol table 31 and 32: reserved for library program 15
3. DESCRIPTION OF THE SUBROUTINES LIBRARY 16

3.1. Subroutine 32 - PLC_INI (PLC Initializing) 16
3.2. Subroutine 33 - EMG_STOP (Emergency Stop) 18
3.3. Subroutine 34 - MCP_802D (802D MCP signal transferring) 20
3.4. Subroutine 35 - SPD_OVR (Spindle override with toggle keys) 27
3.5. Subroutine 37 - MCP_SIMU (MCP simulation) 28
3.6. Subroutine 38 - MCP_NCK (MCP signal processing) 28
3.7. Subroutine 39 - HANDWHL (Handwheel selection) 29
3.8. Subroutine 40 - AXES_CTL (Feed axes and Spindle control ) 30
3.9. Subroutine 43 - MEAS_JOG (Measuring in Jog mode) 32
3.10. Subroutine 44 - COOLING (coolant control) 34
3.11. Subroutine 45 - LUBRICAT (Lubricating control) 35
3.12. Subroutine 46 - TURRET1 (Turret with Hall Effect Device position
sensor) 36
3.13. Subroutine 47 - TURRET2 (Control of a turret with binary encoder) 38
3.14. Subroutine 48 - TOOL_DIR (Tool change direction) 39
3.15. Subroutine 49 - MGZ_INI (Initialization on tool magazine table) 40

3.16. Subroutine 50 - MGZ_SRCH (Search tool from magazine) 42
3.17. Subroutine 51 - MGZ_RNEW (Refresh magazine table) 42
3.18. Subroutine 36, 41, 42 and Subroutine 52 ...58 and 60 …62 are reserved for
subroutine library 43
3.19. Subroutine 59 - GRINDING_CTL (Grinding control) 27
3.20. Subroutine 63 - TOGGLE 43
4. PLC USER ALARMS USED IN SUBROUTINE LIBRARY 46
5. SAMPLE PLC APPLICATION PROGRAMS 46

5.1. PLC Application Program for simulation 46
5.2 Sample PLC Application Program for a Turning Machine 49
5.3 Sample PLC Application Program for a Milling Machine 51

Change Log
V 01.05.00:
New functions
x Measuring in JOG mode
(usable with Version SINUMERIK 802D SW 01.01.05 or higher)
MEAS_JOG (SBR43) V1.0
Needs: PLC_INI (SBR32) V1.4, MCP_NCK (SBR38) V1.4
x Tool Magazine
MGZ_INI (SBR49) V1.0, MGZ_SRCH (SBR50) V1.0, MGZ_RNEW (SBR51) V1.0
Improvements
x Data exchange to PLC User Interface improved
TURRET1 (SBR46) V1.4, EMG_STOP (SBR33) V1.4 , MCP_NCK (SBR38) V1.4
x Signal names have been changed :

V10000004.0 ... V10000005.6 from CK0 ... CK5 to CK1 ... CK6 now.
V16002000.3 from EMG_STOP to EMGY_STOP
x Functionality of spindle keys has been changed. The trigger mode of CCW and CW keys can choose
with MD 14512[19] Bit0 (momentary or continuous).
MCP_802D (SBR34) V1.4
V 01.06.00:
Improvements
x Signal names have been changed :
V10000001.0 and V11000001.0 from not used to CONTINUOUSLY (CONT) now.
MCP_802D (SBR34)
x M133.5 is continuously traversing and M133.6 most significant Bit of INC buffer now.
MCP_802D (SBR34) V1.5, MCP_SIMU (SBR37) V1.4, MCP_NCK(SBR38) V1.5
V 01.07.00:
Improvements
x New interface signals for MCP 802D sl are used in SBR34 (VB10001000, VB10001001,
VB10001002, VB1001003, VB10001004, VB10001005, VB11001000).
x Description subroutine SBR34 and sample PLC application programs are changed.
V 01.08.00:
Improvements
x New interface signals from HMI are used in SBR38 (AUTO from area V18000000.0,
MDA V18000001.1. JOG V18000000.2, Mode change disable V18000000.5,

REF V18000001.2 to NCK interface).
V 02.00.00 for 802D solution line:
New functions
x Grinding
GRINDING_CTL (usable with Version SINUMERIK 802D sl SW 01.01.06 or higher)
GRINDING_CTL (SBR59) V01.00
Improvements
x New interface signals from NCK are used in SBR59 (V28001001.4, V28001001.5, V28001001.6),
V28001001.6, V38005004.0, V38025004.0), SBR60 (V27000002.5).
x M134.0 OS_REV_CMD flag for M-command enable oscillation reversal in SBR59

1. General Description
SINUMERIK 802D sl is a compact numerical control system with profibus drive interface,
ideally suited for turning and milling machines.
To adapt the SINUMERIK 802D to machine tools, machine control logic must be designed
with the PLC Programming Tool. The tool used is PLC 802 Version 3.0 or higher, The PLC
tool contains STEP7-Micro / WIN32 V3.0 programming language.
This document describes the PLC Subroutine Library V02.00.00 & is designed for Machine
Tool Builders who have basic knowledge of CNC and PLC functioning & programming.
Please, refer to following documents for more detailed information on 802D sl:
x SINUMERIK 802D sl Operating instructions

x SINUMERIK 802D sl Function description
x SINAMICS S120 documents
1.1.Purpose of the library PLC application programs

To acquaint the users with PLC programming tool, 4 PLC projects are provided in the
Internet site: http://www.siemens.com/sinumerik802d.
SUBR_LIBRARY.PTP Library program with all subroutines provided and an empty
main program (OB1)
SIMULATION.PTP Simulation program
SAMPLE_TURN.PTP Sample program for turning (lathe) machine
SAMPLE_MILL.PTP Sample program for milling machine
In project file SUBR_LIBRARY.PTP a variety of subroutines are provided for basic

functions such as emergency stop control, axes control, coolant control, lubrication control
and turret control for turning machines.
The project SIMULATION.PTP is an application PLC program for testing your 802D sl
without Machine control panel. The other 2 project files can be used as samples to show
how to make use of the subroutines in the project file SUBR_LIBRARY.PTP for turning or
milling machines.
Customers can just download the project files from the Internet and read these samples to
understand how a subroutine is programmed and how the subroutine is called. These files
can be saved (SUBR_LIBRARY.PTP) in a new project. By organizing the subroutines,
modifying or adding the necessary networks most of the machine tool requirements can be
met or addressed.
Just download your PLC application program into
SINUMERIK802D sl and test it until all the functions work.

1.2. Pre-condition
The subroutine library and the sample PLC application programs are designed for
standard axis configurations. By downloading one of the initialization files from installed
toolbox (path:Toolbox 802D_sl\Version\Techno\Config Siemens), the standard axis
configurations can be completed. The file SETUP_T.ARC is for turning machine the file
SETUP_M.ARC is for milling machine, the file SETUP_N.ARC, SETUP_N_MC.ARC is for
nibbling machine and the file SETUP_G_C.ARC, SETUP_G_C_INC.ARC is for cylindrical
grinding machine. (Further information you find in the readme.txt in the toolbox path.)
By downloading the configuration file SETUP_T.ARC from toolbox, the axes configuration
can be changed to a turning machine with 2 feed axes and 1 spindle.
Axis number Axis Name Axis interface address

1st axis X1 V3800 xxxx
2nd axis Z1 V3801 xxxx
3rd axis SP V3802 xxxx
By downloading the configuration file SETUP_M.ARC from toolbox, the axes configuration
can be changed to a milling machine with 4 feed axes and one spindle:

2nd axis Y1 V3801 xxxx
3rd axis Z1 V3802 xxxx
4th axis SP V3803 xxxx
5th axis A1 V3804 xxxx
By downloading the configuration file SETUP_N_MC.ARC from toolbox, the axes

configuration can be changed to a nibbling machine with 4 feed axes:

2nd axis Y1 V3801 xxxx
3rd axis C1 V3802 xxxx
4th axis C2 V3803 xxxx
By downloading the configuration file SETUP_G_C.ARC from toolbox, the axes

configuration can be changed to a cylindrical grinding machine with 4 feed axes:

2nd axis Z1 V3801 xxxx
3rd axis C1 V3802 xxxx
4th axis SP1 V3803 xxxx
To understand the subroutines in the library, the following preconditions must be taken into
consideration.

1.2.1.Division of the System Resources
The system resources can be divided into 3 parts. They are PLC system, NCK, and PLC
programming tool. In this chapter, these available resources are listed and further, divided
& described into resources for sample program and resources free for user.
1.2.2. Resources
1.2.2.1. Resource of PLC

Inputs: I0.0 … I8.7 (72 inputs on 1st PP module with address 9)
I9.0 … I17.7 (72 inputs on 2nd PP module with address 8)
Outputs: Q0.0 … Q5.7 (48 outputs on 1st PP module)
Q6.0 … Q11.7 (48 outputs on 2nd PP module)
Global Memory: M0.0 … M255.7
Retentive Memory: V14000000.0 … V14000127.7 (128 bytes)
User Alarm: V16000000.0 … V16000003.7 (32 user alarms)
Timers: T0 … T15 (16x100ms timers),
T16 … T31 (16x10ms timers)
Counters: C0 … C31 (32 counters)
1.2.2.2. Resource of NC
PLC Machine Data: MD14510 / MD14512 / MD14514
MD14510 User Data INT: V45000000 … V45000062 (32 words)

MD14512 User Data HEX: V45001000 … V45001032 (32 bytes)
MD14514 User Data Real: V45002000 … V45002028 (8 Dword)
1.2.2.3. Resource of Programming Tool
Symbol tables: SYM1 … SYM32
Subroutines: SBR0 … SBR63
1.2.3. Resource free for customers
1.2.3.1. Resource of PLC

Inputs: I0.0 … I17.7 (144 inputs)
Outputs: Q0.0 … Q11.7 (96 outputs)
Retentive Memory: V14000000.0 … V14000063.7 (64 bytes)
Timers: T0 … T15 (16x100ms timers)
Counters: C0 … C23 (24x counters)
Resource of NC

MD14514 User Data Real: V45002000 … V45002028 (8 Dword)
Resource of Programming Tool
Symbol tables: SYM1 … SYM15 (15 symbol tables)
Subroutines: SBR0 … SBR31 (32 subroutines)
1.2.3.2. Resource reserved for sample programs

Resource of PLC
Inputs: -
Outputs: -
Retentive Memory: V14000064.0 … V14000127.7 (64 bytes) (for machining
center, V14000000.0 to V14000040.7 are reserved)
Timers: no 100ms timers reserved
Counters: C24 … C31 (8x counters)
Resource of NC
MD14514 User Data Real: no
Resource of Programming Tool
Symbol tables: SYM16 … SYM32 (17 symbol tables)
Subroutines: SBR32 … SBR63 (32 subroutines)

1.3. Arrangement of symbol table
SYM Name Content of the symbol table
1 PP_1 I/O of PP module 1 will be defined by customers
2 PP_2 I/O of PP module 2 will be defined by customers
3 ~ 15 Reserved for customer
16 IS_MCP Interface signal from and/or to MCP
17 IS_HMI Interface signal from and/or to HMI
18 IS_AUX Interface signal of auxiliary function from NCK
19 IS_NCK Interface signal from and/or to NCK
20 IS_CHA Interface signal from and/or to CHANNEL
21 IS_AX1 Interface signal from and/or to AXIS 1
26 MD_PLC PLC Machine Data for Siemens Subroutine
27 ALARM User Alarms
28 NV_MEM Retentive data area (None Volatile Memory)
29 SPC_MEM Special Memory Bit
30 SBR_MEM Definition of Memory for library PLC application program
31 ~ 32 Reserved for library PLC application program
1.4. Arrangement of subroutine library

SBR Name Subroutine description
0 ~ 30 - Free for customer application
31 USR_INI Reserved for user initializing (called by SBR32 PLC_INI)
32 PLC_INI Initialization of the control
33 EMG_STOP Emergency Stop (including drive power on and power off sequence)
34 MCP_802D Transfer I/O of 802D MCP to interfaceV1000xxxx and V1100xxxx
35 SPD_OVR Spindle override code generator (gray code) to interface V1000 0008
36 Reserved
37 MCP_SIMU Simulating override switches and acknowledging the active signals
38 MCP_NCK MCP_HMI signal (from V1000 000x) to NCK
39 HANDWHL Handwheel(s) for 3 axis (MCS and WCS) selected from PLC
40 AXIS_CTL Enable control for 4 Feed Axis and spindle Control (hardware limit
switch, and brake release if necessary)
41 ~ 42 Reserved
43 MEAS_JOG Measuring in Jog
44 COOLING Coolant control
45 LUBRICAT Lubrication control (interval and time)
46 TURRET1 Turret control 1 (Hall effect device sensor turret with 4 or 6 position)
47 TURRET2 Turret control 2 (encoder sensor turret like SAUTER turret)
48 TOOL_DIR Make out the direction of tool change
49 MGZ_INI Initialization of holder table of tool magazine (max. 40 tools)
50 MGZ_SRCH Search holder position of programmed tool from magazine
51 MGZ_RNEW Refresh holder table
52 ~ 62 Reserved for library PLC application programs
63 TOGGLE Toggle switch K1 ~ K6; Delay Switch K7, K8

1.5. MCP Interface Description (refer to Chapter 18.2.1 and 18.2.2 in Functional
Description)
1000 Signals from MCP [w/r]

Interface MCP to PLC
Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
Operating Mode
10000000 NC- Single JOG MDA AUTOM
STOP block
Spindle function Protec- Machine function
10000001 NC- Spindle Spindle Spindle tion REF REPOS CONT
START CW STOP CCW level 7
Feed Protec- Machine function
10000002 START STOP Var. INC tion INC1000 INC100 INC10 INC1
level 4
Protection level Feed override
10000003 RESET 6 5 E D C B A
Axis Traverse keys Optional Customer keys (CK)

th th
10000004 4 Axis 4 Axis Rapid
- + overlay CK5 CK4 CK3 CK2 CK1
Axis Traverse keys
rd rd nd nd st st
10000005 free CK6 3 Axis 3 Axis 2 Axis 2 Axis 1 Axis 1 Axis
- + - + - +
Free customer Free customer keys
10000006 free free free free free free free
Free customer keys

10000007
free free free free free free free free
Spindle Override
10000008 “0” “0” “0” E D C B A
1100 Signals to MCP [w/r]

Interface MCP to PLC
Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
Operating Mode
11000000 NC- Single JOG MDA AUTOM
STOP block
Spindle function Machine function
11000001 NC- Spindle Spindle Spindle free REF REPOS CONT
START CW STOP CCW
Feed Machine function
11000002 START STOP Var. INC free INC1000 INC100 INC10 INC1
11000003 free free free free free free free free
Axis Traverse keys Customer keys LED`s

th th
11000004 4 Axis 4 Axis Rapid
- + overlay CLED5 CLED4 CLED3 CLED2 CLED1
Axis Traverse keys
rd rd nd nd st st
11000005 free CLED6 3 Axis 3 Axis 2 Axis 2 Axis 1 Axis 1 Axis
- + - + - +
Free customer keys Free customer keys
11000006 free free free free free free free
Free customer keys

11000007 free free free free free free free free

2. Assignment of the symbol tables
x List of Symbols used in the subroutine library obey the same convention:
1. Leading characters are for destinations:

P_ - to PLC interface
H_ - to HMI interface
N_ - to NCK interface
M_ - to MCP interface
2. subsequent characters are for areas:
C_ - Channel
1_ - Axes
M_ - MCP
Other short forms in the symbols:
HWL - Hardware Limit
HW - Handwheel
RT - Rapid Traverse
TK - Traverse Key
ACT - active
SEL - selected (activated)
3. Max. 11 upper case character to compose a symbol (include the leading
character). No special characters such as =, +, -, [, ] etc. are allowed except
underscore.
2.1. Symbol table 1

For 1st PP module
With this symbol table, all the physical inputs and outputs of PP module can be defined by
the customers according to their specific application.
Here customer can Module name, the

number of socket and
define a symbol for I0.0
pin are indicated here.
Customer can also
add the wire label of
I0.0 after colon.

