Sinumerik 840d e 03 00 PDF Free

Service Manual
SINUMERIK 840D
Service Manual
SINUMERIK 840D
Edition 03/2000
Ordering Information Please state title of document, desired language and date of
edition when placing your order.
TRUMPF GmbH + Co. KG

D-71254 Ditzingen
Johann-Maus-Straße 2
Phone (07156)303-0
Telefax (07156)303-540
Internet: http://www.trumpf.com
e-mail: help @ trumpf.com
This document was compiled by the Technical Documentation Dept. of TRUMPF

GmbH + Co. KG
All rights, in particular the right to reproduce, distribute or translate this

documentation, are reserved by TRUMPF GmbH + Co. KG, also in the case of
applications for patents and industrial rights. No part of this documentation may be
reproduced, processed, duplicated or distributed by conventional or electronic
means in any form whatsoever without the prior written consent of TRUMPF GmbH
+ Co. KG. Subject to errors and technical changes
 TRUMPF GmbH + Co. KG
TRUMPF GmbH + Co. KG assumes no responsibility for possible errors in this

documentation or for any direct or indirect damages resulting from the delivery or
use of this documentation as far as this is in conformity with the law.
Before you continue...
SINUMERIK 840D Service This service manual documents the Siemens SINUMERIK 840D
Manual controller as modified and adapted by TRUMPF.
The controlled is employed in the following machines:
• TC 600L
• TC L 2530
• TC L3030/4030/6030
• TC HSL 2502
For whom is this manual This service manual is intended exclusively for use by service
intended? engineers and must not be made available to customers. The
service manual is designed to be used both as course material in
control training and as a reference work for the service engineer.
Contents Chapter 1: Operating panel

Chapter 2: NCU
Chapter 3: PLC
Chapter 4: Data communication
Chapter 5: Configuration and machine data
Chapter 6: Setup/Update
Chapter 7: SIMODRIVE 611D drives
Supplementary The machine documentation also includes the following:

documentation
• Operating manual
• Programming manual
• TLF Laser operating manual
• Spare parts lists
• Schematics
• Folder with vendor-supplied documentation
Manuals for programming systems and documentation for use in

training courses is also available.
Online-Help The documents in paper form are supplemented by Online Help at

the control for operating and programming the machine.
H274e0.doc Before you continue... 0-3

Table of Contents
Chapter 1 Operating panel
Overview...................................................................................... 1-3
1. Hardware components .................................................. 1-4

1.1 Machine control panel (MSTT)......................................... 1-7
1.2 Man Machine Communication (MMC) ............................. 1-8
Interfaces .................................................................... 1-9
Operating elements................................................... 1-11
1.3 ISA adapter .................................................................... 1-11
1.4 3.5“ Floppy Disk Drive.................................................... 1-12
1.5 Modem ........................................................................... 1-14
2. MMC Boot sequence.................................................... 1-18

2.1 Confidential selection menu........................................... 1-19
2.2 Hard disk check (Scandisk) ........................................... 1-20
3. TRUMPF operation environment ................................ 1-21

3.1 Starting the operation environment (BOF) manually ..... 1-21
3.2 MMC directory structure................................................. 1-22
3.3 MMC software structure ................................................. 1-24
3.4 Servers ........................................................................... 1-25
3.5 Further software components ........................................ 1-26
3.6 Changing languages ...................................................... 1-26
3.7 Passwords and exclusions............................................. 1-27
4. Databases ..................................................................... 1-29

4.1 Definition ........................................................................ 1-29
4.2 Database structure......................................................... 1-29
Schematic structure of the databases ...................... 1-31
4.3 Database directory structure and contents .................... 1-32
4.4 Database directories ...................................................... 1-33
Working directory ...................................................... 1-33
Backup directory ....................................................... 1-33
Directories during DB update.................................... 1-34
5. ODBC interface............................................................. 1-35

5.1 ODBC administrator ....................................................... 1-35
0-4 Table of Contents H274e0.doc

6. Database errors............................................................ 1-36
6.1 Automatic database backup........................................... 1-36
6.2 Database backup by the operator.................................. 1-37
6.3 No connection to a database ......................................... 1-37
6.4 Corrupt database ........................................................... 1-46
7. Complete files............................................................... 1-50

7.1 Management .................................................................. 1-50
7.2 Structure of a complete file ............................................ 1-51
7.3 Splitting a complete file .................................................. 1-52
8. Diagnostic possibilities ............................................... 1-54

8.1 MMC 7-segment display ................................................ 1-54
8.2 Fatal System Error 1 ...................................................... 1-55
8.3 Fatal System Error 2 ...................................................... 1-56
8.4 Automatic start error messages ..................................... 1-57
Notes for Diagnostics................................................ 1-57
Initialization ............................................................... 1-58
Asynchronous communication step sequence in
automatic startup ...................................................... 1-61
8.5 Monitoring tools/files ...................................................... 1-65
Description ................................................................ 1-65
9. Maintenance................................................................... 1-73
9.1 Replacing the battery ..................................................... 1-73
9.2 Replacing the complete MMC unit ................................. 1-73
Data which must be saved........................................ 1-74
9.3 Replacing the hard disk drive (only possible with MMC
103) ................................................................................ 1-75
Chapter 2 NCU
1. NCU.................................................................................. 2-4
1.1 Mode of function............................................................... 2-4
1.2 System components......................................................... 2-8
2. NCU Rack........................................................................ 2-9

2.1 Hardware.......................................................................... 2-9
Interfaces .................................................................. 2-12
X121 diagnostics....................................................... 2-18
Operation and display elements ............................... 2-19
2.2 NCK boot-up diagnostics ............................................... 2-20
H274e0.doc Table of Contents 0-5

2.3 Software ......................................................................... 2-22
Directory structure..................................................... 2-22
Cycles ....................................................................... 2-23
2.5 Routine upkeep and maintenance ................................. 2-28
Warnings ................................................................... 2-28
Labels and decals ..................................................... 2-28
Battery and ventilator replacement ........................... 2-30
3. NCU Terminal block ..................................................... 2-32

