SINUMERIK 808D Commissioning Manual 201212 Eng

Commissioning Manual Delivery check 1
___________________
___________________
Mounting 2
___________________
Connecting 3
SINUMERIK Switching on and preparing
___________________
for commissioning 4
SINUMERIK 808D
Commissioning Manual ___________________
Commissioning diagram 5
___________________
Default PLC applications 6
Commissioning Manual
___________________
Commissioning the prototype 7
___________________
Series production 8
Other frequently used
___________________
functions 9
___________________
Appendix A
Valid for the following control systems:

SINUMERIK 808D Turning (software version: V4.4.2)
SINUMERIK 808D Milling (software version: V4.4.2)
Target group:
Electrical engineers, calibration engineers and testing
12/2012
6FC5397-4EP10-0BA0
Legal information
Warning notice system
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
indicates that minor personal injury can result if proper precautions are not taken.
NOTICE
indicates that property damage can result if proper precautions are not taken.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.
Qualified Personnel
The product/system described in this documentation may be operated only by personnel qualified for the specific
task in accordance with the relevant documentation, in particular its warning notices and safety instructions.
Qualified personnel are those who, based on their training and experience, are capable of identifying risks and
avoiding potential hazards when working with these products/systems.
Proper use of Siemens products
Note the following:
WARNING
Siemens products may only be used for the applications described in the catalog and in the relevant technical
documentation. If products and components from other manufacturers are used, these must be recommended
or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and
maintenance are required to ensure that the products operate safely and without any problems. The permissible
ambient conditions must be complied with. The information in the relevant documentation must be observed.
Trademarks
All names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this publication
may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software
described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
editions.
Siemens AG Order number: 6FC5397-4EP10-0BA0 Copyright © Siemens AG 2012.

Industry Sector Ⓟ 12/2012 Technical data subject to change All rights reserved
Postfach 48 48
90026 NÜRNBERG
GERMANY
Table of contents
1 Delivery check ........................................................................................................................................... 7

2 Mounting.................................................................................................................................................. 11
2.1 Mounting the controller ................................................................................................................11
2.2 Mounting the drive .......................................................................................................................13
2.3 Mounting the motor ......................................................................................................................16
3 Connecting .............................................................................................................................................. 17
3.1 Interface overview........................................................................................................................17
3.2 Connecting the battery.................................................................................................................19
3.3 Connecting according to the default PLC program......................................................................20
3.4 Connection Overview...................................................................................................................25
4 Switching on and preparing for commissioning........................................................................................ 27
4.1 Switching on controller.................................................................................................................27
4.2 PPU keyboard function ................................................................................................................28
4.3 MCP mode changeover ...............................................................................................................29
4.4 Status LEDs .................................................................................................................................30
4.5 Password .....................................................................................................................................31
4.5.1 Access levels ...............................................................................................................................31
4.5.2 Setting a password ......................................................................................................................33
4.6 Setting the date and time .............................................................................................................34
4.7 Introduction to the onboard assistants.........................................................................................35
5 Commissioning diagram .......................................................................................................................... 37
6 Default PLC applications ......................................................................................................................... 39
6.1 Turning .........................................................................................................................................39
6.2 Milling ...........................................................................................................................................43
6.3 PLC user alarms ..........................................................................................................................46
6.3.1 General information .....................................................................................................................46
6.3.2 Alarm properties...........................................................................................................................46
6.3.3 Activating the PLC user alarms....................................................................................................49
6.3.4 Editing a PLC user alarm text ......................................................................................................51
7 Commissioning the prototype .................................................................................................................. 57
7.1 Commissioning the controller.......................................................................................................57
7.1.1 Entering machine data .................................................................................................................57
7.1.2 Setting the axis-relevant parameters ...........................................................................................58
7.1.2.1 Enabling the position control........................................................................................................58
Commissioning Manual, 12/2012, 6FC5397-4EP10-0BA0 3
Table of contents
7.1.2.2 Setting the leadscrew pitch, deceleration ratio, and motor rotation direction ............................. 58
7.1.2.3 Setting the axis speed and acceleration ..................................................................................... 59
7.1.2.4 Setting the position-loop gain...................................................................................................... 59
7.1.3 Setting the spindle-relevant parameters ..................................................................................... 60
7.1.4 Approaching the reference point................................................................................................. 62
7.1.5 Compensation parameter settings .............................................................................................. 64
7.1.5.1 Setting the software limit switches .............................................................................................. 64
7.1.5.2 Setting backlash compensation .................................................................................................. 65
7.1.5.3 Making leadscrew error compensation ....................................................................................... 65
7.1.5.4 Setting protection levels .............................................................................................................. 68
7.2 Data backup ................................................................................................................................ 69
7.2.1 Creating a series archive ............................................................................................................ 69
7.2.2 Creating a start-up archive for the prototype .............................................................................. 71
7.2.3 Restoring the control system with the start-up archive file ......................................................... 72
8 Series production..................................................................................................................................... 74
8.1 Uploading the series archive for series commissioning.............................................................. 74
8.2 Data settings for individual machine ........................................................................................... 75
8.2.1 Setting the software limit switches .............................................................................................. 75
8.2.2 Setting the backlash.................................................................................................................... 75
8.2.3 Making leadscrew error compensation ....................................................................................... 75
8.3 Data backup ................................................................................................................................ 76
8.3.1 Overview ..................................................................................................................................... 76
8.3.2 Creating an original status archive.............................................................................................. 76
8.3.3 Creating the start-up archive....................................................................................................... 77
8.3.4 Restoring the control system....................................................................................................... 77
9 Other frequently used functions ............................................................................................................... 79
9.1 Playing a slide show.................................................................................................................... 79
9.2 Defining the service planner........................................................................................................ 81
9.3 Using the OEM startup screen and the OEM machine logo ....................................................... 84
A Appendix.................................................................................................................................................. 87
A.1 Cutting reserved holes ................................................................................................................ 87
A.2 Inserting, printing or cutting the MCP strips ................................................................................ 88
A.3 Basic knowledge about NC programming................................................................................... 89
A.4 Selection of the transformers ...................................................................................................... 90
A.5 Parameter list .............................................................................................................................. 91
A.5.1 Basic machine data..................................................................................................................... 91
A.5.2 SINAMICS V60 parameters ........................................................................................................ 95
A.6 Diagnostics.................................................................................................................................. 97
A.6.1 SINUMERIK 808D alarms........................................................................................................... 97
A.6.2 SINAMICS alarms ....................................................................................................................... 97
A.6.2.1 Overview of alarms ..................................................................................................................... 97
A.6.2.2 Alarm list...................................................................................................................................... 98
A.6.2.3 Errors during drive self-test ....................................................................................................... 102
A.6.2.4 Other faults................................................................................................................................ 102
4 Commissioning Manual, 12/2012, 6FC5397-4EP10-0BA0
Table of contents
A.6.2.5 Display data list ..........................................................................................................................102

A.7 PLC user interfaces ...................................................................................................................104
A.7.1 Addressing ranges .....................................................................................................................104
A.7.2 MCP ...........................................................................................................................................106
A.7.2.1 Signals from MCP ......................................................................................................................106
A.7.2.2 Signals to MCP ..........................................................................................................................106
A.7.2.3 Reading/writing NC data: Job ....................................................................................................107
A.7.2.4 Reading/writing NC data: Result................................................................................................107
A.7.2.5 PI service: Job............................................................................................................................107
A.7.2.6 PI service: Result .......................................................................................................................108
A.7.3 Retentative data area.................................................................................................................108
A.7.4 User Alarms ...............................................................................................................................108
A.7.4.1 User alarms: Activating ..............................................................................................................108
A.7.4.2 Variables for user alarms ...........................................................................................................108
A.7.4.3 Active alarm response ...............................................................................................................109
A.7.4.4 Acknowledgement of alarms......................................................................................................109
A.7.5 Axis/spindle signals....................................................................................................................109
A.7.5.1 Transferred M and S functions, axis specific .............................................................................109
A.7.5.2 Signals to axis/spindle ...............................................................................................................109
A.7.5.3 Signals from axis/spindle ...........................................................................................................111
A.7.6 PLC machine data .....................................................................................................................114
A.7.6.1 INT values (MD 14510 USER_DATA_INT)................................................................................114
A.7.6.2 HEX values (MD 14512 USER_DATA_HEX) ............................................................................114
A.7.6.3 FLOAT values (MD 14514 USER_DATA_FLOAT) ....................................................................114
A.7.6.4 User alarm: Configuring (MD 14516 USER_DATA_PLC_ALARM) ...........................................114
A.7.7 Signals from/to HMI ...................................................................................................................115
A.7.7.1 Program control signals from the HMI (retentive area) (also refer to signals at channel
DB3200) .....................................................................................................................................115
A.7.7.2 Program selection from PLC (retentive area) ............................................................................115
A.7.7.3 Checkback signal: Program selection from HMI (retentive area) ..............................................116
A.7.7.4 Signals from HMI .......................................................................................................................116
A.7.7.5 Signals from PLC .......................................................................................................................116
A.7.7.6 Signals to maintenance planners...............................................................................................117
A.7.7.7 Signals from maintenance planners ..........................................................................................117
A.7.7.8 Signals from operator panel (retentive area) .............................................................................118
A.7.7.9 General selection/status signals from HMI (retentive area).......................................................118
A.7.7.10 General selection/status signals to HMI (retentive area)...........................................................118
A.7.8 Auxiliary functions transfer from NC channel.............................................................................119
A.7.8.1 Overview ....................................................................................................................................119
A.7.8.2 Decoded M signals (M0 to M99) ................................................................................................119
A.7.8.3 Transferred T functions..............................................................................................................119
A.7.8.4 Transferred M functions .............................................................................................................120
A.7.8.5 Transferred S functions..............................................................................................................120
A.7.8.6 Transferred D functions .............................................................................................................120
A.7.8.7 Transferred H functions .............................................................................................................120
A.7.9 NCK signals ...............................................................................................................................121
A.7.9.1 General signals to NCK .............................................................................................................121
A.7.9.2 General signals from NCK .........................................................................................................121
A.7.9.3 Signals at fast inputs and outputs..............................................................................................122
A.7.9.4 Signals from fast inputs and outputs..........................................................................................123
A.7.10 Channel signals .........................................................................................................................124
A.7.10.1 Signals to NC channel ...............................................................................................................124
Table of contents
A.7.10.2 Signals from NC channel .......................................................................................................... 126

A.7.11 Signals, synchronized actions................................................................................................... 129
A.7.11.1 Signals, synchronized actions to channel ................................................................................. 129
A.7.11.2 Signals, synchronized actions from channel............................................................................. 129
A.7.11.3 Reading and writing PLC variables........................................................................................... 129
A.7.12 Axis actual values and distance-to-go ...................................................................................... 130
A.7.13 Maintenance scheduler: User interface .................................................................................... 130
A.7.13.1 Initial (start) data ....................................................................................................................... 130
A.7.13.2 Actual data ................................................................................................................................ 131
A.7.14 User interface for Ctrl-Energy ................................................................................................... 131
Index...................................................................................................................................................... 133
Delivery check 1
System overview
The SINUMERIK 808D is an economic CNC solution for milling and turning machines in the
global market. For the turning variant, it is designed to control three axes, including two feed
axes via two pulse drive interfaces (with SINAMICS V60) and one spindle via one analog
spindle interface. For the milling variant, it is designed to control four axes, including three
feed axes via three pulse drive interfaces (with SINAMICS V60) and one spindle via one
analog spindle interface.
The following diagram shows a system configuration example for the SINUMERIK 808D
control system:
Delivery check
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Figure 1-1 SINUMERIK 808D control system overview (taking a milling machine for an example)
Note
For a turning machine, you need two sets of setpoint cable + SINAMICS V60 drive + motor
cable + brake cable (if necessary) + encoder cable + 1FL5 servomotor.
Delivery check
Legend Name Order number

1) PPU141.1, turning 6FC5370-1AT00-0AA0 (English)
6FC5370-1AT00-0CA0 (Chinese)
PPU141.1, milling 6FC5370-1AM00-0AA0 (English)
6FC5370-1AM00-0CA0 (Chinese)
2) MCP 6FC5303-0AF35-0AA0 (English)
6FC5303-0AF35-0CA0 (Chinese)
3) Setpoint cable PPU141.1 to CPM60.1 6FC5548-0BA00-1AF0 (5 m)
6FC5548-0BA00-1AH0 (7 m)
6FC5548-0BA00-1BA0 (10 m)
4) SINAMICS V60 Controlled Power Module 6SL3210-5CC14-0UA0 (4 A)
(CPM60.1) 6SL3210-5CC16-0UA0 (6 A)
6SL3210-5CC17-0UA0 (7 A)
6SL3210-5CC21-0UA0 (10 A)
5) 1FL5 Motor 1FL5060-0AC21-0AA0 (4 Nm, with key, without brake)
1FL5060-0AC21-0AG0 (4 Nm, without key, without brake)
1FL5062-0AC21-0AA0 (6 Nm, with key, without brake)
1FL5064-0AC21-0AA0 (7.7 Nm, with key, without brake)
1FL5064-0AC21-0AG0 (7.7 Nm, without key, without brake)
1FL5066-0AC21-0AA0 (10 Nm, with key, without brake)
1FL5060-0AC21-0AB0 (4 Nm, with key, with brake)
1FL5060-0AC21-0AH0 (4 Nm, without key, with brake)
1FL5064-0AC21-0AB0 (7.7 Nm, with key, with brake)
1FL5064-0AC21-0AH0 (7.7 Nm, without key, with brake)
6) Setpoint cable PPU141.1 to inverter or servo 6FC5548-0BA05-1AF0 (5 m)
spindle drive 6FC5548-0BA05-1AH0 (7 m)
6FC5548-0BA05-1BA0 (10 m)
7) Motor cable (unshielded) 6FX6002-5LE00-1AF0 (5 m)
6FX6002-5LE00-1BA0 (10 m)
8) Brake cable (unshielded) 6FX6002-2BR00-1AF0 (5 m)
6FX6002-2BR00-1BA0 (10 m)
9) Encoder cable (shielded) 6FX6002-2LE00-1AF0 (5 m)
6FX6002-2LE00-1BA0 (10 m)
10) Inverter or servo spindle drive From Siemens or a third-party manufacturer
Delivery check
Check list
Table 1- 1 PPU package
Component Quantity (pieces)

Panel Processing Unit (PPU) 1
Mounting clamps with screws 8
Connectors  I/O connectors: 7
 24 V power input connector: 1
Table 1- 2 MCP package

Machine Control Panel (MCP) 1
MCP connection cable (for connecting the MCP to the PPU, max. 50 cm) 1
Mounting clamps with screws 6
Pre-printed MCP strip, Milling 1 set of 6 pieces
Blank strip paper, A4 size 1
Product Information for MCP 1
Table 1- 3 CNC accessories

Setpoint cable to SINAMICS V60 (for feed axis) 2 (turning) or 3 (milling)
Setpoint cable to Siemens inverter or third-party drive (for 1
spindle)
Note
Emergency stop button is not included in our scope of delivery. You can, if necessary,
contact your local Siemens salesperson for it.
Table 1- 4 SINAMICS V60 package

SINAMICS V60 1
Getting Started 1
Cable clamps 2
Warranty Card 1
Table 1- 5 1FL5 motor package

1FL5 motor 1
Data sheet for 1FL5 motor 1
Table 1- 6 Cables individually packaged

Motor cable (unshielded) 1
Brake cable (unshielded) 1
Encoder cable (shielded) 1
Mounting
Mounting 2
2.1 Mounting the controller
Cut-out dimensions
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Figure 2-1 Cut-out dimensions (in mm)
Note
Make sure there is enough space around the PPU and the MCP for tightening the screws in
the control cabinet.
Mounting
2.1 Mounting the controller
Mounting dimensions

Figure 2-2 Mounting dimensions for PPU (in mm)

Figure 2-3 Mounting dimensions for MCP (in mm)
Mounting
2.2 Mounting the drive
Mounting clearance (in mm)

To ensure easy maintenance purpose, you must provide sufficient clearance (recommended
distance: 80 mm) between the maintenance door and the cabinet wall for replacing the
battery and CF card:

1
① Cabinet panel ② Maintenance door

Cut-outs and mounting dimensions
5
93 5. 106
2-
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215
5.5
Figure 2-4 4/6/7 A version (in mm)
Mounting
5
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215
5.5
Figure 2-5 10 A version (in mm)
Mounting method
With 4xM5 preassembled screws, the drive can be mounted vertically onto the inner panel of
the cabinet. The maximum screw torque must be 2.0 Nm.
Minimum mounting clearance

To ensure adequate cooling, as a minimum, maintain the specified clearance between
drives, one drive and another device/inner panel of the cabinet.
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Figure 2-6 Drive mounting clearance (in mm)
Using the cable clamps supplied

If the CE marking requirements for cables are mandatory, the line supply cable and the
motor cable used must all be shielded cables. In this case, you can use the cable clamps as
a ground connection between the cable shield and a common ground point.
Clamps can also be helpful in better fixing cables (the unshielded motor cable and the line
supply cable) in place.
Mounting
The illustration below shows you how to use the clamps to fix both cables and to make a
shield connection with the cable.
Line supply cable (shielded)
Ground wire
PE (for connection to ground;

tightening torque: 2.0 Nm)
Cable clamp
Ground wire
Motor cable
Figure 2-7 Cable fixing with two cable clamps
CAUTION
Make sure that the clamp for fixing the shielded motor cable has a good contact with the
cable shield.
Note
Siemens does not provide the shielded motor cable. Please prepare the shielded motor
cable by yourselves for CE certification.
After the installation, it is recommended that the terminal screws should be checked to
ensure that they are tight.
Reference
For further information about the drive mounting, refer to SINAMICS V60 Getting Started.
Mounting
2.3 Mounting the motor
2.3 Mounting the motor
Mounting dimensions (mm)
Motor type A (in mm) B (in mm)

4 Nm 163 (205) 80
6 Nm 181 (223) 90
7.7 Nm 195 (237) 112
10 Nm 219 (261) 136
Note
Value in brackets is the length of a motor with a built-in brake unit.
Motors with plain shaft have the same dimensions.
Reference
For further information about the motor, refer to 1FL5 Motor Technical Data.
Connecting 3
3.1 Interface overview
Interface overview on the Panel Processing Unit (PPU)
NOTICE
The + 24 V and M signals of X200 must be connected; otherwise, the communication

between the PPU and the drives does not function as it should.
1 5 6 7 8 9 10
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Connecting
3.1 Interface overview
Legend Interface Comment

Rear
① X100, X101, X102 Digital inputs
② X200, X201 Digital outputs
③ X21 FAST I/O
④ X301, X302 Distributed I/O
⑤ X10 Hand-wheel inputs
⑥ X60 Spindle encoder interface
⑦ X54 Analog spindle interface
⑧ X2 RS232 interface
⑨ X51, X52, X53 Pulse drive interfaces
⑩ X30 USB interface, for connection with the MCP
⑪ X1 Power supply interface, +24V DC power supply
⑫ - Battery interface
⑬ - Slot for the System CompactFlash Card (CF card)
Front
⑭ - USB interface
Interface overview on the Machine Control Panel (MCP)
1
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Legend Interface Comment