2.2. Symbol table 2
For 2nd PP module
With this symbol table, all the physical inputs and outputs of PP module can be defined by
the customers according to their specific application.
2.3. Symbol table 3 - Symbol table15

These symbol tables are reserved for the application programs of customers.
CAUTION
! If the color of your symbol is changes automatically to RED, the symbol is
not accepted the programming tool. Check if special character is used or
if leading character is a digit.
CAUTION
! If a waved underscore appears under your symbol, the symbol is
duplicated. Check duplicate name or address.
2.4. Symbol table 16: IS_MCP

User Data Interface is defined and symbolized for MCP in this symbol table, i.e.
V1000 xxxx: Signals from MCP to PLC
V1100 xxxx: Signals to MCP
All main programs (OB1) and subroutines in the library PLC application programs access
the signals from MCP which are symbolized here in this table.
The signals from MCP should be transferred to this interface signal area in a subroutine. In
case 802D MCP is used, Subroutine 34 can be used to convey the signals from inputs /
outputs of MCP to the interface. In a similar way, if a customer has his own MCP, he is
only required to write a subroutine to transfer the signals from MCP to this User Data
Interface. Then all the subroutines in the library are available for application.
2.5. Symbol table 17: IS_HMI

Interface Signals from and to HMI are symbolized in this symbol table, i.e.
V1700 0xxx: Signal from HMI – Program Control (retentive, read only)
V1900 0xxx: Signal from HMI – Simulation active (retentive read only)
V1900 1xxx: Signal from HMI – Handwheel selection (retentive read only)
V1900 5xxx: Signal to HMI – Operator key lock (retentive read/write)

2.6. Symbol table 18: IS_AUX
Interface Signals from NCK channel are listed in this symbol table, i.e.
V2500 0xxx: Signal from NCK channel – Auxiliary function (read only)
V2500 1xxx: Signal from NCK channel – decoded M functions (read only)
V2500 2xxx: Signal from NCK channel – T function transferred (read only)
V2500 3xxx: Signal from NCK channel – M function transferred (read only)
V2500 5xxx: Signal from NCK channel – D function transferred (read only)
V2500 6xxx: Signal from NCK channel – H function transferred (read only)
2.7. Symbol table 19: IS_NCK

Interface Signals to and from NCK are listed in this symbol table, i.e.
V2600 xxxx: General signal to NCK (read/write)
V2700 xxxx: General signal from NCK (read only)
2.8. Symbol table 20: IS_CHA

V3000 xxxx: Mode signal to NCK (read/write)
V3100 xxxx: Mode signal from NCK (read only)
V3200 xxxx: Control signal to NCK (read/write)
V3300 xxxx: Control signal from NCK (read only)
2.9. Symbol table 21, 22, 23, 24, 25: IS_AX1, IS_AX2, IS_AX3, IS_AX4, IS_AX5
V380x xxxx: Axis control signals to NCK (read/write)
V390x xxxx: Axis control signals from NCK (read only)
2.10. Symbol table 26: MD_PLC

PLC Machine Data from NCK are listed in this symbol table, i.e.
V4500 0xxx: reflected MD14510 USER_DATA_INT (read only)
V4500 1xxx: reflected MD14512 USER_DATA_HEX (read only)
V4500 2xxx: reflected MD14514 USER_DATA_FLOAT (read only)
There are 32 Machine Data in each area. The last 16 Machine Data of each area are
reserved for the library PLC application program.
2.11. Symbol table 27: ALARM

Activating BIT of PLC Alarms of NCK (V1600 000x) are listed in this symbol table. There
are 32 User Alarms which can be activated by PLC application. The last 16 alarms are
reserved for the library PLC application program.
2.12. Symbol table 28: NV_MEM

There are 128 bytes in this retentive data area and the data used in the library are listed
(V1400 xxxx). The last 64 bytes are reserved for the library PLC application program.

2.13. Symbol table 29: SPC_MEM
There are 7 special memory bits in 802D sl (SM0.0 … SM0.6).
2.14. Symbol table 30: SBR_MEM

All the memories used in the Subroutines Library are listed in this table. These are used as
global variables for diagnosis purpose and arranged in the order of subroutines.
2.15. Symbol table 31 and 32: reserved for library program

3. Description of the subroutines library
The PLC machine data used for the subroutines in the library are listed here to have an
overview:
USER_DATA_INT:
MD14510[16] - Machine type
0: not defined (Initializing according to MD14512[16])
1: Turning machine
2: Milling machine
21: Cylindrical grinding machine
31: Nibbling machine with mechanical coupled punching die
32: Nibbling with servo axis coupled punching die
MD14510[22] - Turret clamping time (unit: 0.01s)

MD14510[24] - Lubrication interval (unit: 1min)
MD14510[25] - Lubrication duration (unit: 0.01s)
USER_DATA_HEX:
MD14512[16] Axis configuration (in case MD14510[16]=0)
Bit 0 - 1st axis is configured.
Bit 1 - 2nd axis is configured
Bit 2 - 3rd axis is configured
Bit 3 - 4th axis is configured
Bit 4 - 5th axis is configured
MD14512[18] special configuration of the machine tool
Bit 0 - Spindle without override switch
Bit 1 - Drive Optimization
Bit 2 - Lubrication at first power on
Bit 3 - When 802D MCP used, User Key1 is Feed Enable toggle key
Bit 4 - External spindle stop signal
Bit 6 - Hardware limits independent from PLC
Bit 7 - Only one hardware limit switch for each axis (with Bit6=0)
MD14512[19] Bit 0 = 0 Spindle key CW and CCW work as momentary trigger mode
Bit 0 = 1 Spindle key CW and CCW work as continuous trigger mode
3.1. Subroutine 32 - PLC_INI (PLC Initializing)

3.1.1. Purpose of Subroutine 32
This subroutine is executed at the 1st PLC cycle to set some interface signals according
to the configuration defined by PLC machine data. In this subroutine the following
interface signals are set:
V32000006.7 - feed override active for NCK channel
V380x0001.5 - Measuring system 1 for the axes defined
V380x0001.7 - feed override active for the axes defined

And also the Machine Data MD14512[18] Bit0 will be evaluated in the program to
determine whether the spindle override switch is installed.
At end of Subroutine 32, Subroutine 31: USR_INI is called. The initialization of customer
PLC project should be programmed in this subroutine.
3.1.2. Local Variable Definition – no local variable defined
3.1.3. Global Memory occupied

24 bytes are defined in the retentive data area and are assigned in this subroutine with
gray code values for applications of rotary gray code switches to select axis, operation
mode etc. See symbol table SYM28 (NV_MEM), from VB14000101 ~ VB14000124.
3.1.4. Corresponding PLC Machine Data

One WORD PLC machine data is defined for the machine type.
MD14510[16] - Machine type
0: not defined (Initializing according to MD14512[16])
1: Turning machine
2: Milling machine
I.e. for turning machine the axes is configured as below:

1st axis X axis
2nd axis Z axis
3rd axis Spindle
And for milling machine the axes is configured as below:
1st axis X axis
2nd axis Y axis
3rd axis Z axis
4th axis Spindle
5th axis A axis
MD14512[16] Axis configuration (in case MD14510[16]=0)
Bit0 - 1st axis is configured.
Bit1 - 2nd axis is configured
Bit2 - 3rd axis is configured
Bit3 - 4th axis is configured
Bit4 - 5th axis is configured
MD14512[18] special configuration of the machine tool
Bit0 - Spindle without override switch
3.1.5. Sample of Subroutine Call
Network 1 Initialization
SCAN_1ST PLC_INI
EN

3.1.5.1. Subroutine 33 - EMG_STOP (Emergency Stop)
CAUTION
! Please check whether this subroutine complies with all the relevant safety
requirements.
3.1.6.Purpose of Subroutine 33
This subroutine handles the emergency stop sequence according to the timing diagram
described in “Function Description”, as well as the power on and off sequence of the
Supply Infeed module. For detailed information about Supply Infeed module please
refer to 611U start-up guide.
On Infeed supply Spindle stop will be synchronized here

module:
Terminal 64
Terminal 63
Terminal 48
t t t t
Power Off sequence Power On sequence
The precondition of this subroutine is that the standard configuration of turning and
milling machine are used. When the enable on the drive is off, i.e. when Terminal 64 is
reset to zero, axes and spindle are braking to standstill. This subroutine evaluates a
feedback signal from V390X0001.4 – n<nmin, or an external spindle stop signal (e.g. an
analog spindle without encoder) according to MD14510[16].
MD14510[16]=0 means non standard configuration. In this case an external spindle stop
signal (for example, zero speed signal from a frequency converter) must be connected to
the subroutine to detect a spindle zero speed.
Drive Enable and Disable signal come from User Data area V1000 xxxx.
2 alarms may be activated from this subroutine:
Alarm 700016 – DRIVE NOT READY
Alarm 700017 – I2/T ALARM FOR INFEED MODULE
Feed Stop to channel will be activated by any alarms from the subroutine library. The
cancellation Feed Stop is RESET after alarm condition is cleared.
Important ! For machine tools with neither digital or analog spindle used, the PLC
machine data should be specified like following table. Otherwise the
emergency can not be released.
For turning machine For milling machine
MD14510[16]=0 MD14510[16]=0
MD14512[16] Bit 0 = 1 MD14512[16] Bit 0 = 1
Bit 1 = 1 Bit 1 = 1
Bit 2 = 1

3.1.7. Local Variable Definition
Inputs:
DELAY WORD Power on / off sequence delay (Unit:10ms)
E_KEY BOOL Emergency Stop Key (NC)
T_72 BOOL Terminal 72 of Infeed module: Drive ready (NO)
T_52 BOOL Terminal 52 of Infeed module: I2/t monitoring (NO)
HWL_ON BOOL any of the hardware-limit switches is active (NO) 1)
SpStop BOOL Spindle Stop (NO) 2)
1)
From subroutine 40 (AXIS_CTL) an output signal is set to “1” when any of the
hardware limit switch active. The signal can be connected to this subroutine to
trigger emergency stop in case of over limit.
2)
By Emergency Stop, spindle standstill signal from NCK will be evaluated before
disable the drive system to make sure that spindle can be stopped if PLC
machine data MD14510[16] = 1 or 2 (i.e. by turning or milling machine tools). If
MD14510[16]=0, this external signal will then be evaluated .
3)
NO – Normal Open; NC – Normal Close
Outputs:
T_48 BOOL To Terminal 48 of Infeed module: Contactor control
T_63 BOOL To Terminal 63 of Infeed module: Pulse enable
T_64 BOOL To Terminal 64 of Infeed module: Controller enable
T_48m M130.0 Status of Terminal 48 of the power module
D_T64m M130.6 Delay for Terminal 64 before verify ready signal
SP_STOPm M130.4 Spindle comes to standstill
PO_END M130.7 Power Up procedure ended
Three 10ms timer are used in this subroutine:
D_T64_T63 T24 Delay from Terminal 64 is off till Terminal 63 off
D_T63_T48 T25 Delay from Terminal 63 is off till Terminal 48 off
D_PON T26 Delay after Power On
MD14510[16] – Machine type is evaluated in this subroutine
Network 2 Emergency Control
ONE EMG_STOP
EN
50 DELAY T_48 Q0.0

I0.0 E_KEY T_63 Q0.1
I0.1 T_72 T_64 Q0.2
I0.2 T_52
Q0.7 HWL_ON
I0.4 SpStop

3.2. Subroutine 34 - MCP_802D (802D MCP signal transferring)
Subroutine34 transferring the input signals from 802D MCP to interface area for further
processing. By using sinumerik 802D the MCP 802D is connected via I/O’s from the PP-
module. The key layout is shown in the figure below and the key assignment can be
found in the following table:
MCP 802D
X1201
Pin Signal Type Description Pin Signal Type Description
1 M Output GND 2 L+ Output +24V
3 Im+0.0 Input #1 4 Im+0.1 Input #2
9 Im+0.6 Input #7 10 Im+0.7 Input #8
11 Im+1.0 Input #9 12 Im+1.1 Input #10
13 Im+1.2 Input #11 14 Im+1.3 Input #12
15 Im+1.4 Input #13 16 Im+1.5 Input #14
17 Im+1.6 Input #15 18 Im+1.7 Input #16
19 Im+2.0 Input #17 20 Im+2.1 Input #18
21 Im+2.2 Input #19 22 Im+2.3 Input #20
23 Im+2.4 Input #21 24 Im+2.5 Input #22
25 Im+2.6 Input #23 26 Im+2.7 Input #24
27 not connected 28 not connected
31 On+0.0 Output LED1 32 On+0.1 Output LED2
37 On+0.6 Output 38 On+0.7 Output
47 DOCOM1 Input 24VDC 48 DOCOM1 Input 24VDC
X1202
1 M Output GND 2 L+ Output +24V
3 Im+3.0 Input #25 4 Im+3.1 Input #26
5 Im+3.2 Input #27 6 Im+3.3 Input
7 Im+3.4 Input 8 Im+3.5 Input
11 Im+4.0 Input Feed_OV_A 12 Im+4.1 Input Feed_OV_B
13 Im+4.2 Input Feed_OV_C 14 Im+4.3 Input Feed_OV_D
15 Im+4.4 Input Feed_OV_E 16 Im+4.5 Input
19 Im+5.0 Input Sp_OV_A 20 Im+5.1 Input Sp_OV_B
21 Im+5.2 Input Sp_OV_C 22 Im+5.3 Input Sp_OV_D
23 Im+5.4 Input Sp_OV_E 24 Im+5.5 Input

For the sinumerik 802D sl you put preferably the MCP 802D sl via MCPA module.
MCP 802D sl
X1201
9 M GND 10 Im+1.0 Input #9
11 Im+1.1 Input #10 12 Im+1.2 Input #11
13 Im+1.3 Input #12 14 Im+1.4 Input #13
15 Im+1.5 Input #14 16 Im+1.6 Input #15
17 Im+1.7 Input #16 18 M GND
19 Im+2.0 Input #17 20 Im+2.1 Input #18
21 Im+2.2 Input #19 22 Im+2.3 Input #20
23 Im+2.4 Input #21 24 Im+2.5 Input #22
25 Im+2.6 Input #23 26 Im+2.7 Input #24
27 M GND 28 On+0.0 Output LED1
33 On+0.5 Output LED6 34 not connected
35 not connected 36 M GND
X1202
1 Im+3.0 Input #25 2 Im+3.1 Input #26
3 Im+3.2 Input #27 4 not connected
9 M GND 10 Im+4.0 Input Feed_OV_A
11 Im+4.1 Input Feed_OV_B 12 Im+4.2 Input Feed_OV_C
13 Im+4.3 Input Feed_OV_D 14 Im+4.4 Input Feed_OV_E
19 Im+5.0 Input Sp_OV_A 20 Im+5.1 Input Sp_OV_B
21 Im+5.2 Input Sp_OV_C 22 Im+5.3 Input Sp_OV_D
23 Im+5.4 Input Sp_OV_E 24 not connected
Further information about the hardware components you find in the Start-up guide/ Operating
instructions.