Interfaces .................................................................. 2-33
3.1 DMP compact module 1E Analog (slow)
6FC5 111-0CA04-0AA0 ................................................. 2-34
Interfaces .................................................................. 2-35
Display elements....................................................... 2-35
Circuitry ..................................................................... 2-35
Circuit example ......................................................... 2-35
Technical data........................................................... 2-36
3.2 DMP compact module 1E NC Analog (rapid)
6FC5 211-0AA10-0AA0 ................................................. 2-37
Interfaces .................................................................. 2-37
Circuit example ......................................................... 2-38
Technical Data .......................................................... 2-38
3.3 DMP compact module 1A Analog .................................. 2-39
Interfaces .................................................................. 2-39
Technical data........................................................... 2-40
3.4 Diagnostics for the Analog NCK Peripheral Devices2-40
4. Bitbus module .............................................................. 2-42

Bitbus module LEDs ................................................. 2-44
Technical data........................................................... 2-44
Interfaces .................................................................. 2-44
Jumper configuration ................................................ 2-45
5. SIMATIC S7-300 PLC periphery module .................... 2-48

5.1 IM 361 switching module................................................ 2-50
Status and error display ............................................ 2-50
Technical data........................................................... 2-51
5.2 Switching module arrangement on s
everal carrier modules.................................................... 2-52
5.3 Addressing the S7-300 modules.................................... 2-54
Slot-dedicated module addressing
(Default addresses)................................................... 2-54

Addressing the digital modules ................................. 2-55
5.4 Module replacement....................................................... 2-56
5.5 S7-300 power rating....................................................... 2-59
5.6 SM 321; DI 16 x DC 24V digital input module ............... 2-60
Technical data........................................................... 2-61
5.7 Digital input module SM 321; DI 32 x DC 24V ............... 2-62
Technical data........................................................... 2-63
5.8 Digital output module SM 322; DO 32 x DC 24 V/0.5 A 2-64
Technical Data .......................................................... 2-65
5.9 Digital output module SM 322; DO 16 x DC 24V/0.5A .. 2-67
Technical Data .......................................................... 2-68
5.10 Digital output module SM 322; DO 8 x DC 24V/2A ....... 2-70
Technical Data .......................................................... 2-71
Chapter 5 PLC
1. Interface Overview ......................................................... 3-4
2. Alarms ............................................................................. 3-6

2.1 NCK and drive error messages........................................ 3-7
2.2 PLC alarms ...................................................................... 3-8
Alarm numbers............................................................ 3-8
Error list....................................................................... 3-9
2.3 PLC-NCK synchronization ............................................... 3-9
2.4 Diagnostics using error messages................................. 3-10
3. PLC diagnostic possibilities ....................................... 3-10

3.1 PLC Diagnostics............................................................. 3-11
PLC <-> NCK interface diagnostics .......................... 3-12
Languages ................................................................ 3-13
Configuration file ....................................................... 3-13
3.2 PLC-Debugger ............................................................... 3-14
Editing R-parameters ................................................ 3-17
3.3 Diagnostics with data blocks .......................................... 3-17
DB127 ....................................................................... 3-17
TYPE.H-File .............................................................. 3-18
3.4 Overview of data blocks used ........................................ 3-20
3.5 DB 21: Punch/nibble package diagnostics..................... 3-21
3.6 DB 77: System applications ........................................... 3-21
3.7 DB 85: Tapping .............................................................. 3-21
3.8 DB 86: PLC Diagnostics................................................. 3-23

3.9 DB 87: Laser function diagnostics ................................. 3-23
Assignment ............................................................... 3-24
DIAS 3....................................................................... 3-26
Gas module............................................................... 3-27
Z-Axis module ........................................................... 3-27
3.10 DB 88: Diagnostics ON/OFF (TC L2530)....................... 3-28
Machine reference cycle diagnostics........................ 3-28
3.11 DB 89: Pallet changer diagnostics (TC L2530).............. 3-30
Guard door ................................................................ 3-30
Lift ............................................................................. 3-31
Lower pallet............................................................... 3-32
Upper pallet............................................................... 3-33
Inside index ............................................................... 3-34
Outside index ............................................................ 3-36
Freeing the pallet changer ........................................ 3-36
3.12 DB 94: Welding diagnostics ........................................... 3-38
3.13 DB 109: Initializing the application data ......................... 3-39
3.14 DB 121: H&L <-> Punching........................................... 3-40
3.15 DB 122: H&L punching................................................... 3-44
3.16 DB 123: H&L <-> Punching............................................ 3-45
3.17 DB 126: Communication ................................................ 3-48
Liftmaster .................................................................. 3-48
TC L1005 manual programming unit (PHG) ............ 3-49
3.18 DB 125 / 127: Tool change diagnostics ......................... 3-50
3.19 Diagnostics with R-parameters ...................................... 3-51
3.20 Diagnostics via machine data ........................................ 3-52
Axis positioning diagnostics ...................................... 3-52
Table programming diagnostics................................ 3-52
Tool management diagnostics .................................. 3-53
R80: Rail assignment check diagnostics .................. 3-54
R80-R87: DIAS diagnostics ...................................... 3-54
R56 – R69: Tapping diagnostics............................... 3-55
3.21 ELSP_VSS.H files.......................................................... 3-56
3.22 Overview: PLC modules................................................. 3-57
Organization modules ............................................... 3-57
Function modules...................................................... 3-57
Data block assignment.............................................. 3-58
Assigned times.......................................................... 3-58
4. Interface signals........................................................... 3-59

4.1 Signals to and from the manual operating unit
(e. g. for TLC 1005)........................................................ 3-59
4.2 MMC and PLC interface signals .................................... 3-61
4.3 PLC messages (DB 2) ................................................... 3-63
4.4 Signals to/from NCK Compiler cycles (DB 9)................. 3-65

4.5 Signals to/from NC (DB 10) ........................................... 3-65
4.6 Signals to/from BAG (DB 11) ......................................... 3-71
4.7 Signals to/from control panel (DB 19) ............................ 3-71
4.8 Signals to/from NCK channel (DB 21 - 28) ................... 3-72
4.9 Signals to/from Axis/Spindle (DB 31-48)....................... 3-80
Chapter 4 Data Communication
1. Communication systems............................................... 4-3
2. MPI interface................................................................... 4-3
3. Modem connection ........................................................ 4-4