Rear
① X10 USB interface, for connection with the PPU
Connecting
3.2 Connecting the battery
3.2 Connecting the battery

A battery has been pre-assembled on the back cover of the PPU.
The battery is not connected when delivered. You must plug the battery connector into the
battery interface by yourself before switching the controller on. You can access it after
removing the maintenance door:
4
3
1 2
① Maintenance door ③ Battery interface

② Battery ④ Battery connector
Note
When connecting the battery, ensure that the groove is at the upper side; otherwise, the
alarm "NCK battery alarm" will be output after you switch on the controller, and you could
lose your data after an unexpected power failure if you do not insert the battery connector
correctly.
Note
Battery
Life time: 3 years
Replacement: do not replace the battery when the controller is switched off; otherwise, your
data can be lost.
Order number: 6FC5247-0AA18-0AA0.
Connecting
3.3 Connecting according to the default PLC program

The SINUMERIK 808D has integrated with a default PLC application. If you perform the
commissioning work with the default PLC application, perform wiring as follows.
Connecting the digital inputs and outputs
Milling
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Connecting
Turning
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Connecting
Connecting the distributed I/O
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Milling Turning
Figure 3-5 Connecting the distributed I/O
Connecting the SINAMICS V60 (take X51: axis X for an example)
SINUMERIK 808D SINAMICS V60

PPU
X5 $
L1
38/6 *UHHQ %
38/6 L2 $&9
38/6 <HOORZ &
38/6 L3
',5 *UD\
',5
',5 3LQN
',5
(1$ %URZQ
(1$
(1$ :KLWH (QFRGHUFDEOH
(1$ X7
X51 X6
% ZKLWH
% %UDNHFDEOH
X3
567 :KLWHJUHHQ %
567 % EODFN
6HWSRLQWFDEOH 0 5HG
0
8
$/0 5HGEOXH U
$/0
9
3RZHUFDEOH
$/0 %OXH $/0 V
5'< %ODFN W :
5'<
5'< 9LROHW 5'<
9 :KLWH\HOORZ 9
=0 *UD\SLQN =0
X1 =0 %URZQJUHHQ 0 )/
VHUYRPRWRU
9
9 9
9 9
9 3(

9'&
SRZHUVXSSO\
9 9 9 9
Figure 3-6 Connecting the SINAMICS V60 (X51: axis X)
Connecting
Note
Filter
A line filter (rated current: 16 A, protection level: IP20) is required so that the system can
pass the CE certification (radiated emission test or conducted emission test). The order
number of Siemens recommended filter is 6SN1111-0AA01-1BA1.
Note
Circuit breaker
You can install a mains linear breaker (rated current: 15 A for 7 A or 10 A version of the drive
and 10 A for 4 A or 6 A version of the drive; rated voltage: 250 VAC) to protect the system.
Connecting the inverter or the servo spindle drive
3LQ 9
3LQ 9
SINUMERIK 808D 3LQ 0 Inverter or servo
3LQ 0
PPU 3LQ =
spindle drive
3LQ =1
3LQ %1
3LQ %
3LQ $1
3LQ $
X60
6SLQGOHHQFRGHUFDEOH
$2 %ODFN
AI
$*1' %ODFN
GND
X54 3(
6HWSRLQWFDEOH
9

X21

6SLQGOH&:
DI1
6SLQGOH&&: .
. DI2
0 . .
COM
9DQDORJYROWDJH
9VLJQDO
Figure 3-7 Connecting the inverter or the servo spindle drive (unipolar)
Connecting
3LQ 9
3LQ 9
SINUMERIK 808D 3LQ 0 Inverter or servo
3LQ 0
PPU 3LQ =
spindle drive
3LQ =1
3LQ %1
3LQ %
3LQ $1
3LQ $
X60
6SLQGOHHQFRGHUFDEOH
$2 %ODFN
AI
$*1' %ODFN
GND
X54
6HWSRLQWFDEOH
6( %ODFN
COM
6( %ODFN
EN
3(
9DQDORJYROWDJH
9VLJQDO
Figure 3-8 Connecting the inverter or the servo spindle drive (bipolar)
Note
Cables for connecting X21 must be shielded ones.
Connecting the handwheel

X10
$ $
$ $
% %
% %

0 0
+DQGZKHHO
Figure 3-9 Connecting the handwheel
Connecting
3.4 Connection Overview
Connection overview (milling)
PPU
9'& ;
; 3&3*
;$[LV ; 6,1$0,&69 6HUYRPRWRU

<$[LV ; 6,1$0,&69 6HUYRPRWRU
=$[LV ; 6,1$0,&69 6HUYRPRWRU
,QYHUWHURUVHUYR
6SLQGOH ; VSLQGOHGULYH
6SLQGOHHQFRGHU ; 6SLQGOHHQFRGHU

(OHFWURQLF
KDQGZKHHO
+DQGZKHHO ;
(OHFWURQLF
KDQGZKHHO
,1
6LJQDO
)DVWLQSXWRXWSXW ; WR
0
,1
'LJLWDOLQSXWV
,WR, ; 0
,WR, ; 6LJQDO
,WR, WR
;
287
3
;
'LJLWDORXWSXWV
4WR4 0
4WR4 ; /RDG
WR
'LVWULEXWHG,2
,WR,
,WR,
,WR,
; 'LJLWDO,2
4WR
4WR
,WR, ;
,WR,
,WR,
4WR4
4WR4
86%LQWHUIDFH
;
86%FDEOH
;
0 3 0 3
86%LQWHUIDFH
MCP 9'&SRZHUVXSSOLHV
Connecting
Connection overview (turning)
PPU
9'& ;
; 3&3*
;$[LV ; 6,1$0,&69 6HUYRPRWRU

<$[LV 2SWLRQDO
; 6,1$0,&69 6HUYRPRWRU
=$[LV ; 6,1$0,&69 6HUYRPRWRU
,QYHUWHURUVHUYR
6SLQGOH ; VSLQGOHGULYH
6SLQGOHHQFRGHU ; 6SLQGOHHQFRGHU

(OHFWURQLF
KDQGZKHHO
+DQGZKHHO ;
(OHFWURQLF
KDQGZKHHO
,1
6LJQDO
)DVWLQSXWRXWSXW ; WR
0
,1
'LJLWDOLQSXWV
,WR, ; 0
,WR, ; 6LJQDO
,WR, WR
;
287
3
;
'LJLWDORXWSXWV
4WR4 0
4WR4 ; /RDG
WR
'LVWULEXWHG,2
,WR,
,WR,
,WR,
; 'LJLWDO,2
4WR
4WR
,WR, ;
,WR,
,WR,
4WR4
4WR4
86%LQWHUIDFH
;
86%FDEOH
;
0 3 0 3
86%LQWHUIDFH
MCP 9'&SRZHUVXSSOLHV
Note
For the turning variant, connection to X52 is optional and depends upon whether you use the
software option "additional axis". If you desire to configure the control system to control a
rotary axis or an additional linear axis, connect X52 to a SINAMICS V60 which connects to a
servo motor.
Switching on and preparing for commissioning 4
4.1 Switching on controller
Before switching on
Make sure that:
● You have finished the mechanical installation of the whole system based on the
information included in the chapter "Mounting (Page 11)" or the Mechanical Installation
Manual.
● You have completed the wirings of the whole system according to the information
included in the chapter "Connecting (Page 17)" (if you use the default PLC program) or
the Electrical Installation Manual.
Switching on
Do as follows:
1. Power on the mains supply.
2. When the NC enters the main screen, check the NC normal status according to the status
LEDs on the PPU.
POK: green
RDY: green
TEMP: unlit
For detailed information about the status LEDs, refer to the section "Status LEDs
(Page 30)".
3. Check the drive normal status:
– "S-run" is displayed.
– LED "RDY/JOG": green
– LED "ERR": dark
For detailed information about the SINAMICS V60 drives, refer to the SINAMICS V60
Getting Started.
Switching on and preparing for commissioning
4.2 PPU keyboard function
4.2 PPU keyboard function
1 2 3 4 5
Legend Name Description

① Return key Returns to higher level menu
② Horizontal softkeys Call corresponding menu functions
③ Extension key Reserved. No function
④ Vertical softkeys Call corresponding menu functions
⑤ Operating area keys Opens the "MACHINE" operating area
Opens the "PROGRAM" operating area
Opens the "OFFSET" operating area
Opens the "PROGRAM MANAGER" operating area
 Opens the "ALARM" operating area

 Combines with the <SHIFT> key to open the
"SYSTEM" area
Opens the "CUSTOM" operating area
4.3 MCP mode changeover
4.3 MCP mode changeover

Use the machine control panel (MCP) to make changeover between the JOG mode, the Ref
Point mode, the AUTO mode and the MDA mode.
The MCP key layout is shown below:
1 2 3 4
Legend Name Description

① Mode navigation Enters the Ref. Point mode for reference point approach
keys
Enters the JOG mode (manual operation)
Enters the AUTO mode (automatic operation)
Enters the MDA mode (manual program input and

automatic execution)
② Incremental feed Axis traverses at the increment of 1

keys
Axis traverses at the increment of 10
Axis traverses at the increment of 100
③ Axis traversing keys Move an axis (X, Y, Z)
④ RESET key  Resets NC programs

 Cancels alarms
4.4 Status LEDs
4.4 Status LEDs
LEDs on the PPU

The following LEDs are installed on the SINUMERIK 808D PPU.
32. 5'< 7(03
The individual LEDs and their functions are described in the table below.
Table 4- 1 Status and error displays
LED Color Significance

POK Green Power supply is OK.
RDY Green Ready for operation
TEMP Yellow Temperature exceeds the limit
For more information, refer to error description in the SINUMERIK 808D Diagnostics Manual.
LEDs on the SINAMICS V60 drives
Possible states
LED RDY / JOG (Ready / JOG mode)
Dark
Flashing green
Light green
Possible states
LED ERR (error)
Dark M ENTER
Light red
Flashing red
Figure 4-1 SINAMICS V60 status LEDs
4.5 Password
Table 4- 2 Description of the LED status
Status LED 1 Status LED 2 Description 7-segment LED display description

RDY/JOG ERR
Green LED Red LED
Dark Dark No 24 V DC Input/Drive Defect Dark
Dark Flashing at 1 Hz Drive not ready Current status
Green Dark Drive ready Depends on the current menu
operation
Dark Red Drvie error Alarm code
Green Red Initialization Display "8.8.8.8.8.8."
Flashing at 1 Hz Dark JOG mode Display "J-run"
4.5 Password
4.5.1 Access levels
Purpose
Access levels/passwords are necessary to prevent system data damages caused by
unexpected mistake operations.
Cases
You must set a password for an access level under following cases:
● Data restoring
● Software update
● Password has been deleted
● A higher or lower access level is required
Access levels
The SINUMERIK 808D provides a concept of access levels for enabling data areas. You can
view such information from the table below:
Table 4- 3 Access level
Access level Default password Target group

Manufacturer SUNRISE OEMs
Customer CUSTOMER End users
No password - -
4.5 Password
With the access level "Manufacturer", you can perform the following operations:
● Inputting or modifying all the machine data
● Commissioning work
With the access level "Customer", you can perform the following operations:
● Inputting or modifying part of the machine data
● Programming
● Setting offsets
● Measuring tools
For the function areas listed below, the input and modification of data depends on the
protection level you have set:
● Tool offsets
● Work offsets
● Setting data
● RS232 settings
● Program creation / program correction
You can set the protection levels for these function areas via the display machine data
(USER_CLASS...): "SYSTEM" operating area > "Mach. data" > "Expert list" > "Display MD".
Note
For detailed information about the display machine data, refer to the Parameter Manual.
Note
For detailed information about how to set the access levels, refer to Programming and
Operating Manual.
Access levels: Manufacturer, Customer

Both access levels require a password.
You can change the password only after being activated with the access level
"Manufacturer".
If you forget your password, you can carry out an NC start-up: "SYSTEM" operating area >
"Start-up" > "NC" > "Power-up with default data". This will reset all passwords to their
defaults according to the software release you have acquired.
Note
Before performing a start-up with default data, you must backup your data; otherwise, you
will lose your data. For detailed information about how to do data backup, refer to section
"Data backup (Page 76)".
4.5 Password
Access level: No password

If you have deleted your password or do not set a password, you only have the access right
of viewing above-mentioned function areas.
Note
The system has no password by default.
4.5.2 Setting a password

The control system is delivered without a password. You must input the password of
"SUNRISE" to perform the commissioning work.
Perform the following steps to input the password:
1. In the "SYSTEM" operating area (key combination: + ), press the vertical

softkey "Set password". The message text at the bottom of the screen shows "No
password set":
2. Enter "SUNRISE" and press the "Accept" softkey.

3. The message text now shows "Access level: Manufacturer", which indicates that you
have successfully set the password.
Note
You can change the default password to you by using the "Change password" softkey.
You can also delete the current password to protect your settings by pressing the "Delete
password" softkey.
After the series production, you must press the "Delete password" softkey to exit the
"Manufacturer" access level.
4.6 Setting the date and time
4.6 Setting the date and time

At delivery, the system date and time remain at the factory settings, and thus you must
manually modify the date and time. Proceed as follows to set the date and time:
1. Press + to enter the "SYSTEM" operating area, then press the softkey "Date
time".
2. Input your date and time.
3. Press the "OK" softkey to confirm your settings.
4.7 Introduction to the onboard assistants

The SINUMERIK 808D system software has three onboard assistants:
● Startup assistant (requires "Manufacturer" access level)
This on-board assistant is designed to help you commission the prototype. With this
assistant, you can complete basic machine tool functions.
● Series assistant (requires "Manufacturer" access level)
This on-board assistant is designed to help you correctly finish the series machine
commissioning.
● Operation assistant (requires "Customer" access level)
This onboard assistant is designed to help you learn about the basic operations of the
machining process.
Where can I find the assistants?

Press the <MENU FUNCTION> key on the PPU to call the assistants:
How can I use the assistants?
Status indicators:
Completed task
Current task
Partially completed task group
Uncompleted task
Press one of the three softkeys to access the

corresponding assistant
Press to start the assistant
Press to return to the main screen of the onboard

assistants
Press any operating area key (CUSTOM excluded) to

exit the main screen of the onboard assistants and
enter the corresponding operating area
Press to enter the current task or a task that is prior to

the current task
Note: This softkey becomes active when you move the
cursor key to a valid task.
Commissioning diagram 5
You can commission the SINUMERIK 808D in two ways:
● Alternative 1: with the onboard assistants
● Alternative 2: without the onboard assistants
When commissioning with the onboard assistants, just follow the assistants step by step.
In this manual, only the second way is described. To do the commissioning work without the
onboard assistants, proceed as follows:
Start
Commissioning the PLC with the

default PLC application
1
Commissioning the NC
Data backup
- Production archive
- Start-up archive for the prototype
Series commissioning
NC data compensation
2
Data backup
- Start-up archive
- Original status archive for delivery
End
1 Commissioning the prototype
2 Series production
Commissioning diagram
Default PLC applications 6
6.1 Turning
Overview of the PLC subroutines
Subroutine No. Name Description
0 to 19 - Reserved for the manufacturer
20 AUX_MCP Auxiliary function
21 AUX_LAMP Lamp control, called in the subroutine "AUX_MCP".
31 PLC_ini_USR_INI Reserved for the initialization by the manufacturer (this subroutine is
automatically called by subroutine 32)
32 PLC_INI PLC initialization
33 EMG_STOP Emergency Stop
37 MCP_NCK Signals from the MCP and the HMI are sent to NCK interfaces
38 MCP_Tool_Nr Display tool numbers via the LED of the MCP
39 HANDWHL Handwheel selection via HMI
40 AXIS_CTL Control of feed axis enable and spindle enable
41 MINI_HHU Handwheel hand held unit
42 SPINDLE Spindle function
43 MEAS_JOG Tool measurement in the JOG mode
44 COOLING Coolant control (Manual Machine key and M code: M07, M08, M09)
45 LUBRICATE Lubrication control (interval and time)
46 PI_SERVICE ASUP (Asynchronous Subroutine Program)
47 PLC_Select_PP PLC selects a subroutine.
48 ServPlan Service plan
49 Gear_Chg1_Auto Automatic gear change of the spindle
50 Gear_Chg2_Virtual Dummy gear change of the spindle
51 Turret1_HED_T Turret control of the turning machine (turret type: Hall element transistor, 4/6
position)
52 Turret2_BIN_T Turret control of the turning machine (turret type: position detection with codings)
53 Turret3_CODE_T Hydraulic turret control of the turning machine (turret type: position detection with
codings)
54 Turret2_3_ToolDir Evaluate tool direction and calculate tool position (called by Turret2_BIN_T,
Turret3_CODE_T)
55 Tail_stock_T Tail stock control
56 Lock_unlock_T Clamp or release control
58 MM_MAIN Manual machine
59 MM_MCP_808D Spindle signal processing for the manual machine
61, 62 Reserved for the subroutine
63 TOGGLE Six key-operated switches: K1 to K6
Two delay switches: k7, K8
Default PLC applications
6.1 Turning
Definition of user-defined keys on the MCP
User-defined key 1 Working lamp

User-defined key 2 Manual cooling
User-defined key 3 Manual tool change
User-defined key 4 Manual chuck clamping and unclamping
User-defined key 5 Chuck clamping internally/externally
User-defined key 6 Tailstock
Structure of the sample application (OB1)
Call Conditions Subroutine Name Description

First scan (SM0.1) PLC_INI (SBR32) PLC initialization
Each scan (SM0.0) EMG_STOP (SBR33) Emergency Stop control
Each scan (SM0.0) MCP_NCK (SBR37) Transferring MCP and HMI signals to the NCK interface
Each scan (SM0.0) HANDWHL (SBR39) Selecting a hand wheel through the interface signal
DB1900.DBB1xxx
Each scan (SM0.0) AXIS_CTL (SBR40) Coordinate enabling control, hardware limit, etc.
Each scan (SM0.0) COOLING (SBR44) Cooling control
Each scan (SM0.0) TURRET1 (SBR46) HALL effect device turret control
Each scan (SM0.0) ServPlan (SBR48) Maintenance plan example: first task
PLC user alarms
Alarm No. Interface Address Alarm Description From SBR