In this subroutine the physical inputs of axis traverse keys are transferred to the logic address in
the interface (V1000 xxxx). Key cross may be different according to variety of machine tool
structure. In this subroutine only 5 different key crosses are available.
802D MCP layout
L1 L2 L3
#1 #2 #3
L4 L5 L6
#4 #5 #6
#7 #8 #9
[.]
#10 #11 #12
,
#13 #14 #15
#16 #17 #18

%
+X
#19 #20 #21
-Z +Z
#22 #23 #24
-X
#25 #26 #27

%
Traverse key layout

For inclined bed turning machine For horizontal bed turning machine
#16 #17 #18 #16 #17 #18
+X -X
#19 #20 #21 #19 #20 #21
-Z +Z -Z +Z
#22 #23 #24 #22 #23 #24
-X +X
For vertical milling machine For knee-type milling machine

#16 #17 #18 #16 #17 #18
+4th +Z +Y +4th -Z -Y
#19 #20 #21 #19 #20 #21
-X +X +X -X
#22 #23 #24 #22 #23 #24
th th
-Y - Z -4 +Y +Z -4
Note: In this subroutine the feed override signals of 802D MCP are checked to be sure
that MCP is available. Otherwise an alarm will be triggered.
Alarm 700024 – 802D MACHINE CONTROL PANEL DEFECT

Inputs:
PB_0 BYTE Parameter buffer for K1 … K8
L0.0: K1: Customer key1
L0.5 K6: Customer key6
L0.6: K7: INC/VAR
L0.7: K8: JOG mode key
PB_1 BYTE Parameter buffer for K9 … K16
L1.0: K9: REF mode key
L1.1: K10: AUTO mode key
L1.2: K11: Single Block key
L1.3: K12: MDA mode key
L1.4: K13: Spindle + key
L1.5: K14: Spindle Stop key
L1.6: K15: Spindle – key
L1.7: K16: Axis key
PB_2 BYTE Parameter buffer for K17… K24
L2.0: K17: Axis key
L2.1: K18: Axis key
L2.2: K19: Axis key
L2.3: K20: Rapid traverse key
L2.4: K21: Axis key
L2.5: K22: Axis key
L2.6: K23: Axis key
L2.7: K24: Axis key
PB_3 BYTE Parameter buffer for K25… K27
L3.0: K25: RESET key
L3.1: K26: NC STOP key
L3.2: K27: NC START key
Fov BYTE Parameter buffer for Feed override

LB4: Feed Override
Sov BYTE Parameter buffer for Spindle override
LB5: Spindle Override
Drv_En BOOL Parameter feed enable key
disable. L6.0: Feed enable key. valid only when
Machine data MD14512[18] bit 3=1 then
Customer Key 1 is designed as toggle switch for drive
enable and disenable in this subroutine
I_En BOOL Parameter condition for NC start
L6.1: Condition for NC start
Xcross WORD Parameter definition for layout of traverse axis keys.
LW8: Layout of traverse keys
0: traverse key not processed in the subroutine
1: traverse key layout for inclined bed turning machine
2: traverse key layout for horizontal bed turning machine
3: traverse key layout for vertical milling machine
4: traverse key layout for knee-type milling machine
5: traverse key sequentially arranged (for variable Xcross)

Key Local Xcross Xcross Xcross Xcross
number Var. =1 =2 =3 =4
th th
#16 L1.7 +4 +4
#17 L2.0 +X -X +Z -Z
#18 L2.1 +Y -Y
#19 L2.2 -Z -Z -X +X
#20 L2.3 Rapid Rapid Rapid Rapid
#21 L2.4 +Z +Z +X -X
#22 L2.5 -Y +Y
#23 L2.6 -X +X -Z +Z
th th
#24 L2.7 -4 -4
Outputs: send out the signals from User Data to V1100 xxxx “signal for User Keys” to
LEDs BYTE Output for L1 to L6 MCP

L10.0: CLED1:
L10.1: CLED2:
L10.2: CLED3:
L10.3: CLED4
L10.4: CLED5
L10.5: CLED6
If other traverse key cross is required than those in previous samples, than use the configuration
Xcross=5 (variable key arrangement).
variable key arrangement
#16 #17 #18
#19 #20 #21
#22 #23 #24
Key Bit transfer Parameter Xcross MCP_802D

number [*written by customer] MCP_802D =5
#16 IBx MBx PB_1 Bit 7 +4. axis
#17 PB_2 Bit 0 -4. axis
#18 PB_2 Bit 1 +1. axis
MB10 PB_1
#19 PB_2 Bit 2 -1. axis
#20 PB_2 Bit 3 Rapid
#21 PB_2 Bit 4 +2. axis
#22 PB_2 Bit 5 -2. axis MB11
#23 PB_2 Bit 6 +3. axis PB_2
#24 IB(x+1) MB(x+1) PB_2 Bit 7 -3. axis

Manufactures can connect their physical I/O addresses in such way that they get their required Xcross
by adding some networks for converting.
The Xcross configuration will be realized by bit wise connection between Ibx (IBx+1) and MBx (MBx+1)
and be transferred to PB_1 Bit7 and PB_2. This program part is written by the customer.
The absolute address is in accordance with the interface port on PP or MCPA module.
Example: #16 #17 #18
+Z +Y +X
#19 #20 #21
-A +A
#22 #23 #24
-X -Y -Z
Key Bit transfer MB10 Parameter Xcross MCP_802D

number [*written by customer] MB11 MCP_802D =5
#16 IBx MBx M11.6 PB_1 Bit 7 +4. axis
#17 M11.4 PB_2 Bit 0 - 4. axis
#18 M11.1 PB_2 Bit 1 +1. axis PB_1
MB10
#19 M11.0 PB_2 Bit 2 - 1. axis
#20 M11.3 PB_2 Bit 3 Rapid
#21 M10.7 PB_2 Bit 4 +2. axis
#22 M11.2 PB_2 Bit 5 - 2. axis MB11
PB_2
#23 M11.5 PB_2 Bit 6 +3. axis
#24 IB(x+1) MB(x+1) M11.7 PB_2 Bit 7 - 3. axis
In above example MB10 and MB11 are used, which represent the keys for MCP_802D.

Two Bytes are used in this subroutine for toggle keys as Single Block and Feed Enable:
MB 133
MB 134
While there are no feed enable and feed disable keys on 802D MCP, two possibilities are
provided by this subroutine, either using User Key 1 as toggle switch for feed enable and disable
or using external key via an input to PP module. Therefore one PLC machine data bit is defined in
MD14512[18] for this special requirement:
If MD14512[18] bit 3=1 Customer Key 1 on 802D MCP is used as toggle key for Feed Enable or
disable
If MD14512[18] bit 3=0 an external key can be connect to the subroutine. The key should be with
holding signal, i.e. 1 – feed enable; 0 – feed disable.
The Spindle key function depends on PLC machine data MD14512[19]:

If MD14512[19] bit 0=0 Spindle key CW and CCW work as momentary trigger mode
If MD14512[18] bit 0=1 Spindle key CW and CCW work as continuous trigger mode

3.2.5. Sample of Subroutine Call MCP 802D
Network 3 Transfer 802D MCP signals to interface area V1000
ONE MCP_802D
EN
IB3 PB_0 LEDs QB2

IB4 PB_1
IB5 PB_2
IB6 PB_3
IB7 Fov
IB8 Sov
ONE Drv_EN
ONE I_EN
MD_INT_16 Xcross
3.2.6. Sample of Subroutine Call MCP 802D sl
Network 3 Transfer 802D sl MCP signals to interface area V1000
ONE MCP_802D
EN
VB10001000 PB_0 LEDs VB11001000

VB10001001 PB_1
VB10001002 PB_2
VB10001003 PB_3
VB10001004 Fov
VB10001005 Sov
ONE Drv_EN
ONE I_EN
MD_INT_16 Xcross

3.3. Subroutine 35 - SPD_OVR (Spindle override with toggle keys)
The purpose of this subroutine is to provide an alternative way to change spindle override value
using toggle keys instead of using rotary gray code switch. Some customers would like to simplify
their design of their own MCP’s, using 3 toggle keys for spindle override to increase or decrease
the override value of the spindle and with a toggle key to get override of 100%. The generated
spindle override code is output to MCP interface VB10000008.
If Gcode=1, the gray code override is selected in steps of 1 not depending on the value of STEPi.
For gray coding, 15 codes are available corresponding to the 15 positions of a rotary switch.
If Gcode=0, binary override code will be generated.
If binary code is selected for spindle, one machine data must be set:
MD12060 OVR_SPIND_IS_GRAY_CODE = 0 (0: Binary code; 1: Gray code)

Inputs:
STEPi WORD Step for increasing or decreasing the override value
with the range from 1 to 10 for binary code
Gcode BOOL 1 - gray code override is selected; 0 – binary code;
OVinc BOOL toggle key for override increasing
OVdec BYTE toggle key for override decreasing
OV100 BYTE toggle key for override 100%
OV_CNT WORD MW242 buffer for override code.

3.3.4. Corresponding PLC Machine Data – no PLC machine defined
Network 4 Spindle override using toggle keys
ONE SPD_OVR
EN
10 STEPi
ZERO Gcode
I2.1 OVinc
I2.2 OVdec
I2.0 OV100

3.4. Subroutine 37 - MCP_SIMU (MCP simulation)
The purpose of this subroutine is to provide a way to operate the 802D without MCP.
With the help of Status Chart of Micro/WIN, most of the MCP functions, such as
selection of operating mode or reference point approach, NC start, stop etc., can be
simulated. The application of this subroutine can be found in chapter 5.1.
3.4.2. Local Variable Definition – no local variable is used in the subroutine
3.4.3. Global Memory used

SIM_CAM1 M249.0 Reference CAM axis 1 for simulation
SIM_T63 M249.3 for simulation of terminal 63 of drive
SIM_T64 M249.4 for simulation of terminal 64 of drive
FOV_P M250.0 Feed override increment
FOV100 M250.1 Feed override 100%
FOV_N M250.2 Feed override decrement
SOV_P M250.3 Spindle override increment
SOV100 M250.4 Spindle override 100%
SOV_N M250.5 Spindle override decrement
SIM_INC M250.7 Increment selection
FOV_POS C25 simulating feed rate override switch
SOV_POS C26 simulating spindle override switch
3.4.4. Corresponding PLC Machine Data – no machine data defined
3.5. Subroutine 38 - MCP_NCK (MCP signal processing)

The purpose of this subroutine is to transfer MCP signals in the interface V1000xxxx to
NCK interface to activate operation mode and control sequences. The main functions in
the subroutine are:
1. Selection of operation mode
2. Selection of increment
3. HMI signals to NCK channel interface
4. AXIS traversing signal to NCK axis interface with condition of no exceeding any
hardware limits.

3.5.2. Local Variable Definition – no local variable is used in the subroutine
3.5.3. Global Memory occupied – no global memory used.

MD14510[16] – Machine data is used to decide the axis number for traversing. For
example, if a turning machine is selected, the Z axis is the second axis and spindle is
third, therefore the signal of traverse key of Z axis on the MCP should be sent to 2nd axis
interface and spindle to 3rd axis interface.
Network 4 Processing MCP signals from V1000 and activating corresponding functions
ONE MCP_NCK
EN
3.6. Subroutine 39 - HANDWHL (Handwheel selection)

The purpose of this subroutine is to select handwheel in MCS or WCS according HMI
interface V1900 1xxx.
3.6.2. Local Variable Definition – no local variables are defined
3.6.3. Global Memory occupied – no memory used
MD14510[16] – Machine type is evaluated in this subroutine

Network 5 Selection handwheel according interface area V1900 1xxx
ONE HANDWHL
EN

3.7. Subroutine 40 - AXES_CTL (Feed axes and Spindle control )
The purpose of this subroutine is to control the interface signals of “Impulse enable” -
V380x4001.7 and “controller enable” (V380x0002.1), to monitor hardware limits and reference
cam signals of all axes. For spindle, the enable signal will be activated by any of the spindle
command, like Spindle CW and CCW, M03, M04, SPOS.
Motor brake will be released with the condition that no emergency stop and position controller is
active.
Two different ways are provided by the subroutine for hardware limit control. One is PLC solution
(MD14512[18] bit 6=0) and the other is hardware solution (MD14512[18] bit 6=1).
By PLC solution, the hardware limit signals, either 2 hardware limit switches (MD14512[18] bit
7=0) or only one hardware limit switch (MD14512[18] bit 7=1) can be configured for each axis.
These signals will be sent to NCK interface V380x1000.0 or V380x1000.1 and a feed stop will be
generated by NCK according to these interface signals. It is also possible to trigger a
EMERGENCY STOP by connecting the output signal OVlmt (subroutine parameter) to the input
parameter HWL_ON of subroutine 33 EMG_STOP.
The hardware solution is actually PLC independent for more safety, see the figure below:
24Vdc
Encoding of HW limit switch Hardware limit
E_Key _1LMTp _2LMTp _3LMTp Direction Reached
3rd axis limit
Input 0 1 1 1 - Only Emg. Stop
0 0 1 1 V39000004.7 1st + over limit
_3LMTp
0 0 1 1 V39000004.6 1st - over limit
Release 0 0 0 1 V39010004.7 2nd + over limit
button 2nd limit switch 0 0 0 1 V39010004.6 2nd - over limit
0 0 0 0 V39020004.7 3rd + over limit
Input 0 0 0 0 V39020004.6 3rd - over limit
_2LMTp
Note: In case of EMERGENCY STOP or any of the
1st limit switch
hardware limits are reached, Terminal 64 switches
Input and Terminal 9 are disconnected by hardware.
_1LMTp
Emergency Stop button Terminal 9
Input
E_Key KA1
KA1 Terminal 64: control enable of Infeed
module
With above solution, the feed stop of all axes (i.e. disable Supply Infeed module by disconnecting
TERMINAL64 and T9 via a relay) will be activated by any active hardware limit switches or
Emergency Stop button by means of hardware. The Inputs signals to PLC shown in above figure
are for diagnosis purpose and to provide more information for PLC, e.g. the feed stop of Supply
Infeed module is caused by either Emergency Stop button or by one of hardware limit switches.
Note: Some precondition should be considered when this solution is used:
1. The axes should be configured one next to the other, e.g. X, Z, spindle or X, Y, Z,
spindle; This subroutine does not support the configuration like X, Y, Spindle, Z;
2. The inputs to the subroutine for hardware limit of unused axis should be assigned
with SM0.0. Otherwise the hardware limit can not be detected.