3.1 Software for remote diagnostics ...................................... 4-4
3.2 Establishing a connection ................................................ 4-4
3.3 Primary setup at the machine control
(pcANYWHERE-Version 2.0)........................................... 4-5
4. Network connection..................................................... 4-13

4.1 Basics of network technology ........................................ 4-13
The ISO / OSI model................................................. 4-13
Cable types / connections......................................... 4-14
Network topologies ................................................... 4-14
Access control........................................................... 4-17
Network protocols ..................................................... 4-18
Coupling devices....................................................... 4-21
Troubleshooting ........................................................ 4-23
4.2 Configuring the network adapter.................................... 4-24
Testing the Ether Link III card ................................... 4-26
Configuring network adapter for a Windows 3.11
network with NETBEUI protocol................................ 4-27
Sharing directories .................................................... 4-32
5. Dual-Port-RAM.............................................................. 4-36
6. Bitbus ............................................................................ 4-37

6.1 Principle of function........................................................ 4-37
6.2 Data flow ........................................................................ 4-37
6.3 Telegram diagnostics ..................................................... 4-39
Recording telegrams................................................. 4-39
R parameters ............................................................ 4-41

Telegram structure file TELE.COM........................... 4-43
Examples of telegram diagnostics ............................ 4-44
Bitbus telegrams over the DDE interface.................. 4-49
Chapter 5 Configuration and Machine Data
1. Configuration data ......................................................... 5-3

1.1 Modifying machine configuration data ............................. 5-3
1.2 Modifying configuration data for operation environment
software............................................................................ 5-5
2. Machine data .................................................................. 5-7

2.1 Modifying machine data ................................................... 5-7
2.2 Saving machine data...................................................... 5-11
2.3 Machine data overview .................................................. 5-15
2.4 Individual machine data groups ..................................... 5-16
Drive data.................................................................. 5-17
Manual configuration................................................. 5-18
Machine data description .......................................... 5-26
Axis dynamics (Speeds, servo gain, acceleration,
backlash)................................................................... 5-30
Referencing............................................................... 5-32
Exact stop, axis monitoring ....................................... 5-36
Digital NCK periphery ............................................... 5-38
Analog NCK periphery .............................................. 5-38
Channel assignment, system cycles......................... 5-40
Memory areas ........................................................... 5-41
Nibbling machine data .............................................. 5-41
Offsets....................................................................... 5-42
5-axes transformation (TLC 1005) ............................ 5-42
TRUMPF machine data ............................................ 5-43
3. List of machine and setting data ................................ 5-45

3.1 Machine drive data......................................................... 5-45
3.2 General machine data.................................................... 5-74
System settings......................................................... 5-74
Override switch settings............................................ 5-83
Central drive data...................................................... 5-84
System-specific memory settings ............................. 5-85
3.3 Channel specific machine data ...................................... 5-89
Basic channel machine data ..................................... 5-89

Machine data for Digitizing........................................ 5-97
Machine data for Grinding......................................... 5-99
Auxiliary channel function settings.......................... 5-100
Transformation definitions in channel ..................... 5-102
Punching and Nibbling ............................................ 5-111
Channel-specific memory settings .......................... 5-112
3.4 Axes-specific machine data ......................................... 5-114
Configuration........................................................... 5-114
Encoder matching ................................................... 5-116
Closed-loop control ................................................. 5-118
Referencing............................................................. 5-123
Spindles .................................................................. 5-125
Monitoring functions................................................ 5-128
Axes-specific memory settings ............................... 5-133
3.5 Setting data .................................................................. 5-133
General setting data................................................ 5-133
Channel-specific setting data.................................. 5-135
Axes-specific setting data ....................................... 5-136
Chapter 6 Setup / Update
1. Loading software for NCK and PLC ............................. 6-3

Softkey functions: Schematic diagram........................ 6-4
Softkey applications .................................................... 6-5
2. Subsequent NC Start-Up ............................................... 6-6

2.1 Scrubbing the NCK .......................................................... 6-6
2.2 Scrubbing the PLC ........................................................... 6-7
2.3 Loading machine data...................................................... 6-7
2.4 Loading PLC programs .................................................... 6-8
2.5 Activating PLC configuration data.................................... 6-8
3. Data Backup ................................................................... 6-9

3.1 Data backup using the GHOST tool................................. 6-9
3.2 Restoring data with the GHOST Tool ........................... 6-14
4. Software selection sheet ............................................. 6-17
5. Software update ........................................................... 6-18

5.1 MMC............................................................................... 6-18

5.2 NC/PLC .......................................................................... 6-21
Changing the PCMCIA card...................................... 6-22
Loading NCK software .............................................. 6-22
Loading PLC software............................................... 6-26
Activating PLC configuration data............................. 6-27
Checking regulator settings at the TASC200
(Lasermatic 1.5 only) ................................................ 6-28
6. Primary installation of MMC........................................ 6-30
Chapter 7 SIMODRIVE 611D Drives
1. Power Supply (NE) ......................................................... 7-3

1.1 V3 Technology ................................................................. 7-3
Power supply to the electronics .................................. 7-5
1.2 Switch S1 settings on the power supply module (NE) ..... 7-6
1.3 LEDs on I/R module ......................................................... 7-7
1.4 Overview of Enable signals.............................................. 7-7
1.4 Terminals on the NE module ........................................... 7-8
Terminal connectors: Explanation ............................ 7-11
1.6 Technical data: Network input module........................... 7-13
Service News: "New I/R module".............................. 7-15
2. Servo drive modules.................................................... 7-16

2.1 Power module ................................................................ 7-18
Power module: Technical data.................................. 7-19
Load cycle definition: Drive modules ........................ 7-23
Interface overview..................................................... 7-23
2.2 Regulation PCBs............................................................ 7-24
Single axis drive regulation ....................................... 7-24
Dual-axis drive regulation ......................................... 7-24
Interface overview..................................................... 7-26
3. Three-phase servo motor ............................................ 7-29