700010 DB1600.DBX1.2 HHU is active SBR41: MINI_HHU
700011 DB1600.DBX1.3 Not able to lock tool in expected time
700012 DB1600.DBX1.4 Spindle in braking progress SBR42: SPINDLE
700013 DB1600.DBX1.5 Operation while chuck is not locked SBR56: Lock_unlock_T
700014 DB1600.DBX1.6 Gear-change time out SBR49: GearChg1_Auto
700015 DB1600.DBX1.7 Gear level position error
700016 DB1600.DBX2.0 Drives not ready SBR33: EMG_STOP
700017 DB1600.DBX2.1 Operate chuck when spindle or part program is SBR56: Lock_unlock_T
running
700018 DB1600.DBX2.2 Cooling motor overload SBR44: COOLING
700019 DB1600.DBX2.3 Coolant liquid position in low level
700020 DB1600.DBX2.4 Lubrication motor overload SBR45: LUBRICAT
700021 DB1600.DBX2.5 Lubricant liquid position in low level
700022 DB1600.DBX2.6 Turret motor overload SBR51: Turret1_HED_T
700023 DB1600.DBX2.7 Programmed tool number > max. turret on turret SBR52: Turret2_BIN_T
number SBR53: Turret3_CODE_T
700024 DB1600.DBX3.0 Max. tool number setting error
6.1 Turning

700025 DB1600.DBX3.1 No position signals from turret
700026 DB1600.DBX3.2 Not able to find expected tool in monitor time
700027 DB1600.DBX3.3 Approach reference point again after rotation SBR40: AXIS_CTL
monitoring
700028 DB1600.DBX3.4 Tool is not locked SBR53: Turret3_CODE_T
700049 DB1600.DBX6.1 Reference point X-axis not reached SBR58: MM_MAIN
700050 DB1600.DBX6.2 Reference point Z-axis not reached SBR58: MM_MAIN
700051 DB1600.DBX6.3 Wrong spindle direction started SBR58: MM_MAIN
700052 DB1600.DBX6.4 Watchdog timer JOG-program SBR58: MM_MAIN
700053 DB1600.DBX6.5 Spindle override not 100% SBR58: MM_MAIN
700054 DB1600.DBX6.6 Spindle is not started SBR58: MM_MAIN
700055 DB1600.DBX6.7 Feed override = 0% SBR58: MM_MAIN
700056 DB1600.DBX7.0 Change of spindle direction not possible in SBR58: MM_MAIN
thread
700059 DB1600.DBX7.3 Safe door not closed, NC start not possible SBR22:
AUX_SAFE_DOOR
700060 DB1600.DBX7.4 Channel not in reset, change PRT not possible SBR37: MCP_NCK
Relevant machine data
MD14510 Unit Range Function

Machine data - Integer
14510[12] * 0 to 1 JOG key layout
14510[20] - 2 to 64 The maximum number of tool positions
14510[21] 0.1s 5 to 30 Time for locking a turret
14510[22] 0.1s 30 to 300 The monitoring time for searching a tool
14510[24] 1 min 5 to 300 Lubrication interval
14510[25] 0.01s 100 to 2,000 Lubrication duration
6.1 Turning
MD14512 Function
Machine data - Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
Hex
14512[16] Handwheel Control of Z Control of
assignment axis rotation X axis
with the MCP monitoring rotation
monitoring
14512[17] Selection Tail stock Clamping
between function function
handwheel
and hand-
held unit
(0:
handwheel;
1: hand-
held unit)
14512[18] Each feed The hardware Spindle Signal that Automatic
axis has a limit is positioning external lubrication
hardware limit independent direction spindle after the
switch of a PLC stops first power-
(activated program on (factory
when Bit 6 = setting)
0)
14512[19] Manual Password Function
machine clearing by of spindle
function (this power-on braking
function (0: delete
becomes the
active if you password;
install 1: do not
licensed delete the
turning password)
machine
system and
call it with a
PLC
subroutine)
6.2 Milling
6.2 Milling
Overview of the PLC subroutines
Subroutine No. Name Description
0 to 19 - Reserved for the manufacturer
20 AUX_MCP Auxiliary function
21 AUX_LAMP Lamp control, called in the subroutine "AUX_MCP".
22 AUX_SAFE_DOOR Safe door control, called in the subroutine "AUX_MCP" of a milling application.
23 AUX_CHIP Chip remover control, called in the subroutine "AUX_MCP" of a milling
application.
31 PLC_ini_USR_INI Reserved for the initialization by the manufacturer (this subroutine is
automatically called by subroutine 32)
32 PLC_INI PLC initialization
33 EMG_STOP Emergency Stop
37 MCP_NCK Signals from the MCP and the HMI are sent to NCK interfaces
38 MCP_Tool_Nr Display tool numbers via the LED of the MCP
39 HANDWHL Handwheel selection via HMI
40 AXIS_CTL Control of feed axis enable and spindle enable
41 MINI_HHU Handwheel hand held unit
42 SPINDLE Spindle function
43 MEAS_JOG Tool measurement in the JOG mode
44 COOLING Coolant control (Manual Machine key and M code: M07, M08, M09)
45 LUBRICATE Lubrication control (interval and time)
46 PI_SERVICE ASUP (Asynchronous Subroutine Program)
47 PLC_Select_PP PLC selects a subroutine.
48 ServPlan Service plan
49 Gear_Chg1_Auto Automatic gear change of the spindle
50 Gear_Chg2_Virtual Dummy gear change of the spindle
58 MM_MAIN Manual machine
59 MM_MCP_808D Spindle signal processing for the manual machine
61, 62 Reserved for the subroutine
63 TOGGLE Six key-operated switches: K1 to K6
Two delay switches: K7, K8
Definition of user-defined keys on the MCP

User-defined key 1 Working lamp
User-defined key 2 Manual cooling
User-defined key 3 Safe door
User-defined key 4 Manual clockwise rotation of the tool magazine
User-defined key 5 Manual reset of the tool magazine
User-defined key 6 Manual counter-clockwise rotation of the tool magazine
User-defined key 7 Removing chip forward
User-defined key 8 Removing chip backward
6.2 Milling
Structure of the sample application (OB1)
Call Conditions Subroutine Name Description

First scan (SM0.1) PLC_INI (SBR32) PLC initialization
Each scan (SM0.0) EMG_STOP (SBR33) Emergency Stop control
Each scan (SM0.0) MCP_NCK (SBR37) Transferring MCP and HMI signals to the NCK interface
Each scan (SM0.0) HANDWHL (SBR39) Selecting a hand wheel through the interface signal V1900 1xxx
Each scan (SM0.0) AXIS_CTL (SBR40) Coordinate enabling control, hardware limit, etc.
Each scan (SM0.0) COOLING (SBR44) Cooling control
Each scan (SM0.0) LUBRICATE (SBR45) Lubrication control
PLC user alarms

700010 DB1600.DBX1.2 HHU is active SBR41: MINI_HHU
700011 DB1600.DBX1.3 Not able to lock tool in expected time
700012 DB1600.DBX1.4 Spindle in braking progress SBR42: SPINDLE
700014 DB1600.DBX1.6 Gear-change time out SBR49: GearChg1_Auto
700015 DB1600.DBX1.7 Gear level position error
700016 DB1600.DBX2.0 Drives not ready SBR33: EMG_STOP
700017 DB1600.DBX2.1 Operate chuck when spindle or part program is SBR56: Lock_unlock_T
running
700018 DB1600.DBX2.2 Cooling motor overload SBR44: COOLING
700019 DB1600.DBX2.3 Coolant liquid position in low level
700027 DB1600.DBX3.3 Approach reference point again after rotation SBR40: AXIS_CTL
monitoring
700029 DB1600.DBX3.5 Reminding information for 1st service plan SBR48:ServPlan
700030 DB1600.DBX3.6 Alarm for 1st service plan
700031 DB1600.DBX3.7 Magazine not in spindle position or original SBR60: Disk_MGZ_M
position
700032 DB1600.DBX4.0 Magazine in spindle position and original SBR60: Disk_MGZ_M
position
700033 DB1600.DBX4.1 Magazine turn key when magazine or spindle SBR60: Disk_MGZ_M
not ready
700034 DB1600.DBX4.2 Block search, tool in spindle <> programmed SBR60: Disk_MGZ_M
tool
700035 DB1600.DBX4.3 Spindle not reach tool-release pos. in time SBR60: Disk_MGZ_M
700036 DB1600.DBX4.4 Spindle not reach tool-lock pos. in time SBR60: Disk_MGZ_M
700059 DB1600.DBX7.3 Safe door not closed, NC start not possible SBR22:
AUX_SAFE_DOOR
700060 DB1600.DBX7.4 Channel not in reset, change PRT not possible SBR37: MCP_NCK
6.2 Milling
Relevant machine data

MD14510 Unit Range Function
Machine data - Integer
14510[12] * 0 to 1 JOG key layout
14510[20] - 2 to 64 The maximum number of tool positions
14510[24] 1 min 5 to 300 Lubrication interval
14510[25] 0.01s 100 to 2,000 Lubrication duration
MD14512 Function
Machine data Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
- Hex
14512[16] Handwheel Control of Z Control of Control of When the Function of Function
assignment with axis rotation Y axis X axis function of safe door of chip
the MCP monitoring rotation rotation safe door remover
monitoring monitoring is active, it
can be
triggered
by
M01/M02
14512[17] Selection Tool
between magazine
handwheel
and hand-
held unit
(0:
handwheel
; 1: hand-
held unit)
14512[18] Each feed axis The Spindle Signal that Automatic
has a hardware hardware positionin external lubrication
limit switch limit is g direction spindle after the
(activated when independent stops first power-
Bit 6 = 0) from a PLC on (factory
program setting)
14512[19] Manual Password Function
machine clearing by of
function (this power-on spindle
function (0: delete braking
becomes active the
if you install password;
licensed turning 1: do not
machine delete the
system and call password)
it with a PLC
subroutine)
6.3 PLC user alarms
6.3 PLC user alarms
6.3.1 General information

PLC user alarms can be used as one of the most effective diagnosis methods.
The SINUMERIK 808D control system provides 128 PLC user alarms (700xxx). Each alarm
corresponds with an alarm variable that is relevant to an alarm text, and each alarm
corresponds with a machine data MD14516 used to configure alarm properties.
6.3.2 Alarm properties
Alarm responses
You can configure the response of the control system after a user alarm is output:
● PLC STOP: When the user alarm is output, PLC detection stops, interface signal "NC
RDY" is disabled and all outputs are disabled.
● EMERGENCY STOP: The user alarm automatically activates interface signal "EMER
STOP".
● Feed disabled for all axes: The user alarm automatically activates interface signal "Feed
disable".
● Read-in disabled: The user alarm automatically activates interface signal "Read-in
disable".
● NC Start disabled: The user alarm automatically activates interface signal "NC Start
disable".
● Only display: No response occurs when the user alarm is output. Only alarm number and
alarm text are displayed.
Cancelling methods
You can configure a cancelling method for a PLC user alarm. There are totally three
cancelling methods available:
● POWER ON: cancel the user alarm by re-powering on the control system after clearing
the conditions for the alarm.
● <ALARM CANCEL> key on the PPU or <RESET> key on the MCP: cancel the user alarm
by pressing the <ALARM CANCEL> key or the <RESET> key after clearing the
conditions for the alarm.
● Auto-cancelling: the user alarm disappears automatically after clearing the conditions for
the alarm.
6.3 PLC user alarms
Configuring the properties

Each user alarm has a corresponding 8-bit parameter called "USER_DATA_PLC_ALARM":
MD14516[0] to MD14516[127]. You can configure a cancelling method and a response for
each user alarm based on your actual situation.
The parameter structure is shown as follows:
&DQFHOOLQJPHWKRG $ODUPUHVSRQVH
1&VWDUWGLVDEOHG
5HDGLQGLVDEOHG
)HHGGLVDEOHGIRUDOOD[HV
(0(5*(1&<6723
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32:(521
Note
 If both bit 7 and bit 6 are "0", the user alarm is an "auto-cancelling" alarm.
 If bits 5 to 0 are all "0", the user alarm is a "display-only" alarm.
 You can directly use the alarm response in a PLC application.
PLC user alarms list with corresponding interface addresses and MD14516
No. Alarm description Interface address MD14516

700000 - DB1600.DBX0.0 MD14516[0]
... - ... ...
700010 HHU is active DB1600.DBX1.2 MD14516[10]
700011 Not able to lock tool in expected time DB1600.DBX1.3 MD14516[11]
700012 Spindle in braking progress DB1600.DBX1.4 MD14516[12]
700013 Operation while chuck is not locked DB1600.DBX1.5 MD14516[13]
700014 Gear-change time out DB1600.DBX1.6 MD14516[14]
700015 Gear level position error DB1600.DBX1.7 MD14516[15]
700016 Drives not ready DB1600.DBX2.0 MD14516[16]
700017 Operate chuck when spindle or part program is running DB1600.DBX2.1 MD14516[17]
700018 Cooling motor overload DB1600.DBX2.2 MD14516[18]
700019 Coolant liquid position in low level DB1600.DBX2.3 MD14516[19]
700020 Lubrication motor overload DB1600.DBX2.4 MD14516[20]
6.3 PLC user alarms
No. Alarm description Interface address MD14516

700021 Lubricant liquid position in low level DB1600.DBX2.5 MD14516[21]
700022 Turret motor overload DB1600.DBX2.6 MD14516[22]
700023 Programmed tool number > max. turret on turret number DB1600.DBX2.7 MD14516[23]
700024 Max. tool number setting error DB1600.DBX3.0 MD14516[24]
700025 No position signals from turret DB1600.DBX3.1 MD14516[25]
700026 Not able to find expected tool in monitor time DB1600.DBX3.2 MD14516[26]
700027 Approach reference point again after rotation monitoring DB1600.DBX3.3 MD14516[27]
700028 Tool is not locked DB1600.DBX3.4 MD14516[28]
700029 Reminding information for 1st service plan DB1600.DBX3.5 MD14516[29]
700030 Alarm for 1st service plan DB1600.DBX3.6 MD14516[30]
700031 Magazine not in spindle position or original position DB1600.DBX3.7 MD14516[31]
700032 Magazine in spindle position and original position DB1600.DBX4.0 MD14516[32]
700033 Magazine turn key when magazine or spindle not ready DB1600.DBX4.1 MD14516[33]
700034 Block search, tool in spindle <> programmed tool DB1600.DBX4.2 MD14516[34]
700035 Spindle not reach tool-release position in time DB1600.DBX4.3 MD14516[35]
700036 Spindle not reach tool-lock position in time DB1600.DBX4.4 MD14516[36]
700037 - DB1600.DBX4.5 MD14516[37]
... - ... ...
700048 - DB1600.DBX6.0 MD14516[48]
700049 Reference point X-axis not reached DB1600.DBX6.1 MD14516[49]
700050 Reference point Z-axis not reached DB1600.DBX6.2 MD14516[50]
700051 Wrong spindle direction started DB1600.DBX6.3 MD14516[51]
700052 Watchdog timer JOG-program DB1600.DBX6.4 MD14516[52]
700053 Spindle override not 100% DB1600.DBX6.5 MD14516[53]
700054 Spindle is not started DB1600.DBX6.6 MD14516[54]
700055 Feed override = 0% DB1600.DBX6.7 MD14516[55]
700056 Change of spindle direction not possible in thread DB1600.DBX7.0 MD14516[56]
700057 - DB1600.DBX7.1 MD14516[57]
700059 Safe door not closed, NC start not possible DB1600.DBX7.3 MD14516[59]
700060 Channel not in reset, change PRT not possible DB1600.DBX7.4 MD14516[60]
... - ... ...
700127 - DB1600.DBX15.7 MD14516[127]
6.3 PLC user alarms
6.3.3 Activating the PLC user alarms

The control system provides totally 128 PLC user alarms. Each user alarm has a
corresponding NCK address. Setting "1" for an address activates its corresponding alarm,
while resetting "0" for this address clears the alarm.
Each user alarm also corresponds to a 64-bit alarm variable DB1600.DBD1000 to
DB1600.DBD1508.
Value of a variable can be inserted into the displayed alarm text according to the data type
defined by the alarm text.
Available data types for the alarm variables are shown as follows:
● %d: decimal
● %x: hex
● %b: binary
● %o: octal
● %u: unassigned integral
● %f: floating
You can insert a variable into your alarm text to display variable information. For example,
700009 "Signal of cooling start is active but the contactor KM %d does not absorb."
PLC user alarms list with corresponding interface addresses and variables
No. Alarm description Interface address Variable

700000 - DB1600.DBX0.0 DB1600.DBD1000
... - ...
700009 - DB1600.DBX1.1 DB1600.DBD1036
700010 HHU is active DB1600.DBX1.2 DB1600.DBD1040
700011 Not able to lock tool in expected time DB1600.DBX1.3 DB1600.DBD1044
700012 Spindle in braking progress DB1600.DBX1.4 DB1600.DBD1048
700013 Operation while chuck is not locked DB1600.DBX1.5 DB1600.DBD1052
700014 Gear-change time out DB1600.DBX1.6 DB1600.DBD1056
700015 Gear level position error DB1600.DBX1.7 DB1600.DBD1060
700016 Drives not ready DB1600.DBX2.0 DB1600.DBD1064
700017 Operate chuck when spindle or part program is running DB1600.DBX2.1 DB1600.DBD1068
700018 Cooling motor overload DB1600.DBX2.2 DB1600.DBD1072
700019 Coolant liquid position in low level DB1600.DBX2.3 DB1600.DBD1076
700020 Lubrication motor overload DB1600.DBX2.4 DB1600.DBD1080
700021 Lubricant liquid position in low level DB1600.DBX2.5 DB1600.DBD1084
700022 Turret motor overload DB1600.DBX2.6 DB1600.DBD1088
700023 Programmed tool number > max. turret on turret number DB1600.DBX2.7 DB1600.DBD1092
700024 Max. tool number setting error DB1600.DBX3.0 DB1600.DBD1096
700025 No position signals from turret DB1600.DBX3.1 DB1600.DBD1100
6.3 PLC user alarms
No. Alarm description Interface address Variable

700026 Not able to find expected tool in monitor time DB1600.DBX3.2 DB1600.DBD1104
700027 Approach reference point again after rotation monitoring DB1600.DBX3.3 DB1600.DBD1108
700028 Tool is not locked DB1600.DBX3.4 DB1600.DBD1112
700029 Reminding information for 1st service plan DB1600.DBX3.5 DB1600.DBD1116
700030 Alarm for 1st service plan DB1600.DBX3.6 DB1600.DBD1120
700031 Magazine not in spindle position or original position DB1600.DBX3.7 DB1600.DBD1124
700032 Magazine in spindle position and original position DB1600.DBX4.0 DB1600.DBD1128
700033 Magazine turn key when magazine or spindle not ready DB1600.DBX4.1 DB1600.DBD1132
700034 Block search, tool in spindle <> programmed tool DB1600.DBX4.2 DB1600.DBD1136
700035 Spindle not reach tool-release position in time DB1600.DBX4.3 DB1600.DBD1400
700036 Spindle not reach tool-lock position in time DB1600.DBX4.4 DB1600.DBD1144
700037 - DB1600.DBX4.5 DB1600.DBD1148
... - ... ...
700048 - DB1600.DBX6.0 DB1600.DBD1192
700049 Reference point X-axis not reached DB1600.DBX6.1 DB1600.DBD1196
700050 Reference point Z-axis not reached DB1600.DBX6.2 DB1600.DBD1200
700051 Wrong spindle direction started DB1600.DBX6.3 DB1600.DBD1204
700052 Watchdog timer JOG-program DB1600.DBX6.4 DB1600.DBD1208
700053 Spindle override not 100% DB1600.DBX6.5 DB1600.DBD1212
700054 Spindle is not started DB1600.DBX6.6 DB1600.DBD1216
700055 Feed override = 0% DB1600.DBX6.7 DB1600.DBD1220
700056 Change of spindle direction not possible in thread DB1600.DBX7.0 DB1600.DBD1224
700057 - DB1600.DBX7.1 DB1600.DBD1228
700059 Safe door not closed, NC start not possible DB1600.DBX7.3 DB1600.DBD1236
700060 Channel not in reset, change PRT not possible DB1600.DBX7.4 DB1600.DBD1240
... - ...
700127 - DB1600.DBX15.7 DB1600.DBD1508
Note
For more information about NC-PLC interfaces, refer to the SINUMERIK 808D Parameter
Manual.
6.3 PLC user alarms
6.3.4 Editing a PLC user alarm text