Inputs:
NODEF WORD reserved word
T_64 BOOL Status of terminal 64 of infeed module
T_63 BOOL Status of terminal 63 of infeed module
OPTM BOOL input for brake release during drive optimization (NO)
_1LMTp BOOL 1st axis hardware limit plus (NC)
_1LMTn BOOL 1st axis hardware limit minus (NC)
_1REF BOOL 1st axis reference point cam (NO)
_2LMTp BOOL 2nd axis hardware limit plus (NC)
_2LMTn BOOL 2nd axis hardware limit minus (NC)
_2REF BOOL 2nd axis reference point cam (NO)
_3LMTp BOOL 3rd axis hardware limit plus (NC)
_3LMTn BOOL 3rd axis hardware limit minus (NC)
_3REF BOOL 3rd axis reference point cam (NO)
_4REF BOOL 4th axis reference point cam (NO)
_5REF BOOL 5th axis reference point cam (NO)
Note: NO – Normal Open;
NC – Normal Close
Outputs:
_1BRK BOOL Brake release output for 1st axis (high effective)
_2BRK BOOL Brake release output for 2nd axis (high effective)
_3BRK BOOL Brake release output for 3rd axis (high effective)
OVlmt BOOL Over limit output (any of HW limit is active, also high
effective)
If only one HW limit switch (with 2 cams) is installed on the machine tool for each axis, the local
variable for positive limit switch is used for this switch signal. In the PLC program the traversing
direction is evaluated to decide the over limit direction.
SP_CMD M138.1 Spindle start command (CW or CCW)

MD14510[16] – machine type 0: not defined;
1: turning machine;
2: milling machine
MD14512[16] - axes configuration (valid only if MD14510[16]=0)

Bit 0 – 1: 1st axis is selected
Bit 1 – 1: 2nd axis is selected
Bit 2 – 1: 3rd axis is selected
Bit 3 – 1: 4th axis is selected
Bit 4 – 1: 5th axis is selected
MD14512[18] Bit 6 – 1: Hardware solution for over limit monitoring;
0: PLC solution with the condition defined by:
MD14512[18] Bit 7 – 1: only one hardware limit switch for each axis or
0: 2 hardware limit switches for both directions of an axis;

MD14512[18] Bit 1 – 1: Switch #OPTM for brake release by drive optimization;
0: Switch #OPTM is not valid.
Note: The motor brake must be released by optimization, which is controlled by

SimoCom U via RS232 interface. In this case it is necessary to install a
switch for optimization. If MD14512[18] bit1=1, the condition for brake
release is no emergency stop (V27000000.1=0) and switch #OPTM=on.
Note: an PLC alarm will be generated to provide a message that brake is
released for optimization.
Alarm 700026 – BRAKE RELEASED FOR DRIVE OPTIMIZATION
Important: After drive optimization, MD14512[18] Bit 1 should be set to “0” .

st nd rd
Network 6 Axes control for X(1 axis), Y(2 axis), Z(3 axis) and spindle
ONE AXIS_CTL
EN
0 NODEF _1BRK NULL_b

Q0.2 T_64 _2BRK NULL_b
Q0.1 T_63 _3BRK Q0.3
ZERO OPTM OVlmt NULL_b
I0.1 _1LMTp
I0.2 _1LMTn
I0.7 _1REF
I0.4 _2LMTp
I0.5 _2LMTn
I1.0 _2REF
I0.5 _3LMTp
I0.6 _3LMTn
I1.1 _3REF
ZERO _4REF
ZERO _5REF
3.8. Subroutine 43 - MEAS_JOG (Measuring in Jog mode)

This subroutine handles the information of the probe and realizes the function
“Measurement in Jog Mode”. With this subroutine it is possible to calibrate the probe and
measure the tools.
To use this subroutine, it is necessary to call up the subroutine MCP_NCK (SBR38) in the OB1.
In case if there is any change the operating area while function “Measurement in Jog Mode” is
active, this function will be stopped automatically.
Following message will be activated in this subroutine:

700031 – MEASUREMENT IN JOG IS ACTIVE

Inputs:
Meas_Enable BOOL Enable MEAS_JOG
VD14000064 DWORD Active tool number
MEAS_OPAUT M240.0 Meas in operating mode automatic

MEAS_OPJOG M240.1 Meas in operating mode jog
CHL_HMI M240.2 Meas in operating mode change look from HMI
NO_KEY M240.3 no traversing keys in the axis
OUT_HMI M240.4 operating mode automatic from HMI
FDI_MEASJOG M240.5 feed disable in Meas_JOG
ON_MEASJOG M240.6 start Meas_JOG
PROBE_ON M240.7 probe signal has released
JOG_MEASJOG M241.0 output operation mode jog in Meas_JOG
AUT_MEASJOG M241.1 output operation mode auto in Meas_JOG
CHL_MEASJOG M241.2 operation mode change look in Meas_JOG
KEY_MEASJOG M241.3 traversing keys in Meas_JOG
RES_MEASJOG M241.4 reset in Meas_JOG
ESC_MEASJOG M241.5 abort Meas_JOG
DRY_MEASJOG M241.6 dry run feed in Meas_JOG
SBL_MEASJOG M241.7 single block in Meas_JOG
3.8.4. Corresponding PLC Machine Data – no machine data defined
Network 7 Measuring in JOG Mode
ONE MEAS_JOG
EN
VD14000064 T_ACT

3.9. Subroutine 44 - COOLING (coolant control)
The coolant is controlled under JOG mode by a key on MCP and in AUTO/MDA mode
by M07/M08 for coolant on and M09 for coolant off in part program. In case of
emergency stop, coolant motor overload, or by active functions like Program Test or
simulation, coolant will be inhibited.
2 alarms will be activated from this subroutine:
Alarm 700018 – COOLING MOTOR OVERLOAD
Alarm 700019 – COOLANT LEVEL LOW
Inputs:
C_key BOOL Manual operating key (trigger signal required)
OVload BOOL Coolant motor overload (NC)
C_low BOOL Coolant level low (NC)
Outputs:
C_out BOOL Coolant output
C_LED BOOL output for status display
COOLon M150.0 Status of coolant on
3.9.4. Corresponding PLC Machine Data – no PLC machine data related
Network 7 Coolant control
ONE COOLING
EN
P_M_USER_K6
C_KEY
I2.4
OVload
I2.5
C_low
C_out Q1.0
C_LED M_LED_CK6

3.10. Subroutine 45 - LUBRICAT (Lubricating control)
Lubrication is controlled according a specified time interval for a specified duration (not
distance related). A manual key is available to start lubricating, and during power on of
the machine tool it is also possible to start lubrication. Normally the lubrication will be
started periodically in the time interval defined by input parameter Lintv. The lubrication
lasts for the duration specified by another input parameter Ltime. In case of emergency
stop, lubrication motor overload, lubrication will be not started.
2 alarms will be activated in this subroutine:
Alarm 700020 – LUBRICATING MOTOR OVERLOAD
Alarm 700021 – LUBRICANT LEVEL LOW
Inputs:
Lintv WORD Lubrication time interval (unit: 1 min)
Ltime WORD Lubrication duration (unit: 0.01s, max. 327.67s)
L_key BOOL manual lubrication key (trigger signal required)
L1st BOOL Lubrication by first PLC cycle (power on)
Ovload BOOL lubrication motor overload
L_low BOOL lubricant level low
Outputs:
L_out BOOL Lubrication output
L_LED BOOL output for status display
L_cmd M152.0 lubrication command
L_interval C24 used to calculate lubrication interval (unit: 1 minute)
L_time T27 used to calculate lubrication time (unit: 0.01s, max.
327,67s Approx. 5 min)
MD 14510 [24]: Lubrication time interval (unit: 1 min)
MD 14510 [25]: Lubrication duration (unit: 0,01 s, max. 327.67s)
Network 8 Lubrication by interval specified by MD14510[23] and duration by MD14510[24]
ONE LUBRICAT
EN
MD_INT_24 Lintv L_out Q4.5

MD_INT_25 Ltime L_LED M_LED_CK5
P_M_USER_K5 L_key
ONE L1st
I8.7 OVload
I8.6 L_low

3.11. Subroutine 46 - TURRET1 (Turret with Hall Effect Device position sensor)
This subroutine controls the kind of turret with Hall Effect Device sensor (HED).Turret
motor is controlled by PLC output. During tool search the motor turns clockwise. When
the desired tool is in-position, turret motor runs counter clockwise for a specified duration
for clamping. The subroutine verifies the parameter for turret CCW to limit the value
within 3 seconds in order to avoid the damage of the turret motor.
T function from NCK will start turret change in AUTO and MDA mode and a short strike
on the manual key will change one turret position and long press for more position turret
change in JOG mode.
During time of turret change one interface signal (V32000006.1 “Read-in disable”) is set,
so that a part program will be stopped waiting for the turret change.
In case of emergency stop, turret motor overload, or by active functions like Program
Test or simulation, turret will be inhibited.
The timing diagram for this kind of turret is shown below:
Signal Start Target Start Target

T1 T3 T6 T4
Clamp time Clamp time
Motor CW CW CCW CW CCW
Off
CCW
Tool T1
Pos. T2
T3
T4
T5
T6

Alarm 700022 – TURRET MOTOR OVERLOAD
Alarm 700023 – PROGRAMMED TOOL NUM. > MAX. TURRET NUMBER
Alarm 700026 – NO POSITION SIGNALS FROM TURRET
Inputs:
Tmax WORD max. number of tool on the turret
T_01 … T_06 BOOL tool position sensors (low effective)
T_key BOOL manual lubricating key (trigger signal required)
OVload BOOL lubricating motor overload
Outputs:
T_cw BOOL turret positioning
T_ccw BOOL turret clamping
T_LED BOOL output for status display

T_CURRENT VD14000064 Current tool (retentive data)
ClampTime MW154 Turret clamping time
T_cw_m M156.0 Turret CW flag
T_ccw_m M156.1 Turret CCW flag
CcwDelay M156.2 Turret CCW delay
K_active M156.3 Manual key is active
TC_end M156.4 Tool Change complete
Tp_ne_Tc M156.5 Programmed Tool number not equal current tool
T__P_INDX MD160 Buffer to monitor the change of the turret by JOG mode
T_CHL M168.4 Operation mode change look
T1clamp T28 Turret1 clamping timer.
MD14510[22]: Turret clamping time (unit: 0.01s max. 300 unit)
By PLC initialization if MD14510[16]=1 (turning machine), the value of MD14510[22] will
be automatically evaluated and the result will be saved in memory word MW154 which is
used by subroutine 46 for turret change.
IF MD14510[22]=0 THEN MW154= 50 (default)
IF MD14510[22]>300 THEN MW154=300 (max.)
Network 9 HED turret control
ONE TURRET1
EN
6 Tmax T_cw Q5.0

MD_INT_22 C_time T_ccw Q5.1
I7.0 T_01 T_LED M_LED_CK4
I7.1 T_02
I7.2 T_03
I7.3 T_04
I7.4 T_05
I7.5 T_06
P_M_USER_K4 T_key
I7.6 OVload

3.12. Subroutine 47 - TURRET2 (Control of a turret with binary encoder)
This subroutine is used to control turret with encoder. The encoder is installed in this
kind of turret, with the capability to index in 2 directions in order to have a shorter tool
change time. For the timing diagram and the principle, please refer turret description.
During time of turret change one interface signal (V32000006.1 “Read-in disable”) is set,
so that a part program will be stopped waiting for the turret change.
In case of emergency stop, turret motor overload, or during Program Test active or
simulation active, turret will be inhibited.
Alarm 700022 – TURRET MOTOR OVERLOAD
Alarm 700023 – PROGRAMMED TOOL NUM. > MAX. TURRET NUMBER
Inputs:
Tmax DWORD max. tool number on turret
T_1 BOOL T code A
T_2 BOOL T code B
T_3 BOOL T code C
T_4 BOOL T code D
Parity BOOL parity
Strobe BOOL signal strobe
OVload BOOL turret motor overload
T_key BOOL manual change key
Outputs:
T_cw BOOL turret CW
T_ccw BOOL turret CCW
T_CURRENT VD14000064 Current tool number (retentive data)
T_cw_m M156.0 Turret CW flag
T_ccw_m M156.1 Turret CCW flag
T__P_INDX MD160 Buffer to monitor the change of the turret by JOG mode
T_DES MD164 Destination tool number
T_DIR M168.0 Turret change direction
T_POS M168.1 Turret in-positioning
T_LOCK M168.2 Turret clamping command
T_MAG M168.3 Turret solenoid for clamping

3.12.4. Corresponding PLC Machine Data – no machine data related
Network 9 Control of turret with encoder
ONE TURRET2
EN
8 Tmax T_cw Q1.6

1000 Delay T_ccw Q1.7
I3.0 T_1 Magnet Q1.5
I3.1 T_2 LED M_LED_CK4
I3.2 T_3
I3.3 T_4
I3.4 Parity
I3.5 Strobe
I3.6 OVload
I3.7 P_indx
P_M_USER_K4 T_key
3.13. Subroutine 48 - TOOL_DIR (Tool change direction)

The purpose is to identify the direction and pre-indexing position of the turret or tool
chain according to the maximum tool number and programmed tool number. In
subroutine library this subroutine is called by subroutine 47 - TURRET2 for turrets like
from SAUTER Company. Tool number should be limited between 2 and 64.
Inputs:
Tmax DWORD max. tool number on turret
Pnum DWORD programmed tool number
Pcurr DWORD current turret position
Outputs:
P_INDXo DWORD pre-indexing position; one position before the destination
in direction of shortest way.
DIR BOOL tool change direction: 1 - CW; 0 - CCW

3.13.3. Global Memory occupied – no global memory defined
Network 9 Make out the direction of turret as well as pre-indexing position
ONE TOOL_DIR
EN
12 Tmax P_INDEXo P_INDEXo

P_C_TFUNC Pnum DIR M20.1
T_CURRENT Pcurr
3.14. Subroutine 49 - MGZ_INI (Initialization on tool magazine table)

In order to realize tool magazine control for machining center, which requires random
access of tools from magazine, PLC library provides some subroutines for magazine
management. These subroutines include initialization, searching for position of the
destination tool, refreshing holder table.
It is defined in the library that the number of tool holders of a magazine must not exceed
40. Initialization is to establish a table in retentive data area VB14000000 to
VB14000040 representing up to 40 tools on the magazine.
After initialization, the tool holders on the magazine contain the same number of tools as
holders and no tool in the spindle.
In tool change, the holder with programmed tool should be allocated first. The number of
the holder is used to control the magazine to turn clockwise or counter clockwise to
exchanging position.
After ATC exchanges the tools on the holder and spindle, the holder table should be
refreshed. The programmed tool is on the spindle and existing tool on spindle, should be
put back into empty holder. Please refer the following table for principal.
The control logic for magazine as well as ATC is hardware dependent, therefore should
be designed by machine tool builders.