3.1 Position sensing ............................................................. 7-30
4. Diagnostic aids............................................................. 7-31

4.1 Service mask: Axis/Spindle............................................ 7-31
Description ................................................................ 7-32
4.2 Service mask: Drives (for digital drives only) ................. 7-36
Description ................................................................ 7-37

4.3 Interface signals ............................................................. 7-44
4.4 Machine data.................................................................. 7-45
5. Setup Tool..................................................................... 7-46

5.1 Instructions for use......................................................... 7-46
Starting the program ................................................. 7-47
Quitting the program ................................................. 7-47
5.2 Measuring function......................................................... 7-47
5.3 NST signals: Travel request and motion
enable drive test............................................................. 7-49
5.4 Measuring functions abort.............................................. 7-49
5.5 Frequency response reading ......................................... 7-50
Torque regulation circuit reading .............................. 7-50
RPM regulation circuit reading.................................. 7-51
Position control loop reading..................................... 7-53
5.6 Graphic display .............................................................. 7-56
5.7 Analog output (DAU) ...................................................... 7-58
5.8 File functions .................................................................. 7-59
Index

Chapter 1
Operating panel
H274E1.DOC Operating panel 1-1

Overview
Customer Network
PC MMC MSTT PHG
MPI bus
Central COM module

peripheral device
TASC
K bus PLC NCK H&L LS DIAS 3
100
Drives bus
Profibus DP
Bitbus
Decentral
peripheral device Servo module
external ASI bus
NCK peripheral device
PLC Bitbus
(AS614)
master
module
Central Decentral
peripheral peripheral
device device
Machine Machine Machine Drives Machine

elements elements elements elements
Control components Fig. 23763E
MMC
Data:
NC programs,
Data: Tables,
Application data Machine data
Messages: Messages:
Orders: Errors, Errors, Orders:
switch elements, Operator messages Operator messages Program selection,
etc. Individual record,
Data: Data: Program start, etc.
Status Axis values,
VSH, ELSP, VSS, NC text,
PLC diagnostics, Program status,
etc. Machine data, étc.
Data: tables, VDI interface, M functions, telegrams, etc.
PLC NCK
Order: NC start, VSH, Reset, etc..
Data exchange Fig. 23764E

1. Hardware components
The TRUMPF operating panel consists of:
• Machine panel (MSTT)

• Man Machine Communication (MMC)
• ISA network adapter
• Power supply
1 2
7 8 9
4 5 6
N10
N20
1 2 3
0
Esc
LASER
LASER
TEST
1 Color display 2 MMC operating components 3 MSTT operating components
Front view of operating panel Fig. 11913
1-4 Operating panel H274E1.DOC

MSTT pushbutton Pushbutton Pushbutton Input Output
assignment combination PLC PLC
(ASCII keyboard)
E20.0 A20.0
E21.1 A20.5
E20.1 A20.1
E20.2 A20.2
E22.1 A21.5
E25.2 A20.6
E21.0 A20.4
E20.3 A20.3
E21.3 A20.7
E21.6 A21.2
LASER
E21.7 A21.3
E22.0 A21.4
LASER
E21.4 A21.0
E21.5 A21.1
LASER
TEST
Feed override E20.4–20.7

potentiometer

MSTT pushbutton Pushbutton Pushbutton Input Output
assignment combination PLC PLC
(ASCII keyboard)
<Shift> + <F2> A22.7
<Shift> + <F3> A23.0
<Shift> + <F4> A23.1

N10
N20
<Shift> + <F5> A23.2
<Shift> + <F6> A23.3
<Shift> + <F7> A23.4
<Shift> + <F8> A23.5
<Shift> + <F9> A23.6
<F1>
<F10> or <ALT> A23.7
<F12> or <TAB>
<F11>
<Shift> + <F11>
<Shift> + <F12>
Soft keys <F2> to <F9>

1.1 Machine control panel (MSTT)
3 1 2
1 MPI interface MSTT-MMC-NCU 2 Power supply 3 Interface for

• Emergency Stop
• Laser controller key switch
• 2-hand key (TC L2530)
• Teach Panel ON/OFF (TLC
1005)
• Cutting gas pressure
Machine control panel Fig. 13982
1 2 3
1 ISA adapter for network interfacing 2 MMC 3 Power supply
Rear view of operating panel Fig. 13983

1.2 Man Machine Communication (MMC)
1 2 3 4 5 6 7 8 9 10 11 12
1 PCMCIA interface (Siemens 5 NMI switch (RESET function for 9 X7, COM2 (serial interface for
option) developers) modem)
2 Buffer battery 6 X10 (MMC-ASCII keyboard 10 X6, COM1 (serial interface for
3 X9 (MMC – floppy disk interface) interface) trackball)
4 RESET switch 7 7 segment display 11 X5, VGA interface

8 X8, LPT1 (ZIP drive, Interlink) 12 X4, MSTT-MMC-NCU (MPI)
interface
MMC 103 Fig. 17670

The MMC is an AT compatible, industrial PC module consisting of:
• INTEL Pentium133 processor with 32 MB RAM and a 500MB

hard disk drive.
• Integrated VGA chipset
• AT standard interfaces (COM1, COM2, ...)
• ISA socket (for a network card)
• ASCII keyboard
• Floppy disk drive
• Modem for remote diagnostics (Teleservice)
Interfaces
X3 Power supply interface (only to MMC 102)
Connector number: X3
Type of connector: 34 pin flat ribbon cable connection
X4 Operating panel interface (MPI)
Type of connector: 9pin sub-D female connector
Max. cable length: 200 m
X5 VGA interface
Type of connector: 15 pin sub-D female connector
Max. cable length: 1.5 m
X6, X7 Serial interface RS232 (COM1, COM2)
Connector number: X6, X7

Max. cable length: 30 m
Pin assignment
Pin Name Type Pin Name Type
1 DCD I 6 DST I
2 RxD I 7 RTS O
3 TxD O 8 CTS I
4 DTR O 9 RI I
5 1M VO