For the SINUMERIK 808D control system, you have two methods to edit a PLC user alarm
text:
● the HMI
● a USB stick
Editing a PLC user alarm with the HMI

To edit a PLC user alarm text with the HMI, proceed as follows:
1. In the "SYSTEM" operating area (press key combination: + ), press the

"PLC" softkey.
2. Press the "Edit PLC alarm text" softkey.
3. Use the up/down arrow key to locate your target alarm text:
4. Press the "Edit text" softkey, and input the text you want to define:
5. Press the "OK" softkey to confirm your entry.
6.3 PLC user alarms
Note
You can create the alarm text either in English or in simplified Chinese.
Note
If you want to create an alarm text in Chinese, you must first change the system language
to simplified Chinese ("SYSTEM" operating area > "Change language"), and then call the
simplified Chinese with the key combination ALT + S when typing in your text.
Editing a PLC user alarm with a USB stick

To edit a PLC user alarm text with a USB stick, proceed as follows:
1. Insert the USB stick into the USB interface at the front of the PPU.
2. In the "SYSTEM" operating area (press key combination: : + ), press

softkeys "Sys. data" > "808D data", and enter the folder "HMI data" using the <INPUT>
key.
3. Select the file "PLC alarm texts (alcu....txt)", press the <INPUT> key and select a file for a
specific language. Press the "Copy" vertical softkey:
4. Press the "USB" horizontal softkey and press the "Paste" vertical softkey.
5. Remove the USB stick and insert it into the PC USB interface.
6. Find the downloaded PLC alarm text file.
By default, the alrm text file in English is named "alcu_eng":
7. Open the alarm text file with Wordpad, and you can view the PLC alarm text list.
6.3 PLC user alarms
8. Find the alarm text you want to edit and type in your own text.
In this example, text for PLC alarm 700048 is changed to "For test":
9. After editing the necessary alarm text, close it by saving.

10.Remove the USB stick from your PC and insert it into the USB interface at the front of the
PPU again.
11.In the "SYSTEM" operating area, press the "USB" softkey. Locate the modified PLC
alarm text and press the "Copy" vertical softkey:
12.Press the "808D data" horizontal softkey, enter directory "HMI data" > "PLC alarm texts
(alcu....txt)" by pressing the <INPUT> key twice.
13.Press the "Paste" vertical softkey to replace existing PLC alarm text file.
The HMI will restart to apply the change to the PLC alarm text file (alcu....txt).
14.After the HMI restart, return to the "SYSTEM" operating area, and press softkeys "PLC" >
"Edit PLC alarm text".
Now you can view the results of what you have edited:
6.3 PLC user alarms
6.3 PLC user alarms
Commissioning the prototype 7
7.1 Commissioning the controller
7.1.1 Entering machine data
Note
Make sure that the current access level is "Manufacturer".
The most important machine data of the individual subareas are listed here to assist you.
You can find a detailed description of the machine data and interface signals in the
Parameter Manual with cross-references to the section on function description.
Entering the machine data (MD)

Use the relevant softkeys to select the following machine data areas and to change the
machine data if necessary:
● Basic list ("SYSTEM" operating areas -> "Mach. data" -> "Basic list")
– Basic machine data
● Expert list ("SYSTEM" operating areas -> "Mach. data" -> "Expert list")
– General machine data
– Axis machine data
– Channel machine data
– Display machine data
Activating conditions
The control system has defined four activating conditions. Each machine has a
corresponding activating condition:
● PO: Power On (activate by powering on)
● RE: Reset (activate by pressing the "RESET" key)
● CF: Config (activate by pressing the "Activate" vertical softkey)
● IM: Immediate (activated immediately after your change)
Note
The activating condition for a machine data is shown at the end of the data line in the
parameter lists. For information about basic machine data, refer to the section "Basic
machine data (Page 91)"; for information about all the machine data, refer to the
SINUMERIK 808D Parameter Manual.
Commissioning the prototype
7.1.2 Setting the axis-relevant parameters
7.1.2.1 Enabling the position control

By default, each axis is a simulation axis. This means that the control system neither
produces an instruction that is output to the drive, nor reads position signals from the motor.
You can enable the position control of this axis by setting the machine data shown in the
table below so that the axis goes into the operating state:
No. Name Unit Set Value Description

30130 CTRLOUT_TYPE - 2 Control setpoint output type
30240 ENC_TYPE - 3 Encoder feedback type
7.1.2.2 Setting the leadscrew pitch, deceleration ratio, and motor rotation direction
The actual moving distance depends on the parameter settings of the drive system. The
parameters are shown in the table below:
No. Name Unit Default Value Description

31030 LEADSCREW_PITCH mm 10 Leadingscrew pitch
31050 DRIVE_AX_RATIO_DEN - 1 Number of gearbox teeth at the drive end
UM [0 to 5] (denominator of the deceleration ratio)
31060 DRIVE_AX_RATIO_NOM - 1 Number of gearbox teeth at the leading
ERA [0 to 5] screw end (numerator of the deceleration
ratio)
Note
For the spindle, index [0] means that both the denominator and the numerator are inactive,
index [1] means the deceleration ratio of the first gearbox, index [2] that of the second
gearbox, and the rest may be deducted in the same way.
For the feed axes, you must set the deceleration ratio at index [0].
For the deceleration ratio of a turning machine, you must enter a same value from the index
[0] to [5] both for the denominator and the numerator; otherwise, the alarm 26050 will occur
during the machining of screw threads.
If the motion direction of this axis does not correspond with the motion direction defined by
the machine, you can modify it by setting the machine data shown in the table below:
No. Name Unit Set Value Description

32100 AX_MOTION_DIR - 1 Motor runs clockwise (factory setting)
-1 Motor runs counter-clockwise
7.1.2.3 Setting the axis speed and acceleration

You can configure the axis velocity and the acceleration by setting parameters shown in the
table below:
No. Name Unit Value Description

32000 MAX_AX_VELO mm/min * Maximum axis velocity
32010 JOG_VELO_RAPID mm/min * JOG rapid velocity
32020 JOG_VELO mm/min * JOG velocity
36200 AX_VELO_LIMIT mm/min * Axis velocity limit
Note
The value of MD36200 should be 10% higher than that of MD 32000; otherwise, alarm
025030 occurs.

32300 MAX_AX_ACCEL m/s2 * Maximum acceleration (standard value: 1
m/s2)
7.1.2.4 Setting the position-loop gain

You can configure the position loop gain by setting the parameters shown in the following
table:

32200 POSCTRL_GAIN - * Position controller gain or servo gain factor (standard
value: 1)
Note
The position-loop gain influences the position following error, so when setting this parameter,
you must make adjustments with reference to the actual position precision of the axes.
7.1.3 Setting the spindle-relevant parameters

The SINUMERIK 808D control system controls one analog spindle, and you can commission
the spindle by setting the parameters listed below:
Table 7- 1 Enabling the position control

30130 CTRLOUT_TYPE - 1 Control setpoint output type
30240 ENC_TYPE - 2 Encoder feedback type
Setting the machine spindle outputs as unipolar/bipolar setpoint output
Table 7- 2 Setting the machine spindle outputs as unipolar/bipolar setpoint output

30134 IS_UNIPOLAR_OUTPUT[0] - 0 Setpoint output is bipolar.
- 1 Setpoint output is unipolar.
2 Setpoint output is unipolar; signals from
pin 8 and pin 9 of the X21 (FAST I/O) are
used.
Note
When MD30134 = 1: X21-8 = Servo enable; X21-9 = Spindle CCW.
When MD30134 = 2: X21-8 = Servo enable, spindle CW; X21-9 = Servo enable, spindle
CCW.
For details, refer to information about connecting the inverter or servo spindle drive in the
section "Connecting according to the default PLC program (Page 20)".
If the spindle has no encoder feedback:

30200 NUM_ENCS - 0 Spindle without encoder
30350 SIMU_AX_VDI_OUTPUT - 1 Axis signals output for simulation axes
31040 ENC_IS_DIRECT - 0 Direct measuring system (no compilation
to load position)
Table 7- 3 Spindle machine data

31020 ENC_RESOL IPR 2048 Encoder pulses/steps per revolution
(encoder No.)
32000 MAX_AX_VELO mm/min * Maximum axis velocity
32260 RATED_VELO RPM 1900 Rated motor speed
36200 AX_VELO_LIMIT[0] to [5] RPM 575 Threshold value for velocity monitoring
Note
The value of MD36200 should be 10% higher than that of MD 32000; otherwise, alarm
025030 occurs.
Fill in weighted machine data

36300 ENC_FREQ_LIMIT Hz 300,000 Encoder limit frequency = Motor rated
velocity/60 x Encoder resolution
Table 7- 4 For spindle with selective gearbox

35010 GEAR_STEP_CHANGE_ENA - 0 Gear change active. Spindle has several
BLE steps
35110 GEAR_STEP_MAX_VELO[0] - * Maximum speed for gear stage change
to [5] (gear stage number): 0 to 5
35130 GEAR_STEP_MAX_VELO_LI - * Maximum speed of gear stage (gear
MIT[0] to [5] stage number): 0 to 5
36200 AX_VELO_LIMIT[0] to [5] - * Threshold value for velocity monitoring
(control parameter set number): 0 to 5
31050 DRIVE_AX_RATIO_DENUM[0] - * Denominator load gearbox (control
to [5] parameter number): 0 to 5
31060 DRIVE_AX_RATIO_NUMERA[ - * Numerator load gearbox (control
0] to [5] parameter set): 0 to 5
Note
A maximum of 5 spindle gear stages can be available. Assigning the same parameters to the
index [0] and [1] can activate gear changes (1 to 5) just by setting the corresponding
interface signals via the PLC application.
7.1.4 Approaching the reference point
Principles for approaching the reference point

● Zero mark is away from the reference cam (MD: REFP_SEARCH_MARKER_REVERS =
0)
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90
9S
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Vc Velocity for searching the reference cam (MD34020: REFP_VELO_SEARCH_CAM)

VM Velocity for searching the zero mark (MD34040: REFP_VELO_SEARCH_MARKER)
Vp Position velocity (MD34070: REFP_VELO_POS)
Rv Shift of the reference point (MD34080: REFP_MOVE_DIST + MD34090:
REFP_MOVE_DIST_CORR)
Rk Set position of the reference point (MD34100: REFP_SET_POS [0])
● Zero mark is above the reference point
5Y
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Vc Velocity for searching for the reference cam (MD34020: REFP_VELO_SEARCH_CAM)

VM Velocity for searching for the zero mark (MD34040: REFP_VELO_SEARCH_MARKER)
Vp Position velocity (MD34070: REFP_VELO_POS)
Rv Shift of the reference point (MD34080: REFP_MOVE_DIST + MD34090:
REFP_MOVE_DIST_CORR)
Rk Set position of the reference point (MD34100: REFP_SET_POS [0])
Relevant parameters

34010 REFP_CAM_DIR_IS_MINUS - 0, 1 Direction for approaching the reference point:
 0: +
 1: -
34020 REFP_VELO_SEARCH_CAM mm/min * Velocity for searching for the reference cam
34040 REFP_VELO_SEARCH_MARKER mm/min * Velocity for searching for the zero mark
34050 REFP_SEARCH_MARKER_REVERSE - 0, 1 Direction for searching for the zero mark:
 0: +
 1: -
34060 REFP_MAX_MARKER_DIST mm * Checking the maximum distance from the
reference cam
34070 REFP_VELO_POS mm/min * Positioning velocity for approaching the
reference point
34080 REFP_MOVE_DIST mm * Reference point distance (with marker)
34090 REFP_MOVE_DIST_CORR mm * Correction of reference point distance
34092 REFP_CAM_SHIFT mm * Shift of the reference cam
34093 REFP_CAM_MARKER_DIST mm * Distance between the reference cam and the
first zero mark
34100 REFP_SET_POS mm * Reference point position for incremental system
34200 ENC_REFP_MODE - 2 Referencing mode
Note
You must set the length of the reference cam based on the velocity set by MD34020. An axis
can stop above the cam after it approaches the cam at the velocity set by MD34020 and
then decelerates to "0".
Approaching the reference point

To approach the reference point, you can proceed as follows:
1. Press the REF. POINT key on the MCP to enter the "Reference point" mode;
2. Keep the direction key pressed for the axis approaching the reference point until the
symbol is displayed on the screen.
Figure 7-1 Example (turning)
You can also approach the reference point in the trigger mode: once you press the direction
key for the reference point, it will return to the reference point automatically. To do this, you
must install a reference cam in the way shown in the figure below so that the axis cannot
stop between the reference cam and hardware limit switch before it arrives at the reference
point.
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If you have defined positions of the reference cam and the hardware limit switch as shown in
the above figure, you can approach the reference point in the trigger mode by setting
MD11300:

11300 JOG_INC_MODE_LEVELTRIGGRD - 0 The trigger mode for returning to the
reference point.
Note
To modify this parameter, the access level "Manufacturer" is required.
7.1.5 Compensation parameter settings
7.1.5.1 Setting the software limit switches

You can set the software limit switches by configuring the parameters described in the
following table:

36100 POS_LIMIT_MINUS mm * - software limit switch
36110 POS_LIMIT_PLUS mm * + software limit switch
7.1.5.2 Setting backlash compensation

You can set the backlash compensation by configuring the parameter shown in the table
below:

32450 Backlash mm * Backlash compensation is active after reference
point approach.
7.1.5.3 Making leadscrew error compensation
No. Name Unit Fixed value Description

38000 MM_ENC_COMP_MAX_POINTS - 125 The max. number of intermediate
points for interpolation
compensation
Compensation theory
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Structure of the compensation arrays

$AA_ENC_COMP [0, 0, AX3] = 0.0 Error value at the lowest point
$AA_ENC_COMP [0, 1, AX3] = 0.0 Error value at the position of the lowest point + 1
... ...
$AA_ENC_COMP_STEP [0, AX3] = 0.0 Measurement distance (in mm)
$AA_ENC_COMP_MIN [0, AX3] = 0.0 The lowest point (absolute)
$AA_ENC_COMP_MAX [0, AX3] = 0.0 The highest point (absolute)
$AA_ENC_COMP_IS_MODULO [0, AX3] = 0.0 (for the turning axis)
Compensation methods
You can make the compensation as follows with a USB stick:
Method 1:
1. Plug your USB stick into the USB interface at the front of the PPU.
2. Find the compensation file ("SYSTEM" operating area > "Sys. data" > "808D data" >
"NCK/PLC data" >: Leadscrew error compensation).
3. Copy it with the "Copy" softkey.

4. Press the "USB" softkey and paste the compensation file into the USB stick by pressing
the "Paste" softkey.
5. Unplug the USB stick from the PPU, and insert it into a USB port of your PC.
6. Open the compensation file with the WordPad in the USB stick (default name:
complete.eec).
7. Move the axis to be compensated based on the pre-set minimum position, maximum
position and measurement distance.
8. Measure each error with a laser interferometer.
9. Record the error values into the compensation file, and delete the check code (for the
compensation point).
For example:
10.Re-insert the USB stick into the USB interface at the front PPU. Copy the modified
compensation file from the USB stick and paste it under the original directory ("SYSTEM"
operating area > "Sys data" > "808D data" > "NCK/PLC data": Leadscrew error
compensation) to replace the old compensation file.
11.Wait for a few seconds: replacing the old compensation file can cause a PLC restart.
12.Set MD32700 = 1 ("SYSTEM" operating area > "Mach. data"> "Basic list").
13.The compensation values are effective after returning to the reference point.
14.Move the axes in JOG mode, and you can view the actual compensation value under
"SYSTEM" operating area > "Serv. displ."> "Service axes": Abs. compens. value meas.
system 1.
Method 2:
1. Follow steps 1 to 4 in method 1.
2. Press the <PROGRAM MANAGER> key.
3. Copy the compensation file from the USB to NC
4. Press the extension softkey ">>" and change the compensation file to a program file with
the "Rename" softkey.
For example, press the "Rename" softkey >change "COMPLETE.EEC" to
"COMPLETE.MPF":
5. Press the <INPUT> key to open the program file:
6. Measure each error with a laser interferometer.