TOOL on Table After ini. T5 M06 T8 M06 T16 M6 T0 M06 T15 M06 T10 M06
SPINDLE VB14000000 0 5 8 16 0 15 10
T_HOLDER_1 VB14000001 1 1 1 1 1 1 1
T_HOLDER_2 VB14000002 2 2 2 2 2 2 2
T_HOLDER_3 VB14000003 3 3 3 3 3 3 3
T_HOLDER_4 VB14000004 4 4 4 4 4 4 4
T_HOLDER_5 VB14000005 5 0 0 0 16 16 16
T_HOLDER_6 VB14000006 6 6 6 6 6 6 6
T_HOLDER_7 VB14000007 7 7 7 7 7 7 7
T_HOLDER_8 VB14000008 8 8 5 5 5 5 5
T_HOLDER_9 VB14000009 9 9 9 9 9 9 9
T_HOLDER_10 VB14000010 10 10 10 10 10 10 15
T_HOLDER_11 VB14000011 11 11 11 11 11 11 11
T_HOLDER_12 VB14000012 12 12 12 12 12 12 12
T_HOLDER_13 VB14000013 13 13 13 13 13 13 13
T_HOLDER_14 VB14000014 14 14 14 14 14 14 14
T_HOLDER_15 VB14000015 15 15 15 15 15 0 0
T_HOLDER_16 VB14000016 16 16 16 8 8 8 8
The purpose of this subroutine is to establish a table for tool magazine representing the
positions of the tools on the magazine. After initialization the table is arranged in the
following way:
Number of Tool Holder Tool number on the holder

1 1
2 2
… …
39 39
40 40
It is possible to have 64 tools for SINUMERIK802D. But in subroutine library, only 40

tools are permitted. For magazine more than 40 tool, the following subroutine should be
modified before application: SBR49–MGZ_INI, SBR50–MGZ_SRCH, and SBR51–
MGZ_RNEW.
3.14.2. Local Variable Definition – no local variable defined
3.14.3. Global Memory occupied – no global memory defined
Network 12 Tool Magazine Initialization
ONE MGZ_INI
EN

3.15. Subroutine 50 - MGZ_SRCH (Search tool from magazine)
The purpose of this subroutine is to find the holder location from magazine, which
contains the wanted tool.
Inputs:
P_TOOL DWORD Programmed tool number
Outputs:
HD_No DWORD Holder number with programmed tool
Find BOOL 1: tool is found, 0: not found
3.15.3. Global Memory occupied - no global memory defined
3.15.4. Corresponding PLC Machine Data - no
Network 32 Finding holder from magazine which contains programmed tool
P_C_TFCT1_C MGZ_SRCH
EN
P_C_TFUNC P_TOOL HD_No MD40

Find M32.5
3.16. Subroutine 51 - MGZ_RNEW (Refresh magazine table)

The purpose of this subroutine is to refresh magazine table after tool exchange, in order
to have a correct magazine table, the subroutine actually exchanges the tool number on
the spindle (located in VB14000000) with tool number in the holder which contains
programmed tool.
Inputs:
P_TOOL DWORD Programmed tool number
Outputs:
HD_No DWORD Holder number with programmed tool
Find BOOL 1: tool is found, 0: not found

3.16.3. Global Memory occupied - no global memory defined
3.16.4. Corresponding PLC Machine Data - no
Network 34 Refresh magazine table
ONE MGZ_RNEW
EN
SPD_TOOL: VB14000000 T_No

HDcurrent: C0 HD_NO
3.18. Subroutine 36, 41, 42 and Subroutine 52 ... 58, 60 … 62 are reserved for
subroutine library
3.19. Subroutine 59 – GRINDING_CTL

This subroutine handles the program control for grinding. The key_1 to key_4 allows making a
program break, dressing interruption while grinding, hand wheel overlay or manual oscillation
reversal. By each activated key the oscillation reversal will be active apart from axis oscillation
reversal manual and activating program break. These two functions are enabled with an
M-command. All commands will be active after NC-start.
Inputs:
KEY_1 BOOL Key for activating program break
KEY_2 BOOL Key for dressing interruption while
grinding
KEY_3 BOOL Key for hand wheel overlay
KEY_4 BOOL Key axis oscillation reversal manual
P_N_EN_OS_REV BOOL M-command enable oscillation reversal
P_N_DEL_EN_OS_REV BOOL M-command deleting enable oscillation
reversal

OS_REV_CMD M134.0 Flag for M-command enable oscillation reversal

MD 14510[16] - machine type 0: not defined
22: face grinding
Network 12 Grinding control

ONE GRINDING_CTL
0 NODEF
I3.0 KEY_1
I3.1 KEY_2
I3.2 KEY_3
I3.3 KEY_4
V25001003.3 P_N_EN_OS_REV
V25001003.4 P_N_DEL_EN_OS_REV
3.20. Subroutine 63 - TOGGLE

Toggle switch is a kind of switch with one push of the key (input of the subroutine) to turn
the output on and second push to turn the output off.
Delayed-switch is a kind of switch, with which once the key (input of the subroutine) is
pressed, the output will be on for the time interval defined by parameter “Delay7” (for key
7) and “Delay 8” for key 8.
There are 6 toggle switches and 2 delayed-switches are available in this subroutine to
simplify the PLC application program of the customers. This subroutine can put in the
main program.
The bit parameter for key inputs and outputs can be connected to physical input or
output or to any memory bits. All the unused bit inputs can be connected to “ZERO”
(M251.0), all the unused byte inputs connected to byte constant “0”, all unused bit
outputs connected to “NULL_b” (M255.7).

Symbol Var. Data Comment
Type type
Delay 7 IN WORD Delay time of switch 7 (unit 10 ms)
Delay 8 IN WORD Delay time of switch 8 (unit 10 ms)
Ki_1 IN BOOL Toggle key 1
Ki_7 IN BOOL Delayed key 7 (delay switch)
Ki_8 IN BOOL Delayed key 8 (delay switch)
Ko_1 OUT BOOL Switch 1 output
Ko_7 OUT BOOL Switch 7 output (delayed)
Ko_8 OUT BOOL Switch 8 output (delayed)
3.20.3. Global Memory used
Symbol Address Comment
K1st1 … K8st1 MB245 Toggle key status 1
K1st2 … K8st2 MB246 Toggle key status 2
K1on … K8on MB247 Toggle key status ON
Network 2 Toggle switch for customer application
ONE TOGGLE
EN
40 Delay7 Ko_1 M_LED_CK1

200 Delay8 Ko_2 M_LED_CK2
P_M_USER_K1 Ki_1 Ko_3 M_LED_CK3
P_M_USER_K2 Ki_2 Ko_4 M_LED_CK4
P_M_USER_K3 Ki_3 Ko_5 NULL_b
P_M_USER_K4 Ki_4 Ko_6 NULL_b
ZERO Ki_5 Ko_7 M12.6
ZERO Ki_6 Ko_8 M12.7
I0.0 Ki_7
I0.1 Ki_8

4. PLC User Alarms used in Subroutine Library
There are several user alarms activated in the subroutines. In the table below the alarms
are listed. In case an alarm comes, please pay attention to this table to know from which
subroutine the alarm is activated.
Alarm Interface Alarm Description Activated in

Number Address Subroutine
700016 V16000002.0 DRIVES NOT READY SBR33: EMG_STOP
700017 V16000002.1 I2/T ALARM FOR INFEED MODULE
700018 V16000002.2 COOLANT MOTOR OVERLOAD SBR44: COOLING
700019 V16000002.3 COOLANT LEVEL LOW
700020 V16000002.4 LUBRICATING MOTOR OVERLOAD SBR45: LUBRICAT
700021 V16000002.5 LUBRICANT LEVEL LOW
700022 V16000002.6 TURRET MOTOR OVERLOAD SBR46: TURRET1
700023 V16000002.7 PROGRAMMED TOOL NUM. > MAX. TURRET SBR47: TURRET2
NUMBER
700024 V16000003.0 802D MACHINE CONTROL PANEL DEFECT SBR34: CP_802D
700025 V16000003.1 BRAKE RELEASED FOR DRIVE OPTIMIZATION SBR40: AXES_CTL
700026 V16000003.2 NO POSITION SIGNALS FROM TURRET SBR46: TURRET1
700031 V16000003.7 MEASURING IN JOG IS ACTIVE SBR43: MEAS_JOG
Feed stop to channel (V32000006.0) will be activated by any alarms from the subroutine library.
To remove the feed stop, clear the alarm condition first and then RESET.
5. Sample PLC Application Programs

There are some special flags that will used in the project files:
SM0.0 - always “1” symbolized as ONE
M251.0 - always “0” (cleared every cycle in subroutine 33), symbolized as ZERO.
(Note: these two bits will finally be replaced with bit constant later)
M255.7 - for unused output bit, symbolized as NULL_b
MB255 - for unused output byte, symbolized as NULL_B
MW254 - for unused output word, symbolized as NULL_W
MD252 - for unused output double word, symbolized as NULL_D
5.1. PLC Application Program for simulation

5.1.1. Purpose of the Simulation Program
The purpose of the simulation program is to provide a way to test the system without
MCP before all 802D components are installed on the machine tool. This simulation
program works with the help of Status Chart of the programming tool. Customers can
simulate the MCP to traverse the axes and spindle, change override, and select
increment, etc.

Hardware connected:
Drive CLiQ PROFIBUS
Sinamics for X and Z

Sinamics for spindle
Infeed power supply
802D
PP module
Keyboard
Note: Here all enable signals on the drive unit must in the case of
simulation enabled.
But these enable signals must be controlled by PLC when
application on the machine tools
Subroutine 37 SIMU_MCP monitors the status such as mode change, NC start, stop,
etc. acknowledges mode changes, generates the override value and also simulates
reference cams via global memory bits for feed axis and spindle. The change of feed
and spindle overrides is carried out via Status Chart. (Refer to chapter 3.4)
Program organization (OB1)

Call condition Subroutine name Description
1st PLC cycle (SM0.1) PLC_INI (SBR32) Initializing
Every cycle (SM0.0) EMG_STOP (SBR33) For enable drives
Every cycle (SM0.0) MCP_SIMU (SBR37) Simulating MCP
Every cycle (SM0.0) MCP_NCK (SBR38) Transferring MCP to NCK interface
Every cycle (SM0.0) AXES_CTL (SBR39) Enabling NCK interface signals
5.1.2. PLC Machine Data related
The related PLC MD is MD14510[16] for machine type.
5.1.3. Application
1. Connect hardware component according to the Start-up and Installation Manual as the figure
above.
2. Power on the NC and drives. Set RS232 interface to “STEP7-Connect” on 802D.
3. Start Programming Tool PLC V3.0 and set Communication parameter to match the setting in
NC.
4. Open the project file: SIMULATION.PTP and download it to 802D. Start PLC.
5. Open the “Status Chart” of the programming tool and give a “1” to the mask in the new value
column of the desired function, and then click the icon with mouse key to write the value to
the 802D.

5.2. Sample PLC Application Program for a Turning Machine
5.2.1 Purpose of the sample turning machine

SAMPLE_TURN.PTP is an application program for turning machine. Through this
sample 802D customers can learn how an application is composed using subroutine
library, and how to make use of the subroutines in the library. Another purpose for this
sample is that for turning machines with similar configuration can be used directly, or
make simply modification to build a PLC application program quickly.
This sample program is suitable for turning machines with following configuration:
x 2 Feed axes: X and Z; 2 HW limit switches for each axis
x 1 digital spindle: SP
x Turret (with HED sensor) of 6 tools
x Lubrication system (Interval and duration are controlled by PLC)
x Cooling system
x 802D: One PP module (2 connector X111 and X222 are reserved 802D MCP,
X333 for machine In- / Outputs)
x 802D sl: One PP module (2 connector X111 and X222 are reserved 802D MCP,
or
one PP module (X333 for machine In- / Outputs)
MCP 802D sl is connected via additional MCPA module with the
control 802D sl (X1201 to X1 and X1202 to x2).

Input / Output assignment:
Terminal Block X333
Signal Terminal Description Note
M 1 Ground of 24VDC
L+ 2 Output 24VDC as Common for all inputs in X333
I 6.0 3 Emergency stop button Button: NC
I 6.1 4 Limit switch X+ NC
I 6.2 5 Limit switch X- NC
I 6.3 6 Limit switch Z+ NC
I 6.4 7 Limit switch Z- NC
I 6.5 8 Reference Cam X NO
I 6.6 9 Reference Cam Z NO
I 6.7 10
I 7.0 11 T1 Sensor NC
I 7.6 17 Turret motor overload Thermal relay NC
I 7.7 18
I 8.0 19 T72 Supply Infeed module ready NO
2
I 8.1 20 T52 I /t monitoring NO
I 8.2 21
I 8.3 22
I 8.4 23 Coolant level low NC
I 8.5 24 Coolant motor overload NC
I 8.6 25 Lubricant level low NC
I 8.7 26 Lubricating motor overload NC
27,28,29,30 Not connected
Q 4.0 31 TERMINAL48 control contactor of Supply Infeed
module
Q 4.1 32 TERMINAL63 pulse enable
Q 4.2 33 TERMINAL64 control enable
Q 4.3 34 X axis motor brake release
Q 4.4 35 Coolant output
Q 4.5 36 Lubrication output
Q 4.6 37
Q 4.7 38
Q 5.0 39 Turret CW
Q 5.1 40 Turret CCW
Q 5.2 41
Q 5.3 42
Q 5.4 43
Q 5.5 44
Q 5.6 45
Q 5.7 46
L+ 47, 48 Input 24VDC for all outputs
x 802D MCP installed

Terminal Block X111 for MCP X1201
Note: the connecting of MCP and PP is different from SAMPLE_MILL.PTP
Definition of User keys on MCP

Customer Key 1 Drive enable (toggle key)
Customer Key 2
Customer Key 3
Customer Key 4 Tool change key
Customer Key 5 Manual lubricating key
Customer Key 6 Manual cooling key
5.2.2 Program Organization (OB1)
Every cycle (SM0.0) MCP_802D (SBR34) 802D MCP signals to MCP interface
Every cycle (SM0.0) COOLING (SBR44) Cooling control
Every cycle (SM0.0) LUBRICAT (SBR45) Lubricating control
Every cycle (SM0.0) TURRET1 (SBR44) Turret of HED sensors
The related PLC MD are:

MD14510[16] = 1 - for turning machine.
MD14510[22] = value - turret clamping time (unit: 0.01S)
MD14510[24] = value - Lubrication interval (unit: 1.0 Min.).
MD14510[25] = value - Lubrication duration (unit: 0.01S).
5.3 Sample PLC Application Program for a Milling Machine

5.3.1. Purpose of the sample milling machine
SAMPLE_MILL.PTP is an application program for milling machine. Through this sample
802D customers can learn how an application is composed using subroutine library, and
how to make use of the subroutines in the library. Another purpose for this sample is that
for milling machines with similar configuration can be used directly, or make simply
modification to build a PLC application program quickly.
This sample program is suitable for milling machines with following configuration:
x 3 Feed axes: X, Y and Z; 2 HW limit switches for each axis

x One digital spindle: SP (4th axis)
x Lubrication system (interval and duration are controlled by PLC)
x Cooling system
x 802D: One PP module (2 connector X222 and X333 are reserved 802D MCP,
x 802D sl: One PP module (2 connector X222 and X333 are reserved 802D MCP,
or
one PP module (X111 for machine In- / Outputs)
MCP 802D sl is connected via additional MCPA module with the
control 802D sl (X1201 to X1 and X1202 to x2).