Signal designation
RxD Receive Data

TxD Transmit Data
RTS Request to Send
CTS Clear to Send
DTR Data Terminal Ready
DSR Data Send Ready
RI Ring Indicator
DCD Carrier Detect
1M Signal Ground
Signal type
O Output
I Input
VO Voltage Output
X8 Parallel printer interface (LPT1)
X9 Floppy-Disk-Interface
Type of connector: 34 pin male ribbon cable connector
X10 External keyboard/mouse interface

Type of connector: 6 pin Mini-DIN
X11 Battery

Type of connector: 2 pin male connector
X13 Hard disk drive interface IDE (ST506 compatible)

Type of connector: 44 pin connector incl. power supply
MMC 7 Segment display See page 54 for description

Operating elements
S1 Reset switch (to re-boot the MMC)
S2 NMI switch (only for developers)
1.3 ISA adapter
Function The ISA adapter is a CPU extension. A maximum of two normal

rd
ISO cards (2/3 length) can be interfaced.
1 2 3
1 ISA interface 2 Ether-Link III network card 3 ISA-Slot interface

(Standard)
ISA adapter Fig. 13981

1.4 3.5“ Floppy Disk Drive
Function An AT-compatible floppy disk drive serves to upload, download

and save data onto 3.5" floppy disks.
2 3 4
1 Front cover 3 FDD shaft

2 LED (indicates FDD activity) 4 Eject button
FDD: Front view Fig. 14105
Always keep the front flap closed to prevent dirt from

entering the FDD.

1 2
1 Flat ribbon cable interface 2 24V power supply interface
FDD: Rear view Fig. 14106
Connection The FDD is connected to the MMC 103 at interface X9.
1 X9 (MMC FDD interface)
MMC interface Fig. 13980

1.5 Modem
The modem is mounted in the operating panel. A telephone cable

with an American RJ11 connector is routed from the modem to an
adapter (country specific) in the switch cabinet. The adapter
establishes contact between the RJ11 connector and the
telephone server.
The following list represents a modem-to-country guide to aid in

the selection of the correct modem for a particular country. This list
is subject to changes without notice!
International modem Country Modem

overview
Countries listed in the MultiTech Order No.
manufacturers list description
Egypt, Russia, Taiwan, MT2834BLI 139698
Czechoslovakian
Republic
Australia MT2834BLI-AUSTRALIA 139699
Belgium MT2834BLI-BELGIUM 139700
Denmark MT2834BLI-DENMARK 139701
Germany MT2834ZDXG 139702
England (UK) MT2834BLK 139703
Finland MT2834BLI-FINLAND 139704
France MT2834BLF 139705
Greece MT2834BLI-GREECE 139706
Ireland MT2834BLI-IRLAND 139707
Island MT2834BLI-ICELAND 139708
Italy MT2834BLI-ITALY 139709
Japan MT2834BLI-JAPAN 139710
Canada MT2834BLR-DOC 139711
Luxembourg MT2834BLI-LUXEMBOURG 139712
Mexico MT2834BL-MEXICO 139714
New Zealand MT2834BLI-NEW ZEALAND 139715
Netherlands MT2834BLI-HOLLAND 139716
Norway MT2834BLI-NORWAY 139717
Austria MT2834BLG-AUSTRIA 139718
Poland MT2834BLI-POLAND 139719
Portugal MT2834BLI-PORTUGAL 139720
Sweden MT2834BLI-SWEDEN 139721
Singapore MT2834BLI-SINGAPORE 139722
Spain MT2834BLI-SPAIN 139723
Switzerland MT2834BLI-SWISS 139728
South Africa MT2834BLI-RSA 139724
Turkey MT2834BLI-TURKEY 139725
Ukraine MT2834BLI-UKRAINE 139726
USA, Brazil MT2834BL-US 139727
ELSA MicroLink 28.8 TQV 133590

Telephone adapter Country Telephone adapter
Designation Order No.
Argentina TDPT 261 134451
Australia TDPT 011 134456
Austria TDPT 021 134461
Belgium TDPT 031 134466
Brazil TDPT 201 134471
Czech Republic TDPT 041 134452
Denmark TDPT 051 134457
Finland TDPT 061 134462
France TDPT 071 134472
Germany (TAE F) TDPT 081 134453
Great Britain TDPT 174 134465
Greece TDPT 222 134454
TDPT 251 134458
Hungary TDPT 091 134468
Israel (new) TDPT 221 134473
Israel (old) TDPT 222 134454
Italy TDPT 101 134459
Netherlands TDPT 121 134463
Norway TDPT 061 134462
Poland TDPT 131 134464
Portugal TDPT 051 134457
Russia TDPT 131 134464
Scandinavia (new) TDPT 062 134467
Slovakia TDPT 041 134452
South Africa TDPT 141 134469
Sweden TDPT 151 134474
Switzerland (new) TDPT 161 134642
Switzerland (old) TDPT 162 134455
Turkey TDPT 211 134460
US RJ11 TDPT 179 134470
Yugoslavia, former TDPT 181 134475
Telephone cable A 15 meter cable between modem and telephone adapter with a
US RJ11 connector at either end is available under Order No.:
134536.

LEDs on modem
1 ON/OFF switch
Modem: Front view Fig. 17669
The modem features 9 LED’s and a microphone jack on the front

panel. A speaker connector is located on the underside of the
modem housing. Neither speaker nor microphone is presently
being used by TRUMPF for verbal communication.
LED LED Description Function with LED ON

MultiTech ELSA
Power Modem ON
TD TxD Transmit data Transmitting data
RD RxD Receive data Receiving data
DTR Data terminal ready Data terminal ready
DSR Data set ready Data modem ready
RTS Request to send Request to transmit
CTS Clear to send Ready to transmit
CD DCD Data carrier detect Data carrier detect O.K.
EC Error connection Error in modem
connection ON
FX Fax mode Modem in fax mode
33/14/96 Transmission speed Displayed transfer rate
LED’s
OH OH Off Hook - Off HK Modem dials, connection
results