7. Record the measurement values in the COMPLETE.MPF for the corresponding axis, and
delete the check code (for the compensation point).
For example:
8. Press the "Execute" softkey. The SINUMERIK 808D enters the AUTO mode.
9. Press the <CYCLE START> key to execute COMPLETE.MPF. And the recorded
compensation values will be saved into the SINUMERIK 808D.
10.Set MD32700 = 1 ("SYSTEM" operating area > "Mach. data" > "Basic list").
11.Restart the NC ("SYSTEM" operating area > "Start-up" > NC: Standard power-up).
12.The compensation values are effective after returning to the reference point.
13.Move the axes in JOG mode, and then you can view the actual compensation value
under "SYSTEM" operating area > " Serv. displ." > "Service axes": Abs. compens. value
meas. system 1.
7.1.5.4 Setting protection levels

The SINUMERIK 808D control system has defined protection levels for user data. You can
set protection levels for the following user data:
● Tool offsets
● Zero offsets
● Setting data
● R parameters
● Part programs
● RS232 settings
● PLC projects
● Protected work areas
You can set the read/write protection for these user data by setting the following display
machine data ("SYSTEM" operating area > "Mach. data" > "Expert list" > "Display MD"):
No. Name Value Description

207 USER_CLASS_READ_TOA 3 to 7 Protection level: read, for tool offsets
208 USER_CLASS_WRITE_TOA_GEO 3 to 7 Protection level: write, for tool
geometry
209 USER_CLASS_WRITE_TOA_WEAR 3 to 7 Protection level: write, for tool wear
data
210 USER_CLASS_WRITE_ZOA 3 to 7 Protection level: write, for zero offsets
212 USER_CLASS_WRITE_SEA 3 to 7 Protection level: write, for setting data
213 USER_CLASS_READ_PROGRAM 3 to 7 Protection level: read, for part
programs
214 USER_CLASS_WRITE_PROGRAM 3 to 7 Protection level: write, for part
programs
215 USER_CLASS_SELECT_PROGRAM 3 to 7 Protection level: select, for part
programs
218 USER_CLASS_WRITE_PRA 3 to 7 Protection level: write, for R
parameters
7.2 Data backup
No. Name Value Description

219 USER_CLASS_SET_V24 3 to 7 Protection level: set, for RS232
settings
221 USER_CLASS_DIR_ACCESS 3 to 7 Protection level: directory access
222 USER_CLASS_PLC_ACCESS 3 to 7 Protection level: PLC project access
223 USER_CLASS_WRITE_PWA 3 to 7 Protection level: protected work area
access
User data with protection level 3 can be read or written with access level "Customer" or
higher.
User data with protection level 4 can be read or written only when the PLC address
DB2600.DBX0.7 is set to "1".
User data with protection level 7 can be read or written without any password or PLC
interface signal.
For detailed information about the PLC user interface, refer to the section "PLC user
interfaces (Page 104)".
7.2 Data backup
7.2.1 Creating a series archive

After commissioning the prototype, you must create a series archive for series production.
The series archive file includes the following data:
● Machine and setting data
● PLC data (for example, PLC program and PLC alarm texts)
● User cycles and part programs
● Tool and work offset data
● R variables
● HMI data (for example, OEM Online Help and OEM Manual)
You can back up the production archive in two ways:
● Internal: on the CNC controller
● External: on a USB stick
7.2 Data backup
To create a series archive, proceed as follows:
1. In the "SYSTEM" operating area (key combination: + ), press the "Archv."

softkey.
2. Select the option of "Create series start-up archive" and press the "OK" softkey:
You must select a back-up path from the list to store the production archive file:
– OEM files: folder on the CNC controller for storing OEM files
– User files: folder on the CNC controller for storing end-user files
– USB: USB stick
The default name of the data archive is "arc_product.arc". You can use your favourite
name for it.
3. Press the <INPUT> key to enter selected directory and press the "OK" softkey to
proceed:
In the "Archive information" box that follows, you can enter the following information:
– Archive creator
– Archive version
– Comment
4. Press the "OK" softkey to create the data archive.
Note
Do not remove the USB stick during the data back-up.
7.2 Data backup
7.2.2 Creating a start-up archive for the prototype

After commissioning the prototype, you must also create a start-up archive for the data
backup of the prototype itself.
The start-up archive file includes the following data:
● Compensation data
● R variables
You can also back up the start-up archive in two ways:
● Internal: on the CNC controller
● External: on an USB stick
To create a start-up archive, proceed as follows:

softkey.
2. Select the option "Create start-up archive":
Press the "OK" softkey and the following window opens:

The default name of the data archive is "arc_startup.arc". You can use your own name for
it.
7.2 Data backup
3. Select the target directory and press the <INPUT> key to enter the directory and press
the "OK" softkey to proceed:
In the "Archive information" box that follows, you can enter the information below:
– Archive creator
– Archive version
– Comment
Note
Do not remove the USB stick during the data back-up.
7.2.3 Restoring the control system with the start-up archive file
You can, if necessary, restore the system of the prototype machine by uploading the start-up
archive file.
To upload the start-up archive, perform the following operations:
1. In the "SYSTEM" operating area, press the "Archv." softkey.
2. Select the option "Restore start-up archive":
Press the "OK" softkey:
7.2 Data backup
3. Find the backed-up path and press the <INPUT> key to enter the directory. Select the
backed-up data archive and press the "OK" softkey:
4. Check the archive information and press the "OK" softkey to proceed if the selected data
archive is correct:
5. Press "OK" to confirm the warning information:
6. Now the upload starts:
It will take you several minutes to complete the upload.

7. The CNC controller restarts after successfully uploading the start-up archive.
Note
Since the system restoring can delete the password, you must input your password again
when the CNC controller restarts.
Series production
Series production 8
8.1 Uploading the series archive for series commissioning
You can use the production archive to do series commissioning for series production. The
series archive is created during the commissioning of the prototype. For details about the
creating of the production archive, refer to the section "Creating a series archive (Page 69)".
You must upload the production archive to the CNC controllers for series commissioning. To
upload the production archive, proceed as follows:
1. In the "SYSTEM" operating area, press the "Archv." softkey.
2. Select the option "Restore start-up archive":
Press the "OK" softkey:
3. Find the back-up path and press the <INPUT> key to enter the directory. Select the
backed-up data archive and press the "OK" softkey:
4. Check the archive information and press the "OK" softkey to proceed if the selected data
archive is correct:
Series production
8.2 Data settings for individual machine
5. Press "OK" to confirm the warning information:
6. Now the upload begins:
It will take you several minutes to complete the upload.

7. The CNC controller restarts after successfully uploading the production archive.
Note
Successfully uploading the data archive can delete the password. You must set the
password again in the "SYSTEM" operating area.
8.2 Data settings for individual machine
8.2.1 Setting the software limit switches

Refer to the section "Setting the software limit switches (Page 64)".
8.2.2 Setting the backlash

Refer to the section "Setting backlash compensation (Page 65)".
8.2.3 Making leadscrew error compensation

Refer to the section "Making leadscrew error compensation (Page 65)".
Series production
8.3 Data backup
8.3 Data backup
8.3.1 Overview
After the series production, you can do the data backup of individual machine for delivery in
two ways:
● Creating an original status archive: data backup only on the CNC controller
● Creating a start-up archive: data backup either on the CNC controller or on an external
USB stick
The original status archive and the start-up archive contain exactly the same data:
● Compensation data
● R-parameter
8.3.2 Creating an original status archive

To create an original status archive, proceed as follows:

softkey.
2. Select the option of "Create start-up archive in the default directory" and press the "OK"
softkey:
Series production
8.3 Data backup
3. In the "Archive information" box that follows, you can enter the information below:
– Archive creator
– Archive version
– Comment
8.3.3 Creating the start-up archive

When creating the start-up archive for the series production, follow exactly the same
procedures used to create the start-up archive for the prototype. Refer to the section
"Creating a start-up archive for the prototype (Page 71)" for details.
8.3.4 Restoring the control system

You can, if necessary, restore the control system either with the original status archive or
with the start-up archive.
Restore the control system with the original status archive

Proceed as follows to restore the CNC controller with the original status archive:

softkey.
2. Select the option "Restore start-up archive from the default directory", and press the "OK"
softkey:
Series production
8.3 Data backup
Note: The option "Restore start-up archive from the default directory" is displayed only
when you have created the original status archive.
3. Check the archive information and press the "OK" softkey to proceed; otherwise, press
the "Cancel" softkey to cancel the restore operation.
4. Press the "OK" softkey to confirm the warning information and the system restoring
begins:
5. Wait until the CNC controller restarts and the control system has been successfully
restored.
Note
Since the system restoring can delete the password, you must input your password again
when the CNC controllers restarts.
Restore the control system with the start-up archive

When restoring the control system with a start-up archive, you can follow exactly the same
procedures used to restore the prototype machine. For details, refer to the section "Restoring
the control system with the start-up archive file (Page 72)".
Other frequently used functions
Other frequently used functions 9

9.1 Playing a slide show
The SINUMERIK 808D has a function of playing a slide show. You can create a slide show
to display your product information.
Playing a slide show

You can press the key combination <CTRL> + <D> on the PPU to show a slide show and
press the key combination again to exit the slide show.
Creating a slide show

By default, the slide show of Siemens product information is provided. You can create the
desired slide show as follows:
1. Prepare your own slides and save them in the respective language folders on a USB
stick. Name each folder according to the following convention.
Chinese: folder name = "chs";
English: folder name = "eng";
Portuguese: folder name = "ptb";
Russian: folder name = "rus".
The SINUMERIK 808D supports two kinds of image formats:
– *.png
– *.bmp
Image size is recommended to be 640*480 pixels for the best display effect.
Name each slide according to the following syntax:
– slide%u.png or
– slide%u.bmp
Here "%u" is the number sequence starting with "1". For example, slide1.png, slide2.png,
slide3.png ...
If your slides include both PNG-format images and BMP-format images, then number
them separately. During the slide show, the PNG-format images will have a higher priority
over the BMP-format images.
9.1 Playing a slide show
3. In the "SYSTEM" operating area, press softkey "Sys. data" > "USB". Select all the
language folders for slide show by using the <Mark all> softkey or you can select the
desired language folder by moving the cursor up and down, and then press the "Copy"
softkey:
4. Press the "808D data" softkey. Enter directory "HMI data" > "OEM slideshow (*.bmp;
*.png)" by pressing the <INPUT> key twice.Press the "Paste" softkey:
5. Press the key combination <CTRL> + <D>, and now you can view the slideshow you
have created.
Note
Using MD9001 TIME_BTWEEN_SLIDES ("SYSTEM" operating area >"Mach. Data" >
"Expert list" > "Display MD") you can set the time between slides.
Press the key combination <CTRL> + <D> again to exit the slide show.
9.2 Defining the service planner

The SINUMERIK 808D has the service planning function. With this function, you can specify
the service timer and define your own service information. This section shows you how to
define the OEM service planner.
Creating a new service task

To create a new service task, perform the following steps:
1. Enter the desired operating area.
+
2. Enter the main screen of service planning.
3. Create a new task. Enter values in the respective fields.
4. Confirm the above input to complete creating the new task.
Viewing the service task

To edit the created service task, proceed as follows:
+
2. Enter the main screen of HMI data.
3. Enter the folder related to HMI data.
4. Navigate to the last folder.
5. Press this key to open the folder.
6. Copy the desired service planner text.
7. Press this softkey to enter the screen form of user cycle.
8. Press this softkey to paste the copied text into the screen form of user
cycle.
9. Press this softkey to view the service task.
Editing the service task
+
2. Enter the main screen of service planning.
3. Press this softkey to enter the screen form of task change.
4. Change the task description in the following box as desired.
4. Confirm the above input to complete changing the task.
9.3 Using the OEM startup screen and the OEM machine logo
The SINUMERIK 808D uses the SIEMENS start-up screen and machine logo by default. If
necessary, you can use you own start-up screen and machine logo.
Using the OEM startup screen

The default start-up screen is shown below:
To change it to your own start-up screen, proceed as follows:

1. Prepare the image of the start-up screen and save it on a USB stick.
The SINUMERIK 808D supports a start-up screen in the BMP format and with a
maximum size of 640*480 pixels (W*H).
Name the image as "startup.bmp".
3. Press softkeys "Sys. data" > "USB" in the "SYSTEM" operating area. Find the start-up
screen file and copy it with the "Copy" softkey.
4. Press the "808D data" softkey. Press the <INPUT> key to enter "HMI data" >
"Customized bitmaps".
The default start-up screen and machine logo are placed under the "Customized bitmaps"
folder:
– OEM machine logo (mtbico.bmp)
– OEM start-up splash screen (startup.bmp)
Press the "Paste" softkey to replace the default startup screen with your own start-up
screen.
5. Press Ctrl + R to restart the HMI. You can view your own start-up screen in the process of
control system start-up.
Note
To restore the default start-up screen, delete the customized bitmap file (startup.bmp)
from the control system.
Using the OEM machine logo

Machine logo can be displayed in the "Machine" operating area. The default machine logo is
displayed as follows:
To use your own machine logo, proceed as follows:

1. Prepare your own machine logo and save it on a USB stick.
The SINUMERIK 808D supports the OEM machine logo in the BMP format with a
maximum size of 124*19 pixels (W*H).
Name the image as "mtbico.bmp".
Note that a machine logo with the size of 124*19 pixels can make the best effect.
3. Press softkeys "Sys. data" > "USB" in the "SYSTEM" operating area. Find the machine
logo and copy it with the "Copy" softkey:
4. Press the "808D data" softkey. Press the <INPUT> key to enter "HMI data" >
"Customized bitmaps".
The default startup screen and machine logo are placed under the "Customized bitmaps"
folder:
– OEM machine logo (mtbico.bmp)
– OEM start-up splash screen (startup.bmp)
Press the "Paste" softkey to replace the default machine with your own machine logo.
5. Press Ctrl + R to restart the HMI. You can view your own machine logo in the "Machine"
operating area.
Note
To restore the default "SIEMENS" logo display, delete the customized bitmap file
(mtbico.bmp) from the control system.
Appendix A
A.1 Cutting reserved holes
On the MCP, three reserved holes with a standard diameter of 16 mm are available for you
to install necessary devices according to your own needs:
5HVHUYHGKROHV
Figure A-1 Reserved holes
To cut a reserved hole, proceed as follows:
1 3ULVHWKHSODVWLFULQJZLWKDVORWWHGVFUHZGULYHURUFXWLWRIIZLWKDGLDJRQDOFXWWLQJQLSSHUV
RU
&XWWKHILOPRIIZLWKDSDSHUNQLIH,WLVUHFRPPHQGHGWRFXWWKHFHQWHUILUVWO\WKHQFXWWKHILOPRIIULJKW
2 DURXQGWKHKROHHGJH
3DSHUNQLIH
Figure A-2 Cutting reserved holes
Appendix
A.2 Inserting, printing or cutting the MCP strips
A.2 Inserting, printing or cutting the MCP strips
Inserting the MCP strips

The MCP strips for the SINUMERIK 808D (Turning) are already pre-assembled into the
MCP. If you are using the control system of Milling version, you need to take these pre-
assembled strips out firstly, and then insert the MCP strips for the Milling version into the
MCP by yourself.
To insert the MCP strips, follow the order shown as follows with reference to the marks (M1
to M6, T1 to T6) on the strips:
7 0 7 0 7 0 7 0 7 0 7 0
Printing customized MCP strips

Siemens provides you a symbol library for customized MCP keys. You can print customized
strips with the A4-size blank paper included in the delivered MCP package. You can find the
symbol library in the Toolbox (...\04040000\examples\MCP).
Siemens also provides you with a template file for printing customized strips. Key positions in
the template accord with real key layout on the MCP. You can copy symbols from the symbol
library and paste them to the key positions that you want to use customized symbols. You
can find the template file in the Toolbox (...\04040000\examples\MCP).
Cutting customized MCP strips

The delivered A4-size paper has been pre-cut with boundaries. You just need to tear them
off after printing customized symbols.
Appendix
A.3 Basic knowledge about NC programming
A.3 Basic knowledge about NC programming

Theory
Table A- 1 Basic NC commands
Commands Descriptions
M3 Spindle rotates CW
M4 Spindle rotates CCW
Tn Activate or change to a new tool.
n = tool number
G00 When G00 is active in the program, the axis traverses at the maximum axis speed in
a straight line.
G01 When G01 is active in the program, the axis traverses at the programmed feedrate in
a straight line, according to the feedrate type defined by G94 (F as the feedrate in
mm/min) / G95 (F as the feedrate in rev/min of the spindle).
G02 CW circular interpolation
G03 CCW circular interpolation
Nn Block number - subblock
n = an integer at the range of 0 to 99,999,999
Programming under the MDA mode (example)
PPU: + MCP:
Figure A-3 NC programming (example)
Appendix
A.4 Selection of the transformers
References
Programming and Operating Manual (Turning)
Programming and Operating Manual (Milling)
A.4 Selection of the transformers

You can select the appropriate transformers according to the desired motor combinations.
Recommended transformer type 380 V/220 V SG series 3AC isolating servo transformer
Supply voltage 3 AC 380 / 220 V
50/60 Hz
Connection group Y/Y-12
Impedance voltage (Uk%) 4
No-load current (%) For a transformer =< 1.0 kVA, the no-load current < 18%;
For a transformer > 1.0 kVA, the no-load current < 14%.
Power selection according to possible 4 Nm ⇔ 1.0 kVA 4 Nm + 4 Nm + 10 Nm ⇔ 2.0 kVA
motor combinations 6 Nm ⇔ 1.5 kVA 4 Nm + 6 Nm + 6 Nm ⇔ 2.0 kVA
7.7 Nm ⇔ 2.0 kVA 4 Nm + 6 Nm + 7.7 Nm ⇔ 2.0 kVA
10 Nm ⇔ 2.0 kVA 4 Nm + 6 Nm + 10 Nm ⇔ 2.0 kVA
4 Nm + 4 Nm ⇔ 1.5 kVA 4 Nm + 7.7 Nm + 7.7 Nm ⇔ 2.0 kVA
4 Nm + 6 Nm ⇔ 1.5 kVA 4 Nm + 7.7 Nm + 10 Nm ⇔ 2.5 kVA
4 Nm + 7.7 Nm ⇔ 1.5 kVA 4 Nm + 10 Nm + 10 Nm ⇔ 2.5 kVA
4 Nm + 10 Nm ⇔ 2.0 kVA 6 Nm + 6 Nm + 6 Nm ⇔ 2.0 kVA
6 Nm + 6 Nm ⇔ 1.5 kVA 6 Nm + 6 Nm + 7.7 Nm ⇔ 2.0 kVA
6 Nm + 7.7 Nm ⇔ 2.0 kVA 6 Nm + 6 Nm + 10 Nm ⇔ 2.5 kVA
6 Nm + 10 Nm ⇔ 2.0 kVA 6 Nm + 7.7 Nm + 7.7 Nm ⇔ 2.5 kVA
7.7 Nm + 7.7 Nm ⇔ 2.0 kVA 6 Nm + 7.7 Nm + 10 Nm ⇔ 2.5 kVA
7.7 Nm + 10 Nm ⇔ 2.5 kVA 6 Nm + 10 Nm + 10 Nm ⇔ 3.0 kVA
10 Nm + 10 Nm ⇔ 3.0 kVA 7.7 Nm + 7.7 Nm + 7.7 Nm ⇔ 2.5 kVA
4 Nm + 4 Nm + 4 Nm ⇔ 1.5 kVA 7.7 Nm + 7.7 Nm + 10 Nm ⇔ 3.0 kVA
4 Nm + 4 Nm + 6 Nm ⇔ 1.5 kVA 7.7 Nm + 10 Nm + 10 Nm ⇔ 3.0 kVA
4 Nm + 4 Nm + 7.7 Nm ⇔ 2.0 kVA 10 Nm + 10 Nm + 10 Nm ⇔ 3.5 kVA
CAUTION
To reduce the risk of electric shock, interference from power supply and electromagnetic
field, an isolating transformer is necessary for the 3AC 380V mains system.
Appendix
A.5 Parameter list
A.5 Parameter list
A.5.1 Basic machine data
No. Name Default Range Type Unit Activating