Input / Output assignment:
Terminal Block X111
Signal Terminal Description Note
M 1 Ground of 24VDC
L+ 2 Output 24VDC as Common for all inputs in X111
I 0.0 3 Emergency stop button Button: NC
I 0.1 4 Limit switch X+ NC
I 0.2 5 Limit switch X- NC
I 0.3 6 Limit switch Y+ NC
I 0.4 7 Limit switch Y- NC
I 0.5 8 Limit switch Z+ NC
I 0.6 9 Limit switch Z- NC
I 0.7 10 Reference Cam X NO
I 1.0 11 Reference Cam Y NO
I 1.1 12 Reference Cam Z NO
I 1.2 13
I 1.3 14
I 1.4 15
I 1.5 16
I 1.6 17
I 1.7 18
I 2.0 19 T72 Supply Infeed module ready NO
2
I 2.1 20 T52 I /t monitoring NO
I 2.2 21
I 2.3 22
I 2.4 23 Coolant level low NC
I 2.5 24 Coolant motor overload NC
I 2.6 25 Lubricant level low NC
I 2.7 26 Lubricating motor overload NC
27,28,29,30 Not connected
Q 0.0 31 Terminal 48: control contactor of Supply module
Q 0.1 32 Terminal 63 pulse enable
Q 0.2 33 Terminal 64 control enable
Q 0.3 34 Z axis motor brake release
Q 0.4 35 Coolant output
Q 0.5 36 Lubrication output
Q 0.6 37
Q 0.7 38
Q 1.0 39
Q 1.1 40
Q 1.2 41
Q 1.3 42
Q 1.4 43
Q 1.5 44
Q 1.6 45
Q 1.7 46
x 802D MCP installed

Definition of User keys on MCP
Customer Key 1 Drive enable (toggle key)
Customer Key 2
Customer Key 3
Customer Key 4
Customer Key 5 Manual lubricating key
Customer Key 6 Manual cooling key

5.3.2. Program Organization (OB1)

Every cycle (SM0.0) MCP_802D (SBR34) 802D MCP signals to MCP interface
Every cycle (SM0.0) COOLING (SBR44) Cooling control
Every cycle (SM0.0) LUBRICAT (SBR45) Lubricating control
The related PLC MD are:

MD14510[16] = 2 - for milling machine.
MD14510[24] = value - Lubrication interval (unit: 1.0 Min.).
MD14510[25] = value - Lubrication duration (unit: 0.01S).
Note:
Load initialization file setup_M.ini to PCU. Standard milling configuration is for 4
feed axes and one spindle, so it is necessary to modify the setting. Machine data
MD20070[5]=0 will cancel axis A1

C033 PLC Functions
1 Brief description
Module Objective:
Upon completion of this module you will be able to:
Select an NC program form the PLC

Read and Write specific NC variables
Read the actual position of an axis
Module Description:
To automate certain tasks on a CNC machine it may become necessary to select a program from the
PLC, or to read the actual position of an axis or execute a command dependant upon certain ma-
chine conditions, the changing of a system variable. This module describes these functions.
Module Content:
Selection of an NC program from the PLC

Read actual position of an axis
Data exchange (NC - PLC)
Selection of an NC
program from the PLC
Section 2
Read actual position of

an axis Section 3
Data exchange
(NC - PLC) Section 4

Section 2 Selection of an NC program from the PLC
Notes Creating a Program List able to be called by PLC

A maximum of 255 programs can be contained in the program list:
1~100 User protection level（CUSTOMER）
101~200 Machine Manufacturer protection level (EVENING)
201~255 Protection level reserved for Siemens, can not be used
by user.
The selection of the program by PLC is based on the program no.
Create a Program List directly: select “System”→“PLC” →“Program

List”
(switch the window with key ):
RS 232 cable
or alternatively, load the Program List from PC into the

802D sl using the RCS tool.
File format: %_N_PLCPROG_LST
;$PATH=/_N_CU_DIR
5|WARM_UP.MPF
Note: Separator in the file can be "|” or TAB.
Selecting a program in the Program List using the PLC

V33000003.7 MOV_B
EN ENo
5 IN OUT VB17001000
When the RESET signal (V33000003.7) is received by the PLC from the MCP,
The value of “5” is moved into VB17001000. This will have the affect of selecting
the 5th program registered in the assignment list “WARM_UP.MPF” so that when
the program start signal is next issued from the MCP, this program will run.
V17002000.0 HMI > PLC Program has been selected

V17002000.1 HMI > PLC Program selection error
VB17001001 = 1 PLC > HMI Saves currently active machining program
VB17001001 = 2 PLC > HMI Restore saved machining program
V17002001.0 HMI > PLC Execute SAVE command
V17002001.1 HMI > PLC Execution error
Other interface signals which are available for this function are:

Read actual position of an axis Section 3
The axis actual values and distances-to-go can be read out using PLC applica- Notes
tions in the 802D sl. Proceed as follows:
Activate axis values reading function via PLC applications:
V26000001.1=1 – request for axis actual values

V26000001.2=1 – request for axis dist
Address Address Axis Data type
(axis actual value) (distance-to-go)
Floating point
VD57000000 VD57000004 1st axis
value
Floating point
VD57010000 VD57010004 2nd axis
value
Floating point
VD57020000 VD57020004 3rd axis
value
Floating point
VD57030000 VD57030004 4th axis
value
Floating point
VD57040000 VD57040004 5th axis
value
Example for reading axis actual values:
The request for data read (Axis actual value) is made via V26000001.1
3rd axis ACTUAL VALUE is transferred into MD20 using MOVE REAL command.
So that it can be displayed in “PLC Status”
The ACTUAL VALUE is compared to a fixed real value of 25.4, If this value is less
than or equal, Then alarm 700001 (V16000000.1) is displayed on the screen.
Section 4 Data exchange (NC - PLC)
The 802D sl provides a 512 byte public memory for the exchange of data between
NC and PLC. The interface addresses defined by the PLC for this public memory
are V49000000.0 ~ V49000512.7, Reading and writing by BYTE, WORD and DOU-
BLE WORD are possible. System variables for this public memory are defined by
the NC in the machining program. It is possible to read and write to these variables.
$A_DBB[n] - Byte (8 Bit)

$A_DBW[n] - Word (16 Bit)
$A_DBD[n] - Double word (32 Bit)
$A_DBR[n] - Real (32 Bit)
Data exchange between NC & PLC (NC controlled)
Example of NC programming:
Real value from R11 written to VD49000004
N10 $A_DBR[4] = R11
N20 R12 = $A_DBR[4]
N30 M30 Real value from VD49000004 written to R12

Notes
Data exchange between NC & PLC (PLC controlled)
Its is also possible to read and write to some system variables via the PLC.
The example shows how the PLC can be programmed so that when I7.7 is acti-
vated, The data in R10 is transferred to VD12003004.
When I7.6 is on when I7.7 is activated, The real value in VD12001008 will be writ-
ten to R parameter R10.
Start request issued to interface by

I7.7 (MUST be reset on completion)
Read or write dependent upon condition

High = Write, Low = Read
Type of NC data to be used is

set into interface
5 = R parameter
Index of NC data to be used is

set into interface
11 = R10+1
Number of data sets to be

used is set to interface
1 (max 8 sets)
VB 12001000 Type of variable (R Parameter)

VW 12001002 NC Variable Index (R Parameter Index +1)
VB 12000000.0 Start Signal MUST be reset after transfer
VB 12000000.1 Read (0) Write (1)
VB 12002000.0 Request complete (Could be used to reset start signal)
VD 12003004 Variable value (When read from NC)
VB 12000001 Number of data sets to be transfered
VB 12003000.0 Variable is Valid
VD 12001008 Variable value (When Written to NC)

Data exchange (NC - PLC) Section 4
Notes

Notes

Data exchange (NC - PLC) Section 4
Notes

Notes

C044 Commissioning of Options
1 Brief Description
Module Objective:
Upon completion of this module you will be able to commission the 3 listed options.
Module Description:
Depending on the control model, various options can be generated. This module describes the 3
listed options.
Module Content:
Communication via Ethernet

Tool monitoring
Travel to fixed stop
Communication via
Ethernet Section 2
Tool monitoring
Section 3
Travel to fixed stop Section 4

Section 2 Communication via Ethernet
Notes
This screenshot option is available with 802D sl pro only.
For communication via Ethernet, a connection between the computer and

the controller has to be established (crossed cable for direct connection).
To be able to access the controller via Ethernet, you have to be registered
and logged on. This is done in the “System” operating area “RSC Log-
on”
RCS log-on
RCS log-on
Defaults
Name: SERVICE
Password: $SERVICE$
Or
See SK Authorisation for new user
Entering user name and password

Communication via Ethernet Section 2
Notes
You can access the control via a company network (with or without DHCP)
or locally.
The following sequence of operations is required: “System” operating area
“Service Display” “Service Controller” “Service Network”.

Section 3 Tool monitoring
Notes
General information
This option is available with 802D sl plus and pro only.
The tool monitoring function allows the monitoring of the

tool time
workpiece count
of the active cutting edge of the active tool.
It is possible to activate both monitoring functions simultaneously for one
tool.
There are monitoring counters available for each type of monitoring. The
monitoring counters run from a set value > 0 to zero. When a monitoring
counter reaches the value <= 0, the limit value is regarded as being
reached. An alarm message is transferred and an interface signal issued.
Before that, another interface signal is issued when a cutting edge has
reached the preset warning limit. The tool monitoring data as well as the
type and state of monitoring are stored in system variables. System vari-
ables can be read and described in the NC program.
Activation
To activate this option, the password for protection level 2 or higher has to
be entered .
The tool monitoring is activated via the following machine data:

MD 18080: MM_TOOL_MANAGEMENT_MASK
MD 20310: TOOL_MANAGEMENT_MASK.
Sequence of operations for changing the MD 18080:
“System” operating area “Machine Data” “General MD” .

Tool monitoring Section 3
Notes
MD 18080: MM_TOOL_MANAGEMENT_MASK
The alarm 4400 points out that a NC start-up with the changed date results
in a reorganization of the buffered memory. Thus, all the buffered user
data (parts programs, tool data, GUD, etc.) are lost.
Sequence of operations for changing the MD 20310: “System” operating

area “Machine Data” “Channel MD” .
If the tool monitoring option is available, the changed machine data be-
comes effective after a NC start-up. If this option is not available, the data
is reset.
If the controller comprises unsecured user data, a data backup has to be

carried out before the next NC start-up “System” operating area “
Startup files.
A new archive must be made prior to NC reset, this archive should be

loaded to the system to activate the new functions without data loss.

Section 3 Tool monitoring
Notes
MD 20310: TOOL_MANAGEMENT_MASK

Travel to fixed stop Section 4
Notes
General information
This option is available with 802D sl plus and pro only.
With the function “Travel To Fixed Stop” it is possible to build up defined

forces for the clamping of workpieces (e.g. for quills and grippers). More-
over, mechanical reference points can be approached. With an adequately
reduced torque, simple measuring processes are also possible without the
use of a sensor.
Activation
To activate this option, the password for protection level 2 or higher has to
be entered.
“Travel To Fixed Stop” is activated via MD 37000: FIXED_STOP_MODE.

This function can then be started from the NC program. Sequence of op-
erations: “System” operating area Axis MD
MD 37000: Travel to fixed stop
If the option “Travel To Fixed Stop” is available, the changed machine data
becomes effective after a NC start-up.

Notes

C085 ISO Dialect Commissioning
1 Brief Description
Module Objective:
Upon completion of this module you will be able to install the ISO dialect.
Module Description:
Apart from the SIEMENS NC programming language, another programming language ISO dialect
with a modified G code instruction set can be activated. The required files and their storage location
as well as the procedure for installation are described in this module.
Module Content:
Setup files
Procedure
Setup files
Section 2
Procedure
Section 3

Section 2 Setup files
Notes
For the commissioning of the ISO dialect M (for milling) or T (for turning), the re-
spective setup files have to be loaded from the toolbox to the controller.
After having installed the toolbox in the standard directory of the PC, the setup
files for milling are located, for example, at C:\Programs\Siemens\Toolbox
802D_sl\ V01002001\Techno\Milling\Config_ISO:
setISO_M.arc Milling with cycle package

ISOG70_M.ini
millG22.ini.
The setup files for turning are, for example, in the directory
C:\Programs\Siemens\Toolbox 802D_sl\V01002001\Techno\Turning\Config_ ISO:
setISO_T.arc Turning with cycle package

ISOTra_T.arc Turning with transformation
turnG22.ini
ISO_x_T.ini Machine data for the Tracyl function -
peripheral surface milling
(x corresponds to the rotary axis A, B, or C).
Setup files for the ISO dialect M

Procedure Section 3
Notes
For the commissioning of the ISO dialect, a connection via RS232 or

Ethernet has to exist between the PC and the controller.
After switch-on and start-up of the controller, the password for protection
level 2 or higher is set in the “System” operating area.
After setting the password level, it is necessary to log in to the system to

make external Ethernet available. This is done by selecting “RCS log-in”
user profiles can be created although default profiles are already config-
ured. For this exersize, The user name SERVICE is used. With a pass-
word $SERVICE$

Section 3 Procedure
Notes Next, start the RCS 802 tool on the PC then click the connection icon
Alternative IP address
for the controller can be
set here
After clicking “OK”, if the communication parameters are correct, The log - box is
displayed, Log in using SERVICE with a password of $SERVICE$ as previously
used on the controller

Procedure Section 3
Notes
After successful connection, The 802D sl controller is visible in the explorer panel of
the RCS 802 tool.
Note:
Ensure that the RCS 802 tool is disconnected prior to NCK reset. Failure to do this
will result in the RCS 802 tool crashing.

Section 3 Procedure
Notes
The required installation files (*.ini) have to be copied from the directory of
the toolbox to the Data folder of drive A of the 802D sl and a NCK RESET
to be triggered.
The following message is displayed, Confirm the action with “Yes”
The next message asks you to confirm the files which are to be over-written.
Select “Yes to All”
On competition, The message is displayed confirming successful transfer. Aknowl-

edge with “Yes”

Procedure Section 3
Notes
Now the technology archive must be copied to the controller.
A:\Start-up archive (NC/PLC)
A message is displayed informing you of the recommendation to reset the control
with default data, This should be confirmed with “Yes”
Due to the loading of default data, The password is reset. The password must be
set back to expert mode and the copy procedure repeated. The archive is now
copied and installed into the control.
During this time the machine data is reconfigured and new system cycles are
loaded. NCK reset is performed several times.
Finally the message is displayed confirming successful transfer.
After a further NCK reset the system will show it has now been setup in ISO mode

Section 3 Procedure
Notes
The controller is now operating in permanent ISO mode. Unfortunatly, the
axis configuration MD is different from that of standard SIEMENS mode.
Example:
SIEMENS mode: ISO mode:

Axis 4 = SP Axis 4 = A
Axis 5 = A Axis 5 = SP
Note:
ISO mode can be termporarily activated from within SIEMENS mode with
the use of command G291. This is cancelled with G290 or by pressing the
reset key. But, because all commands specified in this way under G291
have to be translated into SIEMENS cycles, the performance of the system
will be reduced.