1 2 3
1 Power supply 3 Telephone cable socket

2 Serial interface to COM2 interface
of the MMC
Modem: Rear view Fig. 19606

2. MMC Boot sequence
Following machine power ON, the MMC begins its boot-up cycle.
The booting sequence and manipulation possibilities during the
booting cycle are illustrated in Fig. 18355.
Main switch ON
BIOS start routine

run
CTRL + ALT + ESC yes BIOS setup starts

pressed ?
Basic configuration
no can be changed, e.g.
Boot Features
Boot Sequence
Starting MS-DOS
from C:, A:
to A:, C:
(allows booting from
floppy disk)
Entered
yes Protected
"SYSTEM" ?
selection menu
(3 sec.)
no
Starting TRUMPF-
Operating-System
yes DOS session

Entered "t" ?
(3 sec.) of pcAnywhere
Entered
"GOTO DOS" ?
(3 attempts)
no
yes
Scandisk DOS input

is run prompt
no Entered
Pressed
"exit"?
SHIFT?
yes yes
Windows boots
Windows Protected
and BOF starts
starts selection menu
Block diagram: MMC boot sequence Fig. 18355E

Please pay special attention to assure that passwords are
never passed on to the customer!
2.1 Confidential selection menu
There are two ways of calling up the confidential selection menu

during the MMC booting sequence (see Fig. 18355).
PLEASE SELECT
1 TRUMPF Operating System

2 SIEMENS Operating System
3 Reboot System (Warm boot)
4 DOS SHELL
5 TRUMPF Service with INTERSVR
6 TRUMPF Tele Service (DOS-Session)
7 Valitek streamer (600)
Confidential selection menu
Selection Response
1 TRUMPF Operating Windows is fully booted and the TRUMPF operation
System environment is automatically started. If a network has
been installed, it will be available after the boot-up
routine.
2 SIEMENS Operating This selection causes a temporary change in the

System CONFIG.SYS file. This change causes the system to
be re-booted to the SIEMENS operation environment.
The CONFIG.SYS resumes its original state during
the boot sequence so that it automatically boots to the
TRUMPF operation environment the next time the
system is started.
3 Reboot System Automatic re-boot of the system after calling up the

(Warm boot) C:\TCOMMC\SYSTEM\REBOOT.EXE Siemens
routine (equivalent to the <CTRL> + <ALT> +
<DEL> keystroke combination.)
4 DOS SHELL Activates of the DOS input prompt through the

COMMAND.COM call-up.
5 TRUMPF Service DOS INTERSVR.EXE is called-up. This program

with INTERSVR makes it possible to access the MMC (HDD) from an
external device (laptop etc.), by means of a parallel or
serial null modem cable. To enable access, the
following entry must be stated in the CONFIG.SYS of
the external device:
DEVICE=C:\DOS\INTERLNK.EXE.

6 TRUMPF Tele Ser- Start a DOS PcAnywhere session with the following:
vice (DOS-Session) C:\TCOMMC\SYSTEM\HOST.BAT call-up. The
modem will be initialized and will wait for a call from
the service department.
7 Valitek-Streamer Activates the streamer driver software for a Valitek

(600) 600 streamer (C:\TOOLS\VALITEK.600\MAIN.EXE).
2.2 Hard disk check (Scandisk)
Scandisk is started automatically every time the machine is

powered up. If no errors are found during the Scandisk check, the
following message will be displayed:
Hard disk was successfully checked
If Scandisk does find an error the following message will appear:
!!! SCANDISK DETECTED ERRORS !!!
Press ’t’ for DOS-Teleservice or

Press ’r’ for the repair with SCANDISK
Please call TRUMPF-Service!
Selection Response
t DOS-Teleservice Starts a DOS session of pcAnywhere. The hard
disk structure can now be inspected whereby the
cause of the error can be localized.
r Repair with SCANDISK SCANDISK checks and (if required), repairs the
FAT (File Allocation Table) sector.
SCANDISK generates a C:\HDCHECK.LOG file. When Scandisk

discovers an error, change to DOS by pressing <t> when
prompted. The DOS editor must now be started to view the
HDCHECK.LOG file. The following table shows the correct
response to the error or errors displayed.
Error Repair?
*.mdb Yes, press <R>
*.tmp Yes, press <R>
Lost clusters Yes, press <R>

Error Repair?
Crosslinks Teleservice
Mediabyte Teleservice
GUD (Global User Data) Delete the SGUD.DEF file in the

DEF.DIR of the NCK directory.
All others Teleservice
Yes A warm start must be performed if you choose YES. The error
must be repaired with <r> with the next Scandisk operation to
follow.
No Perform a warm start if you choose NO and close the subsequent

!!!! SCANDISK DETECTED ERRORS !!! message by pressing
<ESC>. Following this, you must repair the respective database.
Teleservice This function is activated from the confidential selection menu.
3. TRUMPF operation environment
The TRUMPF operation environment software is stored on the

MMC hard disk.
3.1 Starting the operation environment

(BOF) manually
To load servers and start Proceed as follows if only WINDOWS was booted up and no
the operation environment servers have been loaded yet:
1. Change to the Program Manager

2. Open the TCO-MMC program group
Fig. 19608
3. Click on the TCOMMC START ALL icon

The servers are loaded and the operation environment is
started.
To start the operation If the operation environment had been started and subsequently
environment closed via 'Diagnose – Service – Development', the servers are still
active. Only the operation environment therefore needs to be
started.