11300 JOG_INC_MODE_LEVELTRIGGRD 1 - BOOL - PO
INC and REF in JOG mode
14510 * USER_DATA_INT[0] ... [31] 0 -62,768 to DWORD - PO
32,767
User data (INT)
14512 * USER_DATA_HEX[0] ... [31] 0H 0 to 0x0FF BYTE - PO
User data (HEX)
14514 * USER_DATA_FLOAT[0] ... [7] 0.000000 -3.4e+038 to DOUBLE - PO
3.4e+038
User data (float)
20700 REFP_NC_START_LOCK 1 - BOOL - RE
NC start disable without reference point
30350 SIMU_AX_VDI_OUTPUT FALSE - BOOL - PO
Axis signals output for simulation axes
30600 FIX_POINT_POS[0] ... [3] 0.000000 - DOUBLE mm, PO
degrees
Fixed-value positions of axis with G75
30130 CTRLOUT_TYPE 0 0 to 3 BYTE - PO
Output type of setpoint
30134 IS_UNIPOLAR_OUTPUT[0] 0 0 to 1 - - PO
Setpoint output is unipolar
30200 NUM_ENCS 1 0 to 1 BYTE - PO
Number of encoders
30240 ENC_TYPE 0 0 to 5 BYTE - PO
Encoder type of actual value sensing (actual position value)
31020 ENC_RESOL[0] 10,000 DWORD - PO
Encoder lines per revolution
31030 LEADSCREW_PITCH 10.000000 ≥0 DOUBLE mm PO
Pitch of leadscrew
31040 ENC_IS_DIRECT FALSE, - BYTE - PO
FALSE
Direct measuring system (no compilation to load position)
31050 DRIVE_AX_RATIO_DENOM[0] ... [5] 1 1 to DWORD - PO
2,147,000,000
Denominator load gearbox
Appendix
A.5 Parameter list

31060 DRIVE_AX_RATIO_NUMERA[0] ... 1 1 to DWORD - PO
[5] 2,147,000,000
Numerator load gearbox
31400 STEP_RESOL[0] 10,000 100 to 100,000 DWORD - PO
Steps per stepper motor revolution
32000 MAX_AX_VELO 10,000 - DOUB mm/min, rpm CF
(mm/min) LE
27.77 (rpm)
Maximum axis velocity
32010 JOG_VELO_RAPID 10,000 - DOUBLE mm/min, RE
(mm/min) rpm
27.77 (rpm)
Rapid traverse in JOG mode
32020 JOG_VELO 20,000 - DOUBLE mm/min, RE
(mm/min) rpm
5.55 (rpm)
Jog axis velocity
32060 POS_AX_VELO 10,000 - DOUBLE mm/min, RE
(mm/min) rpm
27.77 (rpm)
Initial setting for positioning axis velocity
32100 AX_MOTION_DIR 1 -1 to 1 DWORD - PO
Traversing direction (not control direction)
32110 ENC_FEEDBACK_POL[0] 1 -1 to 1 DWORD - PO
Sign actual value (control direction)
32200 POSCTRL_GAIN[0] ... [5] 1.000000 0.000000 to DOUBLE User CF
2000.000000 defined
Servo gain factor
32260 RATED_VELO[0] 1,900.0 - DOUBLE rpm CF
Rated motor speed
32300 MAX_AX_ACCEL[0] ... [4] [0]...[2]: 2.0 ≥ 0.001 DOUBLE mm/s2, CF
[3]...[4]: 1.0 rev/s2
Maximum axis acceleration
32450 Backlash[0] 0.0 - DOUBLE mm CF
Backlash
32700 ENC_COMP_ENABLE[0] 0 - BOOL - CF
Encoder/spindle error compensation
34000 REFP_CAM_IS_ACTIVE 1 - BOOL - RE
Axis with reference point cam
34010 REFP_CAM_DIR_IS_MINUS 0 - BOOL - RE
Approach reference point in minus direction
Appendix
A.5 Parameter list

34020 REFP_VELO_SEARCH_CAM 5,000.0 - DOUBLE mm/min, RE
(mm/min) rpm
13.88 (rpm)
Reference point approach velocity
34040 REFP_VELO_SEARCH_MARKER[0] 300.0 - DOUBLE mm/min, RE
(mm/min) rpm
0.833 (rpm)
Creep velocity
34050 REFP_SEARCH_MARKER_REVER 0 - BOOL - RE
SE[0]
Direction reversal to reference cam
34060 REFP_MAX_MARKER_DIST[]0[ 20.0 - DOUBLE mm, RE
degrees
Maximum distance to reference mark
34070 REFP_VELO_POS 10,000.00 - DOUBLE mm/min, RE
(mm/min) rpm
27.77 (rpm)
Reference point positioning velocity
34080 REFP_MOVE_DIST[0] -2.0 - DOUBLE mm, RE
degrees
Reference point distance
34090 REFP_MOVE_DIST_CORR[0] 0.0 - DOUBLE mm, RE
degrees
Reference point offset/absolute offset
34092 REFP_CAM_SHIFT 0.000000 - DOUBLE mm RE
Electronic cam offset for incremental measuring system
34093 REFP_CAM_MARKER_DIST 1.054500 - DOUBLE mm PO
Reference cam/reference mark distance
34100 REFP_SET_POS[0] ... [3] 0.0 - DOUBLE mm, RE
degrees
Reference point for incremental system
34200 ENC_REFP_MODE 1 0 to 8 BYTE - PO
Referencing mode
35010 GEAR_STEP_CHANGE_ENABLE 0 - BOOL - RE
Parameterize gear stage change
35100 * SPIND_VELO_LIMIT 10,000.0 - DOUBLE rpm PO
Maximum spindle speed
35110 GEAR_STEP_MAX_VELO[0] ... [5] [0]...[1]: 500 - DOUBLE rpm CF
[2]: 1,000
[3]: 2,000
[4]: 4,000
[5]: 8,000
Maximum speed for gear stage change
Appendix
A.5 Parameter list

35120 GEAR_STEP_MIN_VELO[0] ... [5] [0]...[1]: 50 - DOUBLE rpm CF
[2]: 400
[3]: 800
[4]: 1,500
[5]: 3,000
Minimum speed for gear stage change
35130 GEAR_STEP_MAX_VELO_LIMIT[0] [0]...[1]: 500 - DOUBLE rpm CF
... [5] [2]: 1,000
[3]: 2,000
[4]: 4,000
[5]: 8,000
Maximum speed for gear stage
35140 GEAR_STEP_MIN_VELO_LIMIT[0] ... [0]...[1]: 5 - DOUBLE rpm CF
[5] [2]: 10
[3]: 20
[4]: 40
[5]: 80
Minimum speed for gear stage
36100 POS_LIMIT_MINUS -100,000,000 - DOUBLE mm, RE
degrees
1st software limit switch minus
Access level: Manufacturer
36110 POS_LIMIT_PLUS 100,000,000 - DOUBLE mm, RE
degrees
1st software limit switch plus
36120 POS_LIMIT_MINUS2 -100,000,000 - DOUBLE mm, RE
degrees
2nd software limit switch minus
36130 POS_LIMIT_PLUS2 100,000,000 - DOUBLE mm, RE
degrees
2nd software limit switch plus
36200 AX_VELO_LIMIT[0] ... [5] 11,500 - DOUBLE mm/min, CF
(mm/min) rpm
31,944 (rpm)
Threshold value for velocity monitoring
38000 MM_ENC_COMP_MAX_POINTS 125 - DWORD - PO
Number of intermediate for interpolar compensation (SRAM)
The machine data followed by an asterisk (*) have the access level of "Customer", while those without an asterisk have the
access level of "Manufacturer".
Appendix
A.5 Parameter list
A.5.2 SINAMICS V60 parameters
Par. No. Name Range Default Increment Unit Effective

P01 Parameter write protection 0-1 0 1 - Immediately
0: Sets all parameters other than P01 as read-only parameters.
1: Sets all parameters to be both readable and writable.
P01 automatically resets to 0 after power-on!
P05 Internal enable 0-1 0 1 - Immediately
0: JOG mode can be enabled externally.
1: JOG mode can be enabled internally.
P05 automatically resets to 0 after power-on!
P16 Maximum motor current 0-100 100 1 % Power On
Specifies the maximum motor current (2 x rated motor current) of your choice.
P20 Speed loop proportional gain 0.01-5.00 Depends on drive 0.01 Nm*s/rad Immediately
version
Factory defaults:
4 Nm: 0.81; 6 Nm: 1.19; 7.7 Nm: 1.50; 10 Nm: 2.10
Note:
Default value varies with software version.
This parameter specifies the proportional gain (Kp, proportional component) of speed control loop.
The bigger the value, the higher the gain and rigidity. The setting depends on specific drive and load.
Generally, the bigger the load inertia, the bigger the value is to set. However, if there is no oscillation occurring
in the system, you can set the value as big as possible.
P21 Speed loop integral time 0.1-300.0 Depends on drive 0.1 ms Immediately
constant version
Factory defaults:
4 Nm: 17.7; 6 Nm: 17.7; 7.7 Nm: 17.7; 10 Nm: 18.0
Note:
Default value varies with software version.
This parameter specifies the integral action time (Tn, integral component) of speed control loop.
The smaller the value, the higher the gain and rigidity. The setting depends on specific drive and load.
P26 Maximum motor speed 0-2,200 2,200 20 rpm Power On
Sets the maximum possible motor speed.
P30 Position loop proportional 0.1-3.2 3.0 0.1 1,000/min Immediately
gain
1. This parameter specifies the proportional gain of position loop.
2. The bigger the value, the higher both the gain and rigidity, and at the same pulse command frequency the
smaller the position hysteresis. However, excessively high value setting may cause system oscillation or
overshooting.
3. The setting depends on specific drive and load.
P31 Position loop feedforward 0-100 85 1 % Immediately
gain
Appendix
A.5 Parameter list

1. This parameter specifies the feedforward gain of position loop.
2. Setting the value to 100 % means position hysteresis is always 0 at any pulse command frequency.
3. Increasing the feedforward gain of position loop improves the high-speed response characteristics of the
control system, but meanwhile causes the system's position loop unstable and liable to oscillation.
4. Unless very high response characteristics are necessary, set the feedforward gain of position loop to 0.
P34 Maximum following error 20-999 500 1 100 pulses Immediately
This parameter specifies the maximum possible following error. When the actual following error is larger than
the setpoint, the drive sends an over-position alarm (A43)
P36 Input pulse multiplier 1, 2, 4, 5, 1 - - Power On
8, 10, 16,
20, 100,
1,000
This parameter specifies the input pulse multiplier.
For example, when P36 = 100, input frequency = 1 kHz, output frequency = 1 kHz x 100 = 100 kHz.
Note:
Pulse frequency setpoint = Actual pulse frequency x input pulse multiplier;
This parameter is applicable only when the software version is V01.06 or later;
When P36 = 100 or 1,000, speed stability will decrease with higher multiplication factor.
P41 Brake open delay 20-2,000 100 10 ms Power On
The setpoint transfer after drive enable is delayed by this time.
Drive can be enabled under the following conditions:
A: When the following three conditions are all met:
1. Terminal 65 (external enable) has been enabled;
2. The drive has received an enable signal from NC;
3. No alarm is detected by the drive.
B: When the following two conditions are both met:
1. Terminal 65 (control enable) has been activated;
2. Motor operates in "JOG-RUN" mode (enabled from function menu )
C: When the following two conditions are both met:
1. P05 = 1 (The JOG mode can be enabled internally);
2. Motor operates in "JOG-RUN" mode (enabled from function menu )
P42 Brake close time while motor 20-2,000 100 10 ms Power On
operation
When motor speed exceeds 30 rpm, the drive generates an alarm. If, within the specified brake close time
(P42), the actual motor speed remains bigger than brake close speed setpoint (P43), brake is closed after the
specified brake close time (P42) expires.
P43 Brake close speed while 0-2,000 100 20 r/min Power on
motor operation
When motor speed exceeds 30 rpm, the drive generates an alarm. If, within the specified brake close time
(P42), the actual motor speed becomes smaller than the P43 setpoint, brake is closed when the actual speed
reaches the speed setpoint.
P44 Drive enable time after the 20-2,000 600 10 ms Power on
brake close
When motor speed is lower than 30 rpm, the drive remains enabled within the time period set by P44 after
brake close.
Appendix
A.6 Diagnostics

P46 JOG speed 0-2,000 200 10 rpm Immediately
This parameter specifies the motor speed in JOG mode.
P47 Ramp-up/-down time 0.0 – 4.0 0.1 s Power on
constant 10.0
This parameter defines the time period when the motor ramps up from 0 rpm to 2,000 rpm or ramps down from
2, 000 rpm to 0 rpm.
P99 Reserved for Siemens internal use only
A.6 Diagnostics
A.6.1 SINUMERIK 808D alarms

Some alarms may occur during the commissioning work. In the "ALARM" operating area,
you can press the <HELP> key to call the help information for an alarm. For details about it,
refer to the Diagnostics Manual.
A.6.2 SINAMICS alarms
A.6.2.1 Overview of alarms
Table A- 2 Overview of alarms
Alarm code Alarm name Description

A01 Power board ID number Unable to identify the power board
error
A02 Parameter error Parameter validation error (CRC error, encoder type or parameter header
invalid)
A03 Memory-write failure Unable to write data to memory
A04 Control voltage error Control voltage is lower than 3.5 V.
A05 IGBT overcurrent IGBT is detected overcurrent.
A06 lnternal chip overcurrent Internal chip is detected overcurrent.
A07 Grounding short circuit Grouding short circuit occurs during drive initialization
A08 Endoder UVW sginals error Signals from encoder phases U, V, W are detected all the same (all high or all
low)
A09 Encoder TTL signals error TTL pulse error
A14 Internal error Software failure
A21 DC link overvoltage DC link voltage is higher than 405 V
A22 IT protection IGBT current exceeds the upper limit for 300 ms
A23 DC link undervoltage DC link voltage is lower than 200 V
Appendix
A.6 Diagnostics
Alarm code Alarm name Description

A41 Overspeed Actual motor speed is higher than 2200 rpm
A42 IGBT overtemperature IGBT becomes overheating
A43 Over-position Position offset is out of limit
A44 I2T protection Motor load exceeds nominal motor torque
A45 Emergency stop Enable signal from Terminal 65 is lost during normal drive operation
A.6.2.2 Alarm list
Alarm Background Possible Cause Remedy Result Acknowledgement

code
A01 Power board is broken Replace the drive with a Free stop Power on
new one
A02 The memory is damaged due to Restore default Free stop Power on
unexpected power-off during parameters
data saving
A03 Memory is damaged Replace the drive with a Free stop Power on
new one
A04 The 24 V DC supply is abnormal Check the 24 V DC Free stop Power on
supply
The drive is defective Replace the drive with a
new one
A05 This alarm may 1. There is a short-circuit 1. check the wiring Free stop Power on
occur when the between terminals U, V, W 2. make a correct
DC link is and PE on the drive grounding
connected 2. bad grounding 3. replace the motor
This alarm may 3. motor insulation is broken with a new one
occur when the
motor is running 4. the drive is broken 4. replace the drive
with a new one
A06 This alarm may 1. There is a short-circuit 1. check the wiring or Free stop Power on
occur when the between terminals U, V, W whether the
DC link is and PE on the drive connection to U, V
connected 2. bad grounding or W is broken
This alarm may 3. motor insulation is broken 2. make a correct
occur when the grounding
the drive is broken
motor is running 3. replace the motor
with a new one
4. replace the drive
with a new one
A07 This alarm may 1. IGBT module is broken 1. replace the drive Free stop Power on
occur when the 2. There is a short-circuit with a new one
DC link is between U, V or W and PE 2. Check the wiring
connected
This alarm may
occur when the
motor is running
Appendix
A.6 Diagnostics

code
A08 1. UVW signals of the encoder 1. replace the encoder Free stop Power on
are bad with a new one
2. bad cable 2. check the interface
3. bad cable shielding circuit of the
encoder
4. bad wiring of the shielded
ground cable
5. there is a failure in the
interface circuit of the
encoder
A09 1. connection failure of encoder 1. check the wiring of Free stop Power on
ABZ encoder cable
2. bad cable 2. check the interface
3. bad cable shielding circuit of the
encoder
4. bad wiring of the shielded
grounded cable
5. there is a failure in the
interface circuit of the
encoder
A14 There is failure at the internal Reset by power-on Free stop Power on
software
A short-circuit occurs to the Check the wiring of
encoder encoder
A21 This alarm may There is a failure at the circuit Replace the drive with a Free stop Press Enter key on
occur when the board new one the operator panel
24 V DC supply or terminal RST of
is connected X6 interface
This alarm may 1. the mains supply voltage is Check the power supply
occur when the too high
DC link is 2. the waveform of mains
connected supply voltage is abnormal
This alarm may 1. disconnection of the internal Replace the drive with a
occur when the brake resistor new one
motor is running 2. the internal brake resistor is
broken
Brake loop has no enough 1. lower the start-stop
space frequency
2. reduce the limit
value of current
3. reduce load inertia
4. use another drive
and motor with
higher frequencies
A22 The motor is mechanically Check the mechanical Free stop Press Enter key on
blocked load the operator panel
Appendix
A.6 Diagnostics

code
Overload or terminal RST of
1. lighten the load
X6 interface
2. use another drive
and motor with
higher frequencies
A23 1. circuit board fails Replace the drive with a Free stop Press Enter key on
2. fuse of the power is burnt out new one the operator panel
or terminal RST of
3. rectifier is broken X6 interface
1. low supply voltage Check the power supply
2. insufficient supply power
capacity
3. transient power failure
A41 This alarm may Circuit board fails Replace the drive with a Emergency Press Enter key on
occur when the new one stop (the the operator panel
24 V DC supply The encoder fails Replace the motor with motor will or terminal RST of
is connected a new one stop with X6 interface
the
This alarm may The encoder fails Replace the drive with a maximum
occur when the new one energy or
motor is running The encoder cable is badly Replace the motor with torque)
connected a new one
This alarm may 1. terminals U, V and W on the Check the wiring
occur when the motor are wrongly connected
motor starts 2. the encoder is wrongly wired
running
A42 Ambient temperature is too high Check the ambient Emergency Press Enter key on
temperature stop (the the operator panel
The drive is overloaded Check the drive load motor will or terminal RST of
stop with X6 interface
Circuit board fails Replace the drive with a the
new one maximum
energy or
torque)
A43 This alarm may Circuit board fails Replace the drive with a Emergency Press Enter key on
24 V DC supply motor will or terminal RST of
is connected stop with X6 interface
The motor does 1. terminals U, V and W on the Check the wiring the
not rotate or motor is wrongly connected maximum
reversely rotate energy or
2. encoder cable is wrongly torque)
if the command connected
pulse is input
after DC-link Encoder fails Replace the motor with
and mains line a new one
are connected
This alarm may The permitted maximum Set a wider value range
occur when the position difference is too small for the detection of
motor is running position over-tolerance
(P34)
Appendix
A.6 Diagnostics

code
The position loop gain is too Give more gains
small
No enough torque Check the limit value of
current
Reduce the load
Use a drive and motor
with higher frequencies
Low speed Check the maximum
speed limitation (refer to
parameter P26)
Command pulse frequency is 1. Lower the frequency
too high 2. Check whether P36
has the right value
A44 This alarm may The circuit board fails Replace the drive with a Emergency Press Enter key on
24 V DC supply motor will or terminal RST of
is connected stop with X6 interface
This alarm may The rated torque is exceeded 1. check the load the
occur when the maximum
2. lower the start/stop energy or
DC link is frequency
connected torque)
3. use drive and motor
with more power
The brake is not open Check whether the
brake is open or not
The motor is not stable 1. modify the gain
value
2. lessen load inertia
The encoder is wrongly wired Check the wiring
A45 The 65 enable signal is lost Check the 65 enable Emergency Press Enter key on
when the motor is running terminal stop (the the operator panel
motor will or terminal RST of
stop with X6 interface
the
maximum
energy or
torque)
Note
Alarms with alarm code < A21 can be cancelled by power-on, while alarms with alarm code
≥ A21 can be cancelled by RST terminal.
Appendix
A.6 Diagnostics
A.6.2.3 Errors during drive self-test