C040 Start-up of NC Parameters
1 Brief Description
Module Objective:
Upon completion of this module you are able to set the basic NC parameters for the startup of the NC
system.
Module Description:
The controller can be started in different ways. This has effects also on the loading of parameters.
Parameters which are preassigned by machine data can be changed or restricted via setting data.
Moreover, it is possible to display workpiece counters and runtimes.
Module Content:
Controller start-up
Setting data
Controller start-up
Section 2
Setting data
Section 3

Section 2 Controller start-up
Notes
The following screen is displayed after having switched on the controller:
By pressing the buttons “Shift” and “Alarm”, you access the System oper-
ating area.
Keyboard 802d sl
Startup
System operating area

Controller start-up Section 2
Notes
The type of controller start-up can be selected via “Start-up “NC”.
NC start-up
The different types of start-up have the following effects:
Normal start-up
Remanent data remains unchanged.
Current PLC machine data is taken over.
Start-up with default data
Remanent data is deleted.
Standard PLC machine data is loaded.
Start-up with saved data
Saved remanent data and saved PLC machine data is loaded.

Section 3 Setting data
Notes
The selection of the setting data is done via “Offset/Param” on the key-
board and the softkey “Setting Data”.
Setting data basic screen
If the value for “JOG Feedrate” and “Spindle Speed” is zero, the controller
uses the value stored in the machine data. Restrictions for the minimum
and maximum spindle speed are only possible within the limits defined in
the machine data.
“Restriction With G96” refers to the programmable upper speed limit at

constant cutting speed. The value entered for “Dry Run Feedrate” is used
when the dry run function is selected in the automatic mode during pro-
gram execution instead of the programmed feedrate. By changing the
“Starting Angle For Thread”, a multiple thread can be cut when repeating
the thread cutting operation.
For making entries, the cursor has to be positioned on the respective field
and the value be confirmed either with “Input” or by moving the cursor.
The softkeys are for branching off to further menu levels.

The working area limitation effects the geometry and additional axes. The
softkey “Set Active” activates/deactivates the values for the axis selected
via the cursor.
By pressing the softkey “Times/Counters”, the various workpiece counters

and runtimes / intervention times are displayed. The timer is automatically
zeroed with default values during the controller start-up.

Setting data Section 3
Notes
Working area limitation
Times / counters
Explanations
Parts total
Number of required workpieces
Parts requested
Total number of produced workpieces
Number of parts
Number of all workpieces produced since the start time
Total runtime
Total runtime of all NC programs in the automatic mode
Program runtime
Runtime of the selected NC program
Feedrate runtime
Runtime of the path axes of all NC programs without active
rapid traverse

Section 3 Setting data
Notes
With the softkey “Other”, all setting data existing in the controller subdi-
vided in
general,
axis-specific
channel-specific
are displayed.
Setting data

C022 Display Options
1 Brief Description
Module Objective:
Upon completion of this module the display machine data can be adapted to the machine.
Module Description:
Various machine data and settings (resolution, colour) can be implemented on the controller to adapt
these to the individual requirements. This chapter describes the machine data which is of general
importance.
Module Content:
Machine data
Display settings
Machine data
Section 2
Display settings
Section 3

Section 2 Machine data
Notes
Display machine data
In the menu “System” “Machine Data” “Display MD“, all important

parameters not assigned to a specific group are stored. Among these are
settings for language, protection levels, V24 connection, coordinate posi-
tions and work load displays (see Figure C22-1).
Parameters
Effectiveness
Effectiveness
The effectiveness levels are listed according to their priority.

A change of data is effective after:
POWER ON (po) Switch-on/-off of the SINUMERIK 802D sl

NEW_CONF (cf) with RESET on the HMI interface
RESET (re) with RESET on the PLC interface or at program end
IMMEDIATELY (im) immediately after having entered the value
Selection of some important machine data.
Number : 202 - First Language with protection level 2/3

In SINUMERIK 802D there are two languages available simultaneously.
Different languages than the ones installed in the as-supplied state can be
loaded during commissioning.
Effective after Power On
Number : 203 - Display Resolution with protection level 2/3

This machine data item is for the position display to define the number of
decimal places with metric systems for linear axes and generally for rotary
axes.
Effective immediately

Machine data Section 2
Notes
Number : 221 - User_Class_Dir_Access with protection level 3/3

This value is for selecting the protection level of the directory access.
Number : 247 - V24_PG_PC_Baud with protection level 3/3

For setting the baud rate between PG and PC
Number : 330 - CMM_POS_Coordinate_System with protection level 3/7

Coordinate layout of the machine with 7 positions
Number : 360 - Spindle_Load_Displ1 with protection level 3/3

For switching on the work load display for spindle 1

Section 3 Display settings
Notes
The color of the display can be adapted individually via the “System” menu
by selecting “Machine Data” “Change Color” .
Colours
Here, the color of the softkeys and the windows can be changed by select-
ing RGB and brightness .

C084 Reference - Encoder Adjustment
1 Brief Description
Module Objective:
Upon completion of this module you will be able to set the reference for absolute encoders.
Module Description:
The referencing (synchronisation) of an axis with an absolute encoder is done automatically when
switching on the controller. Therefore, the actual value of the absolute encoder has to be set once
(also in the case of replacement) during commissioning and taken on by the controller.
Module Content:
Necessity and boundary conditions of the encoder ad-

justment
Procedure for the encoder adjustment
Necessity and bound-

ary conditions Section 2
Procedure
Section 3

SINUMERIK 802D sl Service, Training Manual Page 1 Siemens assumes no responsibility for its contents. C084
Section 2 Necessity and boundary conditions
Notes
With the adjustment, the displacement between the zero point of the ma-
chine and that of the encoder is calculated and stored. This is usually done
just once during the first commissioning. After that, the controller knows
the value and can calculate the absolute machine position from the abso-
lute encoder value at any time. This state is indicated by MD 34210:
ENC_REFP_STATE=2. The displacement is stored in MD
34090:REFP_MOVE_DIST_CORR.
Displacement
Actual value
Axis adjusted
Axis-specific encoder data after the adjustment
A repetition of the adjustment is required in the following cases:

After the assembly/disassembly or exchange of the encoder or motor
including the attached encoder
After having switched a possibly existing gearbox between motor
(with absolute encoder) and load
In general always when the mechanical connection between encoder
and load was separated and not established exactly the same way
again.
When the controller detects the necessity of a re-adjustment, this is indi-

cated by the MD 34210: ENC_REFP being set to the value 0 or 1. The
switching to an encoder level with a different gearbox ratio between en-
coder and load is detected. In all other cases, the users have to overwrite
the MD 34210: ENC_REPF_STATE themselves.
When saving the machine data, the state of the MD 34210:

ENC_REFP_STATE is saved, too. Therefore, the axis is automatically de-
clared as being adjusted when loading such a data record. If the data re-
cord originates from a different machine (e.g. in the case of a series start-
up), an adjustment has to be carried out after the loading and activation of
the data.

Procedure Section 3
Notes
The axis to be adjusted is moved to a defined position and set to the corre-
sponding actual value.
This is done as follows:
1. “System” operating area “Mach. Data” “Axis MD”

Set MD 34200: ENC_REFP_MODE and MD 34210: NC_REFP_STATE
to 0 and activate it with POWER ON.
MD 34200: ENC_REFP_MODE = 0 means that the actual value of the
axis is set once.
Axis-specific encoder data before the adjustment
2. “Position” operating area “JOG” mode

Move the axis manually at low speed to a known position. The direction
with which the position is approached has to correspond to the direction
stored in the MD 34010: REFP_CAM_DIR_IS_ MINUS
(0: positive direction, 1: negative direction).
3. Enter the actual value corresponding to the approached position into the
MD 34100: REFP_SET_POS. This value can be a value given by the de-
sign (e.g. fixed stop) or a value determined by a measuring instrument at
this position.
4. Set MD 34210: ENC_REFP_STATE to 1. This enables the “Adjustment”

function.
5. The changed machine data is activated via RESET.
6. Switch to the “Position” operating area “JOG-REF” mode.

Section 3 Procedure
Notes
Moving the axis manually
7. By activating the traversing key already used in Step 2, the current

displacement is entered into the MD 34090: REFP_MOVE_DIST_CORR
and MD 34210: ENC_REFP_STATE changes to 2 (axis adjusted). When
activating the correct traversing key, the axis does not move. In the actual
value display of the axis position the value entered in the MD 34100:
REFP_SET_POS and the symbol for the reference point are displayed .
8. Exit the “JOG-REF” mode.

C016 Installation of Additional Axes (Retrofit)
1 Brief Description
Module Objective:
Upon completion of this module you will be able to retrofit an additional axis to an existing machine.
Module Description:
If a machine is to be subsequently equipped with a new function, it is usually necessary to install an

additional axis. This requires mechanical, electrical, and software changes. This module describes
the necessary steps to integrate the axis in the controller.
Module Content:
Retrofitting of an additional axis

Commissioning with Starter
Retrofitting of an addi-
Section 2
tional axis
Preperation for exersi-

Section 3
ze
Commissioning new
Section 4
axis

Section 2 Retrofitting of an additional axis
Notes
If there are new tasks planned for an existing machine, it is usually neces-
sary to implement an additional drive axis.
After having correctly installed the motor module with a connected drive
and wired DRIVE-CLiQ interface (below are the possibilities), the corre-
sponding parameters have to be configured.
This can be done with the STARTER commissioning tool.
The first possibility with interface available on existing double axis module.
802D SL PCU
X1 X2
X203
X202
X201
X200
X E
Single axis module(Spindle)

Power infeed module(SLM)
Double axis module(X,Y)
Double axis module(Z,A)

Y E E SP D
Z E
A E
The second possibility with interface available on new single axis module.
Direct measuring systems can also be installed if a drive click inter-
face is also available.
802D SL PCU
X1 X2
X203
X202
X201
X200
X E
Single axis module(A,) NEW
Single axis module(Spindle)
Power infeed module(SLM)
Double axis module(X,Y)
Single axis module(Z,)
Y E
Z E
A E E SP D
NEW

Preperation for exersize Section 3
Notes
Stage 1
For the purposes of our exercise we must modify the configuration of our
training equipment.
Disconnect power from the equipment and re-arrange the Drive-CLiQ to
simulate a machine with 3 axes (X,Y,Z) and spindle (SP) this is to be
achieved by removing the Drive-CLiQ connections from the original spindle
module and also the secondary measuring system.
Switch on the equipment and using the “Sinamics IBN” menu, first perform
“Factory setting load drive” then “Topology recognized and confirmed
(rapid start up)” after these are completed, The equipment must be
switched Off and On.
Axis machine data will now need to be modified to achieve a running situa-
tion. Remembering that now we have X, Y, Z & SP. The spindle “SP” is
now the original “A” axis motor.

Section 4 Commissioning new axis
Notes Stage 2
Sequence:
To install an additional axis on the machine, the procedure listed should be

adhered to.
1. Connect the new hardware including the drive click interface and
power up the system.
2. Connect STARTER and read out from the controller the actual con-
figuration, to a new project.
3. Insert in offline mode the new axis with the Starter Wizard.
4. Change in the expert list the drive data for the new axis - BICO´s
compatible to other axis.
5. Enter axis in configuration list P978[]
6. Change PLC for new axis , enables etc…. + Parked axis signals, for
removal of axis.
7. Enter NC MD for new axis.
1. Connect the new hardware including the drive click interface and
power up the system.
Power OFF the equipment and connect into the Drive CLiQ the origional
spindle motor and secondary measuring circuit to simulate the addition of
another axis. This will now become the new “A” axis.
The drive configuration must now be commissioned off-line. So that the

original axis data can be retained.

Commissioning new axis Section 4
Notes
Prerequisite for the installation of an additional axis:
In order to install an additional axis on the machine, it should be checked if

the Line Module has the necessary power available in order to power an
additional Motor Module.
A free drive click interface should be free on the bus. If in addition to the
axis a direct measuring system has to be installed, it should be checked
also that a drive click interface is available.
2. Connect STARTER and read out from the controller the actual con
figuration, to a new project.
Sequence:
Double click to Launch

Starter

Notes
Enter project name

and continue with
OK
Double click “insert single

drive unit” to obtain the follow-
ing dialog box.
In order to create a drive object, the following should be input to the dialog
box:
SINAMICS in 802D as Device Type

2.4x as SW version Note: 802D sl SW dependant
IP as Address type Note: Protocol
xxx.yyy.zzz.qqq as IP address Note: Destination IP address

Notes
Click ICON online

access to obtain
the following dialog
box >
The dialog box “Online/Offline comparison” shows the difference between

the offline project content and the actual content within the drive. The off-
line project has to be actualised to show a true indication of the online ma-
chine.
To actualise the offline project click > this will re-
sult in the offline project content being the same
as the online drive.
The data is stored in the main memory of the PG (RAM) this should be
stored to file with the SAVE function on the PROJECT menu.
The following can be seen when the data has been successfully uploaded
and subsequently saved.

Notes
3. Insert in offline mode the new axis with the Starter Wizard.
Use the “insert drive”

object to obtain the
following wizard. A
new offline axis object
During parameterisation the BICO for the infeed in operation has to be

given, this should be given from P722.0 (X21.1) on the CU for the ALM
module and on the Servo (P864) SLM

Notes
Drive telegram 116 has to be entered in the last step of the wizard. Tele-
gram type 116 is a standard Sinumerik telegram which should be used in
all cases.
Telegram 116
Upon completion of the wizard, a new object will be available in your offline
project, as can be seen in the following picture:
NOTE: When installing additional components to the drive cliq interface, it

may become necessary to change the SET topology.
Do not forget !!