1. Change to Program Manager
2. Open the TCO-MMC program group.
Fig. 19609
3. Click on the TCOMMC PROGRAM icon.

Only the operation environment is started.
3.2 MMC directory structure
Path Description
C:\535\PLC Directory „gp840d“:
PLC basic functionality by SIEMENS
Subdirectory „MPI“:
fb30.plc, machine PLC program in „C“
„plclaod.ini“ file:
Initialization file for function “PLC LOAD“ in the
"Load Software“ menu
C:\535.bak Data backup directory for the most recently
implemented PLC software release. Contents as in
C:\535
C:\840D Files for operation environment (BOF) functions:
Nckload1.ini Load NCK with softkey „NCK
first load“
Nckload2.ini Load NCK with Softkey „NCK
load“
Ncksich.ini Save NCK with softkey
„NCK save“
C:\840D\MD Machine data directory /files:
INITIAL.INI All machine data
with standard values
MASCHINE.ini All modified machine
data with their specific
values
BOOT Files, Machine data for the servo drive
modules
Files tc....: NCK cycles (see chapter 2,
2.3 “Software cycles”)
C:\840D\SAV File "aktcfg.cfg":
Backup of the current configuration
C:\840D\UPD Backup directory for machine data backup with
function „NCK SAVE“ in menu „Load software“.
File INITIAL.INI is a backup file.
C:\840D.bak Backup directory for the most recently implemented
NCK software release. Contents as in C:\840D

C:\840D.INS Working directory during software update with NCK
disks.
inst_nck.bat Start file for installation routine
for disk installation. With
„nck_nck hd“ from the DOS
window, the NCK settings
can be changed later without
having to re-load from the disk.
install.bat The actual installation routine
for disk installation. This
routine is started by file
„inst_nck.bat“.
C:\840D.INS\doku Log files for NCK disk installation
C:\840D.INS\INSTTOOL Utility files for NCK disk installation
C:\840D.INS\MD Copy of directory C:\840D\MD
C:\840D.INS\MDDAT Directories with machine names: for generating file
INITIAL.INI
C:\840D.INS\SAVE Directory to where the INITIAL.INI and MASCHINE.INI
files of the last software version are saved during the
installation
C:\840D.INS\TCOMMC\ Files installed to directory C:\TCOMMC\EXE during the
EXE NCK disk installation.
C:\840D.INS\ZYKLEN Directories with machine names: for installing
NC cycles
C:\DH\TOPS.dir ToPs programs to be split automatically
C:\DH\TOPSMANU.dir ToPs programs to be split manually
C:\DH\WKS.dir Program parts of the split ToPs programs
C:\DOS MS-DOS files
C:\ETHERIII.isa Initialization file for the network card
C:\IOMEGA Driver files for the ZIP drive. Initialization by the
“guest.exe“ file when Windows is not active
C:\MMC0 Directory for a SIEMENS user interface software
package and DOS. No longer used.
C:\MMC2 SIEMENS communications driver such as: NCDDE;
MBDDE; DH-SERVER; LANGTOOL
C:\NWCLIENT Novell network software, for installation if the customer
uses a Novell network
C:\Service Batch-Manager to assist the service engineer in
troubleshooting via pcAnywhere.
C:\TCOMMC Main directory for “BOF” operation environment
software
C:\TCOMMC\ Location of backed up databases, see 4.4 “Location of
DBUPDATE backed up databases”
C:\TCOMMC\<machine> Machine-specific data:
*.hlp files, language-specific files for the online help
systems
<machine>.mdb, machine-specific database
<machine>*.com, PLC error texts, language-specific
files
C:\TCOMMC\EXE BOF operating environment:
Active databases
Tcommc.exe, BOF execution file
Tcommc.ini, BOF initialization file
Tcommc*.com, BOF error texts, language-specific files
C:\TCOMMC\LOG Log files of the software logbook, such as

"default.log".
C:\TCOMMC\SAVE Data backup directory for specific databases, (see 4.4
“Directory structure and location of databases”.
C:\TCOMMC\SYSTEM System protection
C:\TCPIP Software for TCP/IP network protocols, for installation
if the customer uses TCP/IP protocols
C:\TOOLS\ Driver software for the graphics card in the MMC103
VGA_MMC.103 (Pentium). Initialized by the ”setup.bat“ file.
C:\TRUMPF Software for TOPs-Lite, optional
C:\UPDATE.MMC Directories of all MMC versions installed on this
machine. Contains backups of various files.
C:\WINAW PcANYWHERE software for remote diagnostics
C:\WINDOWS WINDOWS operating system software
C:\WININST WINDOWS installation routines
3.3 MMC software structure
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3.4 Servers
Data transfer within the MMC takes place via DDE (Dynamic Data
Exchange). When the operation environment wishes to
communicate with the NCU, the data transfer takes place via the
NC-DDE server.
NC-DDE-Server The NC-DDE server is the communication interface between the

MMC and the NCK/PLC control. The MB-DDE and DH server
communicate with the control exclusively via the NC-DDE server.
The NC-DDE server reads the system variable data (e.g. axis data)
per link from the control (NCK/PLC), for the MMC:
• Hot Link: System variables are continuously read

• Warm Link: System variables are read only during
actions
• Cold Link: System variables are read only on request
The NC-DDE server offers various services:
• Variable service:
The NCK/PLC control is able to issue the command to read
variables via a defined memory address (DB or I/O) through
this server (e.g. reading of axis data or PLC debugger).
• PI service:
Permanently stored Siemens sub-routines can be called up
with the PI server. A hardware RESET can be initiated by
issuing a command through the PI server, for example.
• Domain service:
Data transfer and program transfer between the MMC and the
NCK takes place through the Domain server. The Domain
server is purely a copy service.
DH-Server The DH (Data Holding) server has the task of continuously reading
the NCK "DH directory" and to transfer this information to the MMC
display.
MB-DDE-Server The report server has the function of transferring all alarms (reports
and error messages) from the PLC and NCK to the display at the
MMC.
Hook-Server • Keyboard server

• Generates display code (String Code or Scan Code) for the
selected operation environment (Siemens or TRUMPF).