The drive module always conducts a self-test at every power-on. If any error occurs during
this period, the drive screen form will show one of the following error codes:
Drive display Description Cause Remedy

Error 1 RAM damaged Replace the drive
Error 2 Flash damaged Replace the drive
Error 3 Program copy error Replace the drive
A.6.2.4 Other faults

1. Motor speed incorrect
– Description: The actual motor position is always wrong, and the motor speed is not
right, either.
– Cause: The pulse signal from the NC to drive is incorrect.
– Remedy: Check the pulse signal line connection
2. Brake not open
– Description: The brake is not open when the drive is in "S-Run" state.
– Cause: A short circuit has occurred in the brake cable.
– Remedy: Check brake cable connection
A.6.2.5 Display data list
Data No. Name Data format Unit Data group

D10 1) Torque setpoint Decimal Nm Current
D11 1) Actual value of the torque (See table below) Nm
D12 1) Actual value of the phase A
current
D20 Motor speed setpoint Integer RPM Speed
D21 Actual motor speed RPM
D30 Position revolution setpoint Motor revolutions Position
D31 Position angle setpoint Increments (10000/r)
D32 Actual position revolutions Motor revolutions
D33 Actual position angle Increments (10000/r)
D34 Position deviation angle Increments (10000/r)
D50 1) Digital input signal Bit (See table below) Bits in hex I/O
D51 1) Digital output signal Bits in hex
D80 1) Firmware version (See table below) HW, FW
D81 Power Board rated current Integer
D82 1) Parameter version number (See table below)
1) The data type of D10, D11, D12, D80, D82 is in all decimal format. The display value for D50 and D51 respectively
varies as the case requires.
Appendix
A.6 Diagnostics
'LVSOD\GDWDIRUPDW''DQG'
H[DPSOH
'ULYHVWDWXVGLVSOD\V '
Zero mark input

The point is lit. This point stands for the Dark
decimal number. No zero mark input
In this example, the value is “1804.1”
Pulse not enabled IGBT under-temperature
Pulse enabled IGBT over-temperature
Drive not enabled Alarm not cancelled
'LVSOD\GDWDIRUPDW' H[DPSOH Drive enabled Alarm cancelled
The point is lit. This point stands for the

decimal number. 'ULYHVWDWXVGLVSOD\V '
In this example, the value means that the
firmware version number is “01.01”.
Brake open
Dark Brake closed
'LVSOD\GDWDIRUPDW' H[DPSOH Alarm output off Power resistor off
Alarm output on Power resistor on
Drive not ready Zero mark output on
Drive ready Zero mark output off

The point is lit. This point stands for
the decimal number.
In this example, the value means that
the parameter version number is “01.01”.
Figure A-4 Special data displays (D10, D11, D12, D80, D82)
Appendix
A.7 PLC user interfaces
A.7.1 Addressing ranges
Table A- 3 Operand identifier
Address identifier Description Range

DB 1) Data DB1000 to DB7999
DB9900 to DB9906
T Times T0 to T15 (100 ms)
T16 to T63 (10 ms)
C Counters C0 to C63
I Image of digital inputs I0.0 to I8.7
Q Image of digital outputs Q0.0 to Q5.7
M Bit memory M0.0 to M255.7
SM Special bit memory SM0.0 to SM0.6 (see table below - Special
Marker SM Bit Definition)
AC ACCU AC0 to AC3
1) When programming with the PLC Programming Tool, you can switch the DBs to V Bits with the
key combination of Ctrl + B.
Structure of the DB-range address

'%'%;
%LWQXPEHU WR
2IIVHW WR
6XEUDQJH WR
5DQJHQXPEHU WR D[LVFKDQQHO
8VHUUDQJH WR
Access Example Description VB format -> DB format (example)

Bit DB3801.DBX1000.7 Bit 7 of the byte with offset 0 in V3801 1000.7-->DB3801.DBX1000.7
subrange 1 for axis 2, user range 38
Byte DB3801.DBB0 Byte with offset 0 in subrange 0 for axis, VB3801 0000-->DB3801.DBB0
user range 38
Word DB4500.DBW2 Work with offset 2 in subrange 0, range VW3801 0002-->DB3801.DBW2
0, user range 45
Double Word DB2500.DBD3004 Double word with offset 4 in subrange VD2500 4000-->DB2500.DBD4000
3, range 0, user range 25
Appendix
Note
The permitted offset for an address is dependent on the access:
 Bit or byte access: any offset.
Byte-size variables are placed one next to another seamlessly in a DB.
 Word access: the offset must be divisible by 2.
Word-size variables (2 bytes) are always saved on straight offsets.
 Double word access: the offset must be divisible by 4.
Double word-size variables (4 bytes) are always saved on offsets that are divisible by 4.
Table A- 4 Special Marker SM Bit Definition
SM bits Description
SM 0.0 Bit memory with defined ONE signal
SM 0.1 Initial setting: first PLC cycle '1', subsequent cycles '0'
SM 0.2 buffered data lost - only valid in first PLC cycle
('0' data ok, '1' data lost)
SM 0.3 POWER ON: first PLC cycle '1', subsequent cycles '0'
SM 0.4 60 s clock (alternating '0' for 30 s, then '1' for 30 s)
SM 0.5 1 s clock (alternating '0' for 0.5 s, then '1' for 0.5 s)
SM 0.6 PLC cycle clock (alternating one cycle '0', then one cycle'1')
Special bit memory SM bit definition (read-only)

Table A- 5 Variable access rights
[r] You can "read only" designated area

[r/w] You can "read and write" designated area
Table A- 6 Data format information
1 BIT
8 BYTE
16 INT/WORD
32 DINT/DWORD/REAL
Note
All the empty fields in the user interface are "reserved for Siemens" and may neither be
written to nor evaluated.
Fields designated with "0" always have the value "logical 0".
If there is no data format information, you can read or write to all the specified data formats.
Appendix
A.7.2 MCP
A.7.2.1 Signals from MCP
DB1000 From the MCP [r]

Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
MCP
DBB0 M01 PROGRAM MDA SINGLE AUTO REF. JOG Hand-wheel
TEST BLOCK POINT
MCP
DBB1 Key 16 Key 15 Key 14 Key 13 Key 12 Key 11 Key 10 ROV
MCP
DBB2 100 (INC) 10 (INC) 1 (INC) Key 21 Key 20 Key 19 Key 18 Key 17
MCP
DBB3 Key 32 Key 31 CYCLE CYCLE RESET SPINDLE SPINDLE SPINDLE
START STOP RIGHT STOP LEFT
MCP
DBB4 Key 39 Key 38 Key 37 Key 36 RAPID Key 34 Key 33
MCP
DBB5
MCP
DBB6
MCP
DBB7
Feed override value (Gray code)
DBB8
Feed override value (Gray code)
DBB9
MCP
DBB10
A.7.2.2 Signals to MCP
DB1100 To MCP [r/w]

DBB0 MCP
LED 8 LED 7 LED 6 LED 5 LED 4 LED 3 LED 2 LED 1
... ...
DBB7 MCP
LED 30 LED 29 LED 28 LED 27 LED 26 LED 25
DBB8 7 SEG LED1
... ...
DBB11 7 SEG LED4
MCP
DBB12 DP 2 DP 1
Appendix
A.7.2.3 Reading/writing NC data: Job

DB1200 Reading / writing NC data [r/w]
PLC -> NCK interface
0 Write Start
variable
1 Number of variables
DB1200 ... Reading / writing NC data [r/w]

1207 PLC -> NCK interface
1000 Variable index
1001 Area number
1002 Column index for the NCK variable x (WORD)
1003 LIne index for the NCK variable x (WORD)
1008 Writing: data to NCK variable x (data type of the variables: 1 to 4 bytes)
A.7.2.4 Reading/writing NC data: Result

DB1200 Reading / writing NC data [r]
2000 Error in job Job
completed
DB1200 ... Reading / writing NC data [r]

3000 Error has Valid
occurred variable
3001 Access result 1)
3004 Reading: data from NCK variable x (data type of the variables: 1 to 4 bytes)
1) 0: no error; 3: illegal access to object; 5: invalid address; 10: object does not exist
A.7.2.5 PI service: Job

DB1200 PI service [r/w]
4000 Start
4001 PI index
4004 PI parameter 1
4006 PI parameter 2
... ...
4022 PI parameter 10
Appendix
A.7.2.6 PI service: Result
DB1200 Reading / writing NC data [r]

5000 Error in job Job
completed
5001
5002
A.7.3 Retentative data area

DB1400 Retentative data [r/w]
User data
0
...
127
A.7.4 User Alarms
A.7.4.1 User alarms: Activating
DB1600 Activating alarm [r/w]

PLC -> HMI interface
0 Activation of alarm no.
700007 700006 700005 700004 700003 700002 700001 700000
... ...
15 Activation of alarm no.
700127 700126 700125 700124 700123 700122 700121 700120
A.7.4.2 Variables for user alarms
DB1600 Variables for user alarms [r32/w32]

DBD1000 Variable for alarm 700000
… …
Appendix
A.7.4.3 Active alarm response

DB1600 Active alarm response [r]
2000 Acknowledge Acknowledge PLC STOP EMERGENCY Feedrate Read-in NC start
POWER ON with STOP disable all disable disable
DB1600DBX3 axes
000.0
A.7.4.4 Acknowledgement of alarms

DB1600 Alarm acknowledgement [r/w]
3000 Ack
A.7.5 Axis/spindle signals
A.7.5.1 Transferred M and S functions, axis specific

DB3700 … 3703 M, S functions [r]
NCK -> PLC interface
0 M function for spindle (DINT)
4 S function for spindle (REAL)
A.7.5.2 Signals to axis/spindle
Common signals to axis/spindle

DB3800 ... Signals to axis/spindle [r/w]
0 Feedrate override
H G F E D C B A
1 Override Position Position Follow up Axis spindle
active measuring measuring mode disable
system 2 system 1
2 Reference point value Clamping in Distance- Controller
4 3 2 1 progress to- enable
go/spindle
reset
3 Axis/spindle Velocity/spi Activate fixed feedrate Enable
Appendix
enable ndle speed Feed 4 Feed 3 Feed 2 Feed 1 approach to

program limiting fixed stop
test
4 Traversing keys Rapid Traverse Feedrate Activate handwheel
Plus Minus traverse key disable stop/spindle 2 1
override stop
5 Machine function 1)
Continuous Var. INC 1000 INC 1000 INC 100 INC 10 INC 1 INC
traversing
7 Contour-
handwheel
direction of
rotation
inverted
9 Parameter set, servo
C B A
1) The machine function is only entered if the signal "INC inputs in the operating-mode signal range active"
(DB2600.DBX1.0) is set.
Signals to axis
DB3800 ... Signals to axis [r/w]
1000 Delay Ref. Module limit Software limit switch Hardware limit switch
pt. enabled Plus Minus Plus Minus
approach
1002 Activate Suppress
program program
test test
Signals to spindle
DB3800 ... Signals to axis [r/w]
2000 Delete S No speed Resynchronize spindle Gear Actual gear stage
value monitoring 2 1 changed C B A
for gear
change
2001 Invert Resynchron Feedrate
M3/M4 ize during override for
positioning spindle
valid
2002 Setpoint direction of Oscillation Oscillation
rotation speed controlled
Counter- Clockwise by PLC
clockwise
2003 Spindle override
H G F E D C B A
Appendix
Signals to drive
4000 Holding
brake
4001 Pulse Integrator Motor
enable disable selected
speed
controller
Signals to technology functions

5000 Torque
equalization
controller
on
5003
5005
5006 Spindle Automatic Setpoint direction of Spindle
(spindle) positioning gear stage rotation stop
change Counter- Clockwise
clockwise
A.7.5.3 Signals from axis/spindle
General signals from axis/spindle

DB3900 ... Signals from axis/spindle [r]
3903 NCK -> PLC interface
0 Position reached Referenced Encoder limit freq. Spindle/no
exceeded axis
With exact/ With exact Synchroniz Synchroniz 2 1
stop, fine stop, ed 2 ed 1
coarse
1 Current Speed Position Axis/spindle Follow up Axis ready Traversing
controller controller controller stationary mode for requests
active active active (n < nmm) active operation
2 Force fixed Fixed stop Activate Measureme Handwheel
stop limited reached travel to nt active override
fixed stop active
3 AxStop
active
Appendix
4 Travel command Travel request Handwheel active (bit/binary coded)

Plus Minus Plus Minus 2 1
5 Active machine function
7 Contour-
handwheel
direction of
rotation
inverted
9 Parameter set, servo
C B A
11 PLC axis, POS_RESTO
permanentl RED 2 RED 1
y assigned
Signals from axis

DB3900 ... Signals from axis [r]
1000 Module limit
enabled
active
1001
1002 Rotary axis Indexing Positioning Path axis Lubrication
in position axis in axis pulse
position
1003
Signals from spindle

DB3900 ... Signals from spindle [r]
2000 Change Setpoint gear stage
gear stage C B A
2001 Actual Speed Spindle in Overlay Setpoint Speed limit
direction of monitoring setpoint range limit Increased Limited exceeded
rotation, range violated
clockwise
2002 Active spindle mode Rigid GWPS Const.
Control Oscillation Positioning tapping active cutting
mode mode mode velocity
active
2003 Spindle in Tool with
position dynamic
reach limiting
Appendix
Signals from drive

4000 Holding RLI active
brake
opened
4001 Pulse Speed Drive ready
enabled controller
integrator
disabled
4002 nact = nset nact < nx nact < nmin Md < Mdx Ramp-up
completed
4003 Generator VDClink <
operation, alarm
minimum threshold
speed
fallen below
Signals from technology functions

5000
5002 Acceleratio Velocity Superimpos Actual Synchronous operation
n warning warning ed motion value Coarse Fine
threshold threshold coupling
reached reached
5003 Max. Max. Synchroniz Axis is Synchronis
acceleratio velocity ation in acceleratin m override
n reached reached progress g travel
5007 Synchronis
m override
is factored
in
5008 Active special axis
(grinding) Axis 6 Axis 5 Axis 4 Axis 3 Axis 2 Axis 1
Appendix
A.7.6 PLC machine data
A.7.6.1 INT values (MD 14510 USER_DATA_INT)
DB4500 Signals from NCK [r16]

0 Int value (WORD/2 byte)
...
62
A.7.6.2 HEX values (MD 14512 USER_DATA_HEX)

1000 Hex value (BYTE)
...
1031
A.7.6.3 FLOAT values (MD 14514 USER_DATA_FLOAT)

2000 Float value (REAL/4 byte)
...
2028
A.7.6.4 User alarm: Configuring (MD 14516 USER_DATA_PLC_ALARM)

3000 Alarm response/cancel criteria, alarm 700000
... ...
3247 Alarm response/cancel criteria, alarm 700247
Note
You can refer to the Diagnostics Manual for the information about how to configure the user
alarms.
Appendix
A.7.7 Signals from/to HMI
A.7.7.1 Program control signals from the HMI (retentive area) (also refer to signals at channel
DB3200)
DB1700 Signals, HMI [r/w]

HMI -> PLC interface
0 Dry run M01 DRF
feedrate selected selected
selected
1 Program Feedrate
test override
selected selected for
rapid
traverse
2 Skip block
selected
3 Measurmen Calculation
t in JOG of
active measureme
nt value not
finished
7 Reset NC stop NC start
A.7.7.2 Program selection from PLC (retentive area)
DB1700 Program selection [r/w]

1000 Program selection from the PLC: Program number
1001 Command job from the PLC: Command
1002
1003
Appendix
A.7.7.3 Checkback signal: Program selection from HMI (retentive area)
DB1700 Program selection [r]

2000 Error Program
program selected
selection
2001 Error Execute
command command
execution
2002
2003
A.7.7.4 Signals from HMI
DB1800 Signals from HMI [r]

HMI -> PLC interface (signals are only present for PLC cycle)
0 Reset Start JOG Mode MDI AUTOMATI
measureme C
nt in JOG
1 Current machine function
REF
A.7.7.5 Signals from PLC
DB1800 Signals from PLC [r]

1000 Commissio Boot with Boot with
ning saved data default
archive has values
been read
in
1004 PLC cycle in μs [DINT]
1008 Year: Tens digit, BCD Year: Units digit, BCD
1009 Month: Tens digit, BCD Month: Units digit, BCD
1010 Day: Tens digit, BCD Day: Units digit, BCD
1011 Hour: Tens digit, BCD Hour: Units digit, BCD
1012 Minute: Tens digit, BCD Minute: Units digit, BCD
1013 Second: Tens digit, BCD Second: Units digit, BCD
1014 Millisecond: Hundreds digit, BCD Millisecond: Tens digit, BCD
1015 Millisecond: Units digit, BCD Weekday, BCD {1, 2, ... 7} (1 = Sunday)
Appendix
A.7.7.6 Signals to maintenance planners
DB1800 Deactivation [r/w]

2000 Deactivatio Deactivatio Deactivatio Deactivatio Deactivatio Deactivatio Deactivatio Deactivatio
n8 n7 n6 n5 n4 n3 n2 n1
... ...
2003 Deactivatio Deactivatio Deactivatio Deactivatio Deactivatio Deactivatio Deactivatio Deactivatio
n 32 n 31 n 30 n 29 n 28 n 27 n 26 n 25

4000 Acknowled Acknowled Acknowled Acknowled Acknowled Acknowled Acknowled Acknowled
gement 8 gement 7 gement 6 gement 5 gement 4 gement 3 gement 2 gement 1
... ...