Notes
4. Change in the expert list the drive data for the new axis - BICO´s
compatible to other axis.
To change drive data

“quick commissioning”
mode has to be set
Various parameters have to be set which are normally set automatically by

the first commissioning. The table on the following page should be taken
into consideration:
P864 - SERVO - Should be set during new axis wizard

P849 - SERVO - Should be changed in the expert list
P488 - SERVO - Should be changed in the expert list
P922 - SERVO - Should be set during new axis wizard
P978 - CU - Should be changed in the expert list : P9 = 1 “Commissioning
mode”
DO NOT FORGET TO RESET P9 and save all with CU P977
Notes
5. Enter axis in configuration list P978[]
The axis configuration in the CNC part of the control as to match the con-
figuration which is in the regulator of the drive. These two components
communicate through the Profibus protocol which is configured in the PLC.
The configuration in the PLC is fixed and must be matched to the drive.
The matching to the PLC is carried out with Drive MD978. Depending upon
the axis configuration values have to be entered here.
Has to be
changed for
new axis

Notes
The values which are input refer to the component number. The compo-
nent numbers differ dependant upon whether a SLM or an ALM is used.
P978 SLM Description ALM Description

P978[0] 2 Servo 1 3 Servo 1
P978[5] 255 Not available 255 Not available
P978[6] 1 CU 802D sl 1 CU 802D sl

P978[7] 255 Not available 2 ALM
P978[8] 0 PZD end 255 Not available
P978[9] 0 0 PZD end
The above is an example, the actual values will be dependant upon how
the drive is physically connected, “Drive click”.
Please do not forget P977 !!
6. Change PLC for new axis , enables etc…. + Parked axis signals, for
removal of axis.
In order that the axis can be used, the relevant enables should be given in
the PLC user interface.
When retrofitting an axis to the machine, the axis is often an axis which is
not permanently attached to the machine, e.g. removable rotary axis on a
milling machine. The axis should be physically attached and detached
when the machine is switched off. When the machine is running without
the additional axis, is should be disabled in the PLC by removing the
“Measuring circuit active” signal and all of the relevant enable signals.
(servo and pulse enable)
7. Enter NC MD for new axis.
In order to use the new NC axis the NC axial machine data has to be set.
Upon completion of the above steps, the relevant stages of the machine
test protocol should be carried out, this will test weather the axis has been
correctly installed.
When everything has been checked a new data backup should be made,
in the case of data loss in the future.

C055 Optimization with STARTER
1 Brief Description
Module Objective:
The objective of this module is the presentation of the options for diagnosing and optimizing drives
with the help of STARTER.
Module Description:
The STARTER commissioning tool provides various functions making an effective and simple diag-
nosis and optimization possible. Apart from fault and alarm displays and a diagnosis overview
(indication of the device status and operating mode of the drives), it is possible to record signals and
to analyze the control behavior.
Module Content:
Setting of signals  Function generator

Recording of signals  Trace function
Analysis of the control behavior  Measuring function
Function generator
Section 2
Trace function
Section 3
Measuring function
Section 4

Section 2 Function generator
Notes
The function generator can be used for the following applications:

Measurement and optimization of control loops
Comparison of the dynamics with coupled drives
Setting of a simple travel profile without a traversing program.
With the function generator, various signal shapes can be generated.
The characteristics of the function generator are the following:

Simultaneous switching to several drives
Freely parameterizable signal shapes settable
Offset possible for each signal
Start-up to offset parameterizable
Restriction of the output signal to minimum and maximum values
possible
Operating modes of the function generator for servo and vector
After having established an ONLINE connection, the function generator is called

either in the project tree or via the toolbar.
Online Start Trace
Calling the function generator

Function generator Section 2
Notes
Control
priority
Drive Operating mode
Signal type
Main screen of the function generator
Operating mode, drive and signal type as well as further settings have to
be entered in the parameterization screen form.
Having the control priority, access to the selected drive is possible. It might
be necessary to carry out an online/offline adjustment.
After having loaded the settings to the target unit, the function generator
can be started .
Parameter
download Start
Starting the function generator

Section 3 Trace function
Notes
With the trace function, measured values can be recorded over a defined
period of time depending on the trigger conditions.
The characteristics of the trace function are the following:

Four recording channels per recorder
Two independent trace recorders per control unit
Triggering
- Without triggering (recording immediately after start)
- Triggering to signal with edge or to level
- Trigger delay and pre-trigger possible
Automatic or settable scaling of the display axes
Signal measurement via cursor
Settable trace cycle.
After having established an ONLINE connection, the function generator is

called either in the project tree or via the toolbar.
The main screen is displayed.
Main screen of the trace function
The drive and the corresponding parameter is selected.
Trace signal selection

Trace function Section 3
Notes
Further parameters can be set.
Start Control priority

Parameter
download
Trigger type
Setting the trace function
be necessary to carry out an online/offline adjustment.
After having loaded the settings to the target unit, the trace recording can
be started.
The recording is represented graphically.

Section 4 Measuring function
Notes
The measuring function is for optimizing the drive control. The influence of
primary control loops can be interrupted selectively and the dynamics of
individual drives be analyzed via simple parameterization. For that, the
function generator and trace are coupled. At one point, the control loop is
supplied with the signal of the function generator and at another point, the
trace makes its recordings. By parameterizing the measuring function, the
trace is also parameterized automatically.
The characteristics of the measuring function are the following:
Current controller setpoint step change (behind current setpoint filter)

Current controller reference frequency response (behind current setpoint filter)
Speed controller setpoint step change (behind speed setpoint filter)
Speed controller disturbance variable step change (interference behind current
setpoint filter)
Speed controller reference frequency response (behind speed setpoint filter)
Speed controller reference frequency response (before speed setpoint filter)
Speed controller interference frequency response (interference behind current
setpoint filter)
Speed-controlled system (excitation behind current setpoint filter).
After having established an ONLINE connection, the measuring function is

called either in the project tree or via the toolbar (Fig. C55-8).
The main screen is displayed then (Fig. C55-9).
Measuring func-
tion
ONLINE
Calling the measuring function

Measuring function Section 4
Notes
Control
priority
Main screen of the measuring function
be necessary to carry out an online/offline adjustment. After having loaded
the settings to the target unit, the measuring function can be started. In
that, it is possible to select the signals to be actually measured.
Measuring function set
The result of the measurement is represented graphically.

Section 4 Measuring function
Notes
Graphical representation of the measurement

C055 Optimization with IBN Tool
1 Brief description
Module Objective:
Upon completion of this module you will be able to go online to the controller with the Start-up Tool
Module Description:
The functionality of a 802D sl is limited in certain areas.

By connecting a laptop with the Start-up Tool installed, this functionality can be attained.
Module Content:
Installation tips Section 2
Connection settings Section 3
Using the IBN Tool Section 4

Section 2 Installation tips
Notes
When running the installation program for HMI advanced, several dialogue
boxes need to be acknowledged.
These are usually acknowledged via a “Yes” or “Next” button.
In the following dialoge box it is necessary to make a choice between

PowerLine or SolutionLine.
The installation should then be continued in the usual manner.

Information: Notes
The 802D sl is equipped with ethernet port X5.

A crossover ethernet cable is required to connect to the external PG/PC
via this port.
Prior to using the HMI Advanced program it is necessary to enter the IP
address of the controller (Default:-169.254.11.22). This is done via the
“NC Connect Wizard”.
The desired control model needs to be selected. Inthis case the selection
for 840D sl is used for 802D sl.

Section 3 Connection settings
Notes
Select the “Engineering Tool (Recommended)“ option. (Ignore the referen-

ce to X127).
Cabling advice is offered which is not relevant. Continue by selecting

the“Next“ button.

The IP address of the 802D sl controller now needs to be entered. Notes
(169.254.11.22)
This is done in in the “Advanced” page.
Leave all other settings untouched and complete the set-up with the
“Finish” button.

Section 4 Using the Start-up Tool
Notes The “Start-up Tool” can now be opened from the “Start Menu”
Once the software is fully booted you are presented with the following
screen:-
Navigation is via the function keys of the PG/PC.
“F1” to ”F8” = Horizontal soft-keys
“Shift” + “F1” to “F8” = Vertical soft-keys
“F10”= Menu select
“Shift” + “F9” = Next page/Page right
The soft-keys can also be selected via the mouse left click function.

Using the Start-up Tool Section 4
An example of a useful function is the automatic servo setting feature. Notes
Use the following key selection to locate the automatic servo setting
screen.
On this page certain selection can be made.
Selection of the correct axis:-
Drive test travel enable:-Without PLC

Travel range:-Inactive
Mode:-Choose the best option from the drop down menu.
When the desired settings are set, select the “Start” softkey and acknowl-
edge the dialogue box with the “OK” key

Notes A message immediately above the horizontal softkeys prompts for the
“Cycle Start” button on the MCP to be pressed.
The axis moves a short distance as part of the procedure.

On completion the part 2 of the test requires acknowledging
The axis moves for a short while. The next part of the test is with reduced
torque in the motor. A vertical axis should therefore be braked in some
way to prevent the axis dropping.

Using the Start-up Tool Section 4
The axis again moves for a short while. Notes
The next dialogue box ask if the results of the test are to be calculated.
They will not be saved to the drive at this time
The results of the tests are shown in a table which allows you to compare
the old and new values.
If you wish to accept the values select “Yes” otherwise select “No”
The values are then saved to the drive.

The measurement of the speed control loop is then carried out at the final
stage

Notes The results of the speed control loop test are shown in a graphical format.
Any unwanted spikes not removed by the auto tuning will have to be re-
moved manually with filters.
Markers can be used to identify the exact area of a problem to enable the
accurate assignment of filters.
This is best left to experienced drive engineers.

C056 On-board Optimization
1 Brief Description
Module Objective:
Upon completion of this module you will be able to use the integrated trace function of the 802D sl
control.
Module Description:
There is an oscilloscope function provided for the optimization of the drives, which also allows for a
graphical representation. There are several functions for the result analysis available.
Module Content:
Trace function

Notes
In the “System” operating area  “Service Display”  “Servo Trace”, the

servo trace main screen is displayed.
Time of the
marker position
Time base
Time difference
Change the
scaling
Save / load
Signal selection
Main screen of the servo trace
The following functions are available for the result analysis:

Change of the scaling of abscissa and ordinate
Measurement of a value with the help of a horizontal or vertical
marker
Measurement of abscissa and ordinate values as the difference be-
tween two marker positions
Storage as a file in the part program directory.
The oscilloscope function allows for the graphical representation of the

speed setpoint
contour deviation
following error
actual position value
position setpoint
exact stop coarse/fine.
The type of recording can be linked to various criteria allowing a synchro-

nous recording of internal control states. The setting is made after having
activated the softkey “Signal Selection”.
With “Trace Display”, another menu level is opened, offering softkeys for
displaying/hiding diagrams.

Notes
Axis Signal type Status
Measuring
time Trigger type
Parameterization of the measuring channel
The following can be selected as signal type:

Following error
Controller difference
Contour deviation
Actual position value
Actual speed value
Speed setpoint
Compensation value
Parameter set
Position setpoint controller input
Speed setpoint controller input
Acceleration setpoint
Controller input
Speed precontrolled value
Signal exact stop fine
Signal exact stop coarse.
Status ON means that the recording is done in this channel. With Status
OFF the channel is inactive.
The measuring time is entered directly in the “Measuring Time” input field.
It applies to all trace channels.
The trigger condition is selected via the toggle key:

No trigger, the measurement is started directly after the activation of
the Start softkey
Positive edge
Negative edge
Exact stop fine reached
Exact stop coarse reached.

Notes
With “Marker Increments”, the marker steps can be set .
Marker increments
With “Start”, the trace recording is started.
Trace recording

C063 Interface signals
1 Brief description
Module Description:
Interface signals
Module Content:
Interface signals
Interface signals
Section 2

Section 2 Interface signals
Notes
2.1 Interface signals

Interface signals Section 2
Notes

Notes

Notes

Notes

Notes

Notes

Notes

Notes

Notes

Notes

Notes

Notes

Notes

Notes

Notes

Notes

Notes

Notes

Notes

Notes

Notes

Notes

C064 Machine Data List
1 Brief description
Module Description:
Machine data list
Module Content:
Machine data list
Machine data list

Section 2

Section 2 Machine data list
Notes
2.1 Machine data list

Machine data list Section 2
Notes

Notes

Notes

Notes

Notes

Notes

Notes

Notes

Notes

Notes

Notes

Notes

Notes

Notes

Notes

Notes

Notes

Notes

Notes

Notes

Notes

Notes

Notes

Notes

Notes

Notes

Notes

Notes

Notes

Notes

C065 PLC Instruction list
1 Brief description
Module Description:
PLC Instruction list
Module Content:

Section 2

Section 2 PLC Instruction list
Notes
2.1 PLC Instruction list

PLC Instruction list Section 2
Notes

Notes

Notes

Notes

Notes

Notes

C062 Component mounting dimensions
1 Brief description
Module Description:
Mounting hole and dimensions of CNC components.
Module Content:
Component mounting dimensions
Component mounting
dimensions
Section 2

Section 2 Component Mounting Dimensions
Notes
2.1 Component Mounting Dimensions

Component Mounting Dimensions Section 2
Notes

Notes

Notes

Notes

Notes

Notes

Notes

Notes

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SINUMERIK 802D solution line

Training Manual Edition 07.2008

This document was produced for training purposes.

System overview C060 Install additional axis C016

Graphic overview of 802D sl CNC system

Graphic overview of Section 2

Common part informa-

SINUMERIK 802D sl Service, Training Manual Page 1

Ethernet connection (Option)

MCP Direct I/O

RS232 cable connection

Smart line 2 -axes

SINUMERIK 802D sl Service, Training Manual Page 2 C060

CNC central processing unit, comprising of a complete embedded system, Contain-

Differences in functionality can be seen in the following table.

Value Plus Pro

CNC main memory (buffered) for programs and data in MB 0.5 1 3

CNC main memory maximum configuration in MB 0.5 1 3

Axes / spindles yes (1) yes (2) yes (2)

Maximum configuration of axes 4 5 5

Maximum configuration of spindles 1 2 2

Maximum configuration of axes and spindles 4 5 5

Maximum configuration of axes incl, spindles 4 5 5

PLC controlled axes - 1 1

CNC Functionality: Program functions

Look ahead 20 50 100

CNC Functionality: Axis functions

Rotary axis, turning endlessly - yes yes

Acceleration with jerk limitation - yes yes

Traversing to fixed stop - yes yes

CNC Functionality: Spindle functions

Changeover to axis mode - yes yes

CNC Functionality: Interpolations

Helical interpolation 2D+1 2D+2 2D+2

CNC Functionality: Transformations

TRANSMIT / peripheral surface transformations - yes yes

CNC Functionality: Measuring

Measuring stage 1, Probe (touch trigger) - yes yes

SINUMERIK 802D sl Service, Training Manual Page 3 C060

CNC Functionality: Motion-synchronous actions

High-speed CNC digital inputs (on-board) - 8 (1) 8 (1)

High-speed CNC digital inputs or outputs (on-board) - 8 (1) 8 (1)

CNC Programming: Language

Program / workpiece management on network drive - - yes

Execute from network drive - - yes

Number of tools 32 64 128

Cutting edges in tool list 32 64 128

Monitoring of tool life and workpiece count - yes yes

Communication and data management

Ethernet connection - - yes

Save data to network drive (Ethernet) - - yes

Feedforward control, speed dependant - - yes

Ladder steps memory configuration 4000 6000 6000

Bit memories, max. number 2048 3072 3072

Timers, max. number 40 40 64

Counters, max. number 32 32 64

PLC Remote diagnostics via Ethernet - - yes (2)

RCS 802 PC License 6FC6000-6DA51-0AA0 option

(1) Software version 1.2 onwards

SINUMERIK 802D sl Service, Training Manual Page 4 C060

X1 & X2 DRIVE-CLiQ interface (Special RJ45)

X5 Ethernet connection to external PG / PC (RJ45)

X6 Profibus DP interface to PLC I/O (12MB fixed)