3.5 Further software components
80386 Exception Handler The exception handler is a diagnostic aid which generates the
CORONER.LOG file in the C:\WINDOWS directory. The system
status (at the time a violation occurs) is written to the
CORONER.LOG file. The development department is hereby able
to determine the cause of the violation.
Language-Server This server is required for language change within the Siemens
(langtool.exe) software. The language server also assures that error texts are
displayed in the selected language. Siemens accesses the *.com
file. The language server is not used for TRUMPF functions.
TRUMPF uses the database texts for display.
3.6 Changing languages
The desired language for the operation environment and error text
display and on-line HELP can be selected from the operation
environment:
1. Select “Operation (1) – Maintenance/Start-up (5)“

2. Select “Display“
3. Mark the desired language with the cursor
4. Press <ENTER>
Fig. 18384E

3.7 Passwords and exclusions
The customer should not be able to close the TRUMPF

environment to open other Windows applications. The great
danger is that the basic system setup can and will be altered,
causing the environment to become unstable. For this reason, a
password has been used to prevent closing the operation
environment.
Please note that passwords may never be passed on to the

customer!
For service and diagnostic purposes, however, the disabling

function must be inactivated.
st
MS-DOS level: 1 Possibility:
"GOTO DOS"
1. Select “Diagnostics – Service – SW-Logbook“
2. Press the <MS-DOS> softkey
3. Enter the “GOTO DOS“ password
The MS-DOS input window will appear on the monitor.
This window can be closed with the EXIT command.
nd
2 Possibility:
1. Press <ALT> + <TAB> to change to the Program Manager

2. Select the “Main“ program group
3. Select “MS-DOS prompt“
4. Enter the “GOTO DOS“ password
The MS-DOS input window appears on the monitor.
This window can be closed again with the EXIT command.
Windows applications: Password “Windows” is required for the following applications:

"Windows" • File Manager
• Windows setup
Procedure:
1. Press <ALT> + <TAB> to change to the Program manager
2. Select the desired program group
3. Select the desired application
4. Enter password “Windows”
The selected Windows application will be started.

Closing the operation Pressing the “CLOSE WINDOWS” button on the operation panel
environment without closes not only the control operating environment but WINDOWS
closing Windows: as well. Further DOS level input is no longer possible after having
"(min)tco" pressed “CLOSE WINDOWS. If you wish to close only the
operation environment without closing Windows, proceed as
follows:
1. Select “Diagnostics – Service – Development – Close“

2. Enter the password:
The password consists of the current minutes display (top-right
of monitor) and “tco” e.g. 35tco
3. Press the <Close> softkey
st
Confidential selection 1 Possibility:
menu: "SYSTEM"
1. Enter password “SYSTEM” within 3 seconds when the
“starting MS-DOS” message appears during system boot-up.
A confidential selection menu appears on the monitor.
nd
2 Possibility:
1. Press <t> for Teleservice within 3 seconds after the “Starting

TRUMPF Operating System” message appears during the
system boot-up phase.
2. When the “Ready for Teleservice (don’t press any key)“
message appears, enter password “GOTO DOS“.
The DOS prompt appears.
3. Enter “exit“
4. Press ENTER
The confidential selection menu appears on the monitor.
Other passwords Low priority: mintco

Highest priority: min530
SIEMENS stage 0 and 7: no write protection
SIEMENS stage 1: sunrise
SIEMENS stage 2: ECHTZEIT

4. Databases
4.1 Definition
Databases are of elementary importance to the TRUMPF operation

environment. A database consists of binary files, which cannot be
executed. In our case, the databases are in MS ACCESS format,
recognizable by the *.mdb extension. Files of this type can be
viewed in Microsoft ACCESS.
A basic element of a database are its tables. These tables contain

the actual information data. Tables consist of lines and rows. Lines
in a database are referred to as data blocks or records, the rows as
data fields.
Fig. 17672
The search for specific data in a database is referred to as a query.
4.2 Database structure
The MMC hard disk carries not only one, but several databases
which are interlinked. This structure allows a machine-
independent operation environment. Further advantages of this
structure are:
• Machine-independent databases such as the PLC software

can be extracted and separately managed.
• Only the machine-specific databases need to be updated
during a software update.
• Data save mechanisms are activated only for customer specific
data. This allows for a substantial time gain when starting the
operation environment.

A global database called “TCOLINK.MDB“ has been created so
that data can be structured logically. This database contains only
links to tables in other databases (which is why it is called
TCOLINK). Otherwise, this database contains no other data.
The database has been split up in such a way that each section in
the development division (PLC, NC, MMC) can perform a software
update independently of the others. This makes absolutely clear
who is responsible for specific data; a further advantage is that the
data belonging to a different section cannot be overwritten, hence
there is no danger of accidentally destroying the functionality.
As development work is done for more than one machine at the

same time, machine-specific data is also saved in machine-
dedicated databases.
The research department supplies technology data, especially for

lasers. This technology data is stored in its own database. Before a
new software version is released, its technology data is adopted.
Each machine / installation has different options or special settings.

This data may not be modified when the software is updated. The
application parameters responsible for ensuring this are defined by
the MMC, and also by the PLC. So there exists customer data
which is MMC-specific and other customer data which is PLC-
specific. The independence of all divisions can therefore only be
achieved by having two customer databases.
During a software update, therefore, only the customer database

and the technology database need to be updated. The data backup
mechanisms (Repair / Compress / Save) are used for these
databases only. When the operation environment is booted up, this
saves a lot of time.
The customer database can be kept much smaller. This means it is

possible to make a backup of the customer database on diskette.

7
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4.3 Database directory structure and
contents
Sub-directories Databases
C:\tcommc\exe TCOLINK.MDB
This database contains only links to tables in other
databases. This database on the operating panel
computer is not updated. All links are defined during the
development phase.
TCOUPD.MDB
This database is similar to the TCOLINK database.
However, the links here go to directory
c.\tcommc\dbupdate\old.
This database is only accessed during a software
update.
C:\tcommc\exe TCOMMC.MDB
Contains all error texts for the BOF operation
environment. Also all other tables needed by the MMC
(all languages).
TCOPLC.MDB
Texts for, and states of, the switch elements in all
languages. Also help texts for configuration data.
TCONC.MDB
The database contains all error texts for the NC in all
languages. The database is machine-independent.
It also contains all texts for the Teach panel.
During installation, the contents are modified,

depending on whether a Siemens or Bosch control
system is connected.
C:\tcommc\exe LTT.MDB
This database is updated constantly by the research
department and contains all laser technology tables.
Before you can replace this database with another one,
you must ensure that the table structure is correct (the
same software version!)
During primary installation, depending on the machine

involved, a LTT_TC?.MDB file is copied from the
appropriate machine directory into the working
directory, and assigned the name LTT.MDB.
C:\tcommc\exe TCOCUST.MDB
This database contains all customer-specific data
(tools, programs, machine data