... ...
A.7.7.7 Signals from maintenance planners
DB1800 Warnings/Alarms [r]

3000 Alarm 8 Alarm 7 Alarm 6 Alarm 5 Alarm 4 Alarm 3 Alarm 2 Alarm 1
... ...
3003 Alarm 32 Alarm 31 Alarm 30 Alarm 29 Alarm 28 Alarm 27 Alarm 26 Alarm 25
Appendix
A.7.7.8 Signals from operator panel (retentive area)
DB1900 Signals from operator panel [r/w]

0 Switch over Simulation
Machine/W active
orkpiece
A.7.7.9 General selection/status signals from HMI (retentive area)
DB1900 Signals from HMI [r]

1003 Axis number for handwheel 1
Machine Handwheel Contour C B A
axis selected handwheel
1004 Axis number for handwheel 2
Machine Handwheel Contour C B A
axis selected handwheel
A.7.7.10 General selection/status signals to HMI (retentive area)
DB1900 Signals to HMI [r/w]

5000 OP key
block
5002 Enable
measureme
nt in JOG
5004 ... T-number for tool measurement in JOG (DINT)
5007
5008 ...
5011
5012 ...
5015
5016 ...
5019
Appendix
A.7.8 Auxiliary functions transfer from NC channel
A.7.8.1 Overview
DB2500 Auxiliary functions from the NCK channel [r]

4 M fct. 5 M fct. 4 M fct. 3 M fct. 2 M fct. 1
change change change change change
6 S fct. 1
change
8 T fct. 1
change
10 D fct. 1
change
12 H fct. 3 H fct. 2 H fct. 1
change change change
A.7.8.2 Decoded M signals (M0 to M99)
Note
The signals are output for the duration of a PLC cycle.
DB2500 M functions from NCK channel [r] 1) 2)

1000 Dynamic M functions
M7 M6 M5 M4 M3 M2 M1 M0
… ...
1012 Dynamic M functions

M99 M98 M97 M96
1) As the PLC user, you must generate basic functions yourself from the dynamic M functions.
2) The basic program decodes dynamic M functions (M0 to M99).
A.7.8.3 Transferred T functions
DB2500 T functions from NCK channel [r]

2000 T function 1 (DINT)
Appendix
A.7.8.4 Transferred M functions

DB2500 M functions from NCK channel [r]
3000 M function 1 (DINT)
3004 Extended address M function 1 (byte)
A.7.8.5 Transferred S functions

DB2500 S functions from NCK channel [r]
4000 S function 1 (REAL) (DINT)
4004 Extended address S function 1 (byte)
4008 S function 2 (REAL)
4012 Extended address S function 2 (byte)
A.7.8.6 Transferred D functions

DB2500 D functions from NCK channel [r]
5000 D function 1 (DINT)
A.7.8.7 Transferred H functions

DB2500 H functions from NCK channel [r]
6000 H function 1 (REAL) (DINT)
6004 Extended address H function 1 (byte)
6008 H function 2 (REAL)
6016 H function 3 (REAL)
Appendix
A.7.9 NCK signals
A.7.9.1 General signals to NCK
DB2600 General signals to NCK [r/w]

0 Protection level Acknowled Acknowled Braking
Keyswitch position 0 to 3 ge ge along the
EMERGEN EMERGEN contour in
4 5 6 7 CY STOP CY STOP case of
EMERGEN
CY STOP
1 Request Request INC inputs
axis axis actual in mode
distances to values signal
go range
active 1)
1) Refer to mode signals
A.7.9.2 General signals from NCK
DB2700 General signals from NCK [r/w]

0 EMERGEN
CY OFF
active
1 Inch Probe actuated
measuring Probe 2 Probe 1
system
2 NC ready Drive ready Drives in
cyclic
operation
3 Air NCK alarm
temperatur is active
e alarm
12 Change counter for motion, handwheel 1
13 Modification counter for motion, handwheel 2
15 Change counter , inch/metric measuring system
Appendix
A.7.9.3 Signals at fast inputs and outputs
DB2800 Signals at fast inputs and outputs [r/w]

0 Block digital NCK inputs
Input 3 Input 2 Input 1
1 Value from PLC for NCK inputs
4 Block digital NCK outputs
Output 1
5 Overwrite mask for digital NCK outputs
Output 1
6 Value from PLC for digital NCK outputs
Output 1
7 Setting mask for NCK outputs
Output 1
DB2800 Signals at fast inputs and outputs [r/w]

1000 Block external digital NCK inputs
1001 Value from PLC for external digit NCK inputs
1008 Block external digital NCK outputs
1009 Overwrite mask for external digital NCK outputs
1010 Value from PLC for external digital NCK outputs
1011 Setting mask for external NCK outputs
Appendix
A.7.9.4 Signals from fast inputs and outputs

DB2900 Signals from fast inputs and outputs [r]
0 Actual value for digital NCK inputs
4 Setpoint for digital NCK outputs
Output 1
DB2900 Signals from fast inputs and outputs [r]

1000 Actual value for external digital NCK inputs
1004 NCK setpoint for external digital NCK outputs
Output 1
DB3000 Mode signals to NCK [r/w]

0 Reset Mode Mode
change JOG MDI AUTO
block
1 Single block Machine function
Type A Type B REF TEACH IN
2 Machine function 1)
traversing
3
1) To use the machine function signals in DB3000.DBB2, you must set the "INC inputs in the
operating-mode signal range active" signal (DB2600.DBX1.0) to "1".
DB3100 Mode signals from NCK [r]

0 Reset 808 Mode
READY JOG MDI AUTO
1 Active machine function
REF TEACH IN
2 Machine function
traversing active active active active active active
active
Appendix
A.7.10 Channel signals
A.7.10.1 Signals to NC channel
Control signals to NC channel
DB3200 Signals to NCK channel [r/w]

0 Activate Activate Activate Activate Activate Activate
test run M01 single block DRF traverse traverse
feedrate 1) forwards backwards
1 Activate Enable Activate
program protection referencing
test zones
2 Activate skip block
7 6 5 4 3 2 1 0
4 Feedrate offset 2)
H G F E D C B A
5 Rapid traverse override
H G F E D C B A
6 Feedrate Rapid Path Program Delete Delete Read-in Federate
override traverse velocity level abort number of distance - disable disable
active 3) override limiting subroutine to-go
active cycles
7 Suppress NC stop NC stop NC stop at NC start NC start
start lock axes plus block limit disable
spindle
8 Activate machine-related protection zone
Area 8 Area 7 Area 6 Area 5 Area 4 Area 3 Area 2 Area 1
9 Activate machine-related protection zone
Area 10 Area 9
10 Activate channel-specific protection zone
11 Activate channel-specific protection zone
Area 10 Area 9
13 Do not Deactivate Activate fixed feedrate
block tool workpiece Feed 4 Feed 3 Feed 2 Feed 1
counter
14 No tool JOG circle Activate Negative Simulation Activate contour handwheel (bit/binary
change associated direction for contour coded)
commands M01 simulation handwheel Handwheel Handwheel
contour ON 1 2
handwheel
15 Activate Activate Invert
skip block 9 skip block 8 contour
handwheel
direction
16 Program
branches
(GOTOS)
control
1) Select the single-block type using the softkey.
2) 31 positions (Gray code)
Appendix
Controls signals to axes in Work
DB3200 Signals to NCK channel [r/w]

1000 Axis 1 in Work
Traversing keys Rapid Traversing Feedrate Activate handwheel (bit/binary coded) 1)
Plus Minus traverse key stop 2 1
override distance
disable
1001 Axis 1 in Work
Machine function 2)
traversing
1003
Handwheel
direction of
rotation
inverted
1004 Axis 2 in Work
Traversing keys Rapid Traversing Feedrate Activate handwheel (bit/binary coded)
Plus Minus traverse key disable stop 2 1
override
1005 Axis 2 in Work
Machine function
traversing
1007
Invert
contour
handwheel
direction
1008 Axis 3 in Work
Traversing keys Rapid Traversing Feedrate Activate handwheel (bit/binary coded)
Plus Minus traverse key disable stop 2 1
override
1009 Axis 3 in Work
Machine function
traversing
1011 Invert
contour
handwheel
direction
1) The handwheel number is represented according to the $MD_HANDWH_VDI_REPRESENTATION machine data in a
bit-coded (=0) or binary-coded (=1) manner.
2) Machine function: the machine function is only entered if the "INC inputs in the operating-mode signal range active"
signal (DB2600DBX1.0) is not set.
Appendix
A.7.10.2 Signals from NC channel
Status signals from NC channel
DB3300 Signals from NCK channel [r]

0 Last action M0/M1 Approach Action Forwards Backwards Execution
block active active block active block active traverse traverse from
active active external
active
1 Program M2/M30 Block Handwheel Rev. Referencin
test active active search override federate g active
active active active
3 Channel status Program status
Reset Interrupted Active Aborted Interrupted Stopped Waiting Running
4 NCK alarm Channel Channel All axes Stop Start
with specific operational Stationary Referenced request request
processing NCK alarm
stop is active
present
5 Contuour handwheel active (bit/binary
coded)
7 Invert Protection
contuour zone not
handwheel guranteed
direction
8 Machine-related protection zone preactivated
9 Machine-related protection zone preactivated
Area 10 Area 9
10 Channel-specific protection zone preactivated
11 Channel-specific protection zone preactivated
Area 10 Area 9
12 Machine-related protection zone violated
13 Machine-related protection zone violated
Area 10 Area 9
14 Channel-specific protection zone violated
15 Channel-specific protection zone violated
Area 10 Area 9
Appendix
Status signals, axes in Work

1000 Axis 1 in Work
Travel command Travel request Handwheel active (bit/binary coded) 1)
1001 Axis 1 in Work
Machine function 2)
traversing
1003
Contour
handwheel
direction of
rotation
inverted
1004 Axis 2 in Work
Traversing command Travel request Handwheel active (bit/binary coded)
1005 Axis 2 in Work
Machine function
traversing
1007
Contour
handwheel
direction of
rotation
inverted
1008 Axis 3 in Work
Traversing command Travel request Handwheel active (bit/binary coded)
1009 Axis 3 in Work
Machine function
traversing
1011 Contour
handwheel
direction of
rotation
inverted
Appendix
Other status signals from NC channel

4000 G00 active
4001 Travel Workpiece External
request, setpoint language
drive test reached mode
present active
4002 Dry run Associated STOP_DEL ASUP is
feedrate M01/M00 AYED stopped
Active Active
4003 No tool DELAY DELAY
change FST FST
command SUPPRES
active S
4004 ProgEvent display
Start after Boot Operator Part Part
block panel program program
search Reset End Start from
RESET
4005 Jog circle Stop StopByColl
Active condition Danger
4006 Dormant ASUP
ASUP active
Active
4008 Active the transformation number
4009 Reserved
...
4011
G functions from NCK channel
DB3500 G functions from NCK channel [r]

0 Active the G function of group 1 (8 bit int)
... ...
63 Active the G function of group 64 (8 bit int)
Appendix
A.7.11 Signals, synchronized actions
A.7.11.1 Signals, synchronized actions to channel
DB4600 Signals, synchronized actions to channel [r/w]

0 Deactivate the synchronized action with ID...
ID8 ID7 ID6 ID5 ID4 ID3 ID2 ID1
A.7.11.2 Signals, synchronized actions from channel
DB4700 Signals, synchronized actions from channel [r]

0 Synchronized action with ID...can be blocked from the PLC
A.7.11.3 Reading and writing PLC variables
DB4900 PLC variables [r/w]

PLC interface
0 Offset [0]
… …
4095 Offset [4095]
Note
The programming engineer (NCK and PLC) is responsible for organizing (structuring) this
memory area. Every storage position in the memory can be addressed provided that the limit
is selected according to the appropriate data format (i.e. a 'DWORD' for a 4-byte limit, a
WORD for a 2-byte limit, etc.). The memory area is always accessed with the information
about the data type and the position offset within the memory area.
Appendix
A.7.12 Axis actual values and distance-to-go

0 Axis actual value (REAL)
4 Axis distance-to-go (REAL)
Note
The axis actual values and distances-to-go can be separately requested:
 DB2600.DBX0001.1 Request axis actual values
 DB2600.DBX0001.2 Request axis distances-to-go
If the particular request is set, then the NCK supplies these values for all axes.
A.7.13 Maintenance scheduler: User interface
A.7.13.1 Initial (start) data
DB9903 Initial data table [r16]

0 Interval 1 [h]
2 Time of the first warning 1 [h]
4 Number of warnings to be output 1
6 Reserved 1
8 Interval 2 [h]
10 Time of first warning 2 [h]
14 Reserved 2
... ...
248 Interval 32 [h]
250 Time of first warning 32 [h]
254 Reserved 32
Appendix
A.7.13.2 Actual data
DB9904 Actual data table [r16]

0 Interval 1 [h]
4 Reserved_1 1
6 Reserved_2 1
8 Interval 2 [h]
11 Reserved_1 2
14 Reserved_2 2
... ...
248 Interval 32 [h]
252 Reserved_1 32
254 Reserved_2 32
A.7.14 User interface for Ctrl-Energy
Table A- 7 Energy saving profile
DB9906 Ctrl energy

0 Control signals
Set time to Immeadiate
pre-warning ly activate
limit the energy
saving
profile
1 Control signals (HMI -> PLC)
Immeadiate
ly activate
the energy
saving
profile
2 Signals to check/test the energy-saving profile
PLC user Master
signal computer
signal
3 Reserved
4 Status signal
Appendix
Activation Energy
time T1 saving
expired profile
active
5 Reversed
6 Actual value: actual value T1
8 Actual value: actual value T2
10 Effectiveness, profile
Disable Energy
energy saving
saving profile
profile configured
11 State conditions (HMI -> PLC)
Screen Data Operator
change transfer panel
Machine
control
panel
NC channel
1 in reset
14
PLC user Master
signal computer
signal
Activation time T1

Activation time T2
Index
A
Access levels, 31 General selection/status signals to HMI, 118
Active alarm reponse, 109 General signals from NCK, 121
Actual data, 131 General signals to NCK, 121
Alarm acknowledgement, 109
approaching the reference point, 62
Axis actual values and distance-to-go, 130 H
axis velocity and the acceleration, 59
H functions from NCK channel, 120
HEX values, 114
C
CNC I
Accessories, 10
MCP package, 10 Initial data, 130
PPU package, 10 Inserting the MCP strips, 88
Compensation methods, 66 INT values, 114
Cutting customized MCP strips, 88 Interface
battery interface, 19
Interface overview on the Machine Control Panel
D (MCP), 18
Interface overview on the Panel Processing Unit
D functions from NCK channel, 120 (PPU), 17
Decoded M signals, 119
Display data list for the SINAMICS V60, 102
Drive and motor M
1FL5 motor package, 10
Cables, 10 M functions from NCK channel, 120
SINAMICS V60 package, 10 Matching the parameters of the drive system, 58
Mounting
Cutout dimensions, 11
E Cut-outs and mounting dimensions for the
drives, 13
Enabling the position control, 58 Minimum mounting clearance for the drives, 14
Entering the machine data (MD), 57 Mounting dimensions, 12
Activating conditions, 57 Mounting dimensions for the motors, 16
External data backup in a data archive, 70, 71, 76 Mounting method for the drives, 14
Using the cable clamps supplied for the drives, 14
Mounting clearance, 13
F
FLOAT values, 114
O
onboard assistants, 35
G Operand identifier, 104
General selection/status signals from HMI, 118 Other faults for the SINAMICS V60, 102
Index
Overview of alarms, 97 U
User alarm:Configuring, 114
User alarms:Activating, 108
P
User interface for ctrl energy, 131
PI service:Job, 107
PI service:Result, 108
position-loop gain, 59 V
Printing customized MCP strips, 88
Variables for user alarms, 108
Program control from the HMI (retentive area), 115
Program selection via lists, 115
R
Reading / writing NC data:Job, 107
Reading / writing NC data:Result, 107
Reading and writing PLC variables, 129
Retentative data, 108
S
S functions from NCK channel, 120
Signals at fast inputs and outputs, 122
Signals from fast inputs and outputs, 123
Signals from maintenance planners, 117
Signals from MCP, 106
Signals from NC channel, 126
Signals from operator panel, 118
Signals from PLC, 116
Signals from the HMI, 116
Signals to axis/spindle, 109
Signals to maintenance planners, 117
Signals to MCP, 106
Signals to NC channel, 124
Signals, synchronized actions from channel, 129
Signals, synchronized actions to channel, 129
SINAMICS parameters, 95
SINAMICS V60 alarms, 98
SINAMICS V60 errors during self-test, 102
Singlas from axis/spindle, 111
software limit, 64
Special bit memory SM bit definition (read-only), 105
Structure of the DB-range address, 104
System overview, 7
T
T functions from NCK channel, 119
Transferred M and S functions, axis specific, 109

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SINUMERIK 808D Commissioning Manual 201212 Eng

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Commissioning Manual Delivery check 1

Valid for the following control systems:

Siemens AG Order number: 6FC5397-4EP10-0BA0 Copyright © Siemens AG 2012.

1 Delivery check ........................................................................................................................................... 7

A.6.2.5 Display data list ..........................................................................................................................102

A.7.10.2 Signals from NC channel .......................................................................................................... 126

Legend Name Order number

Component Quantity (pieces)

Table 1- 2 MCP package

Table 1- 3 CNC accessories

Table 1- 4 SINAMICS V60 package

Component Quantity (pieces)

Table 1- 5 1FL5 motor package

Table 1- 6 Cables individually packaged

Figure 2-1 Cut-out dimensions (in mm)

Figure 2-2 Mounting dimensions for PPU (in mm)

Figure 2-3 Mounting dimensions for MCP (in mm)

Mounting clearance (in mm)

① Cabinet panel ② Maintenance door

2.2 Mounting the drive

Figure 2-4 4/6/7 A version (in mm)

Figure 2-5 10 A version (in mm)

Minimum mounting clearance

$$$ $$$ $ $

> 25 mm > 25 mm > 100 mm

Figure 2-6 Drive mounting clearance (in mm)

Using the cable clamps supplied

Line supply cable (shielded)

PE (for connection to ground;

Figure 2-7 Cable fixing with two cable clamps

2.3 Mounting the motor

Mounting dimensions (mm)

Motor type A (in mm) B (in mm)

Interface overview on the Panel Processing Unit (PPU)

The + 24 V and M signals of X200 must be connected; otherwise, the communication

Figure 3-1 Interface layout

Legend Interface Comment

② X200, X201 Digital outputs

③ X21 FAST I/O

④ X301, X302 Distributed I/O

⑤ X10 Hand-wheel inputs

⑥ X60 Spindle encoder interface

⑦ X54 Analog spindle interface

⑨ X51, X52, X53 Pulse drive interfaces

⑩ X30 USB interface, for connection with the MCP

⑪ X1 Power supply interface, +24V DC power supply

⑬ - Slot for the System CompactFlash Card (CF card)

Interface overview on the Machine Control Panel (MCP)

Figure 3-2 Interface layout

Legend Interface Comment

3.2 Connecting the battery

① Maintenance door ③ Battery interface

3.3 Connecting according to the default PLC program

Connecting the digital inputs and outputs

Figure 3-3 Connecting the digital inputs and outputs (Milling)

Figure 3-4 Connecting the digital inputs and outputs (Turning)

Connecting the distributed I/O

Figure 3-5 Connecting the distributed I/O

Connecting the SINAMICS V60 (take X51: axis X for an example)

SINUMERIK 808D SINAMICS V60

Figure 3-6 Connecting the SINAMICS V60 (X51: axis X)

Connecting the inverter or the servo spindle drive

Connecting the handwheel

Commissioning Manual Delivery check 1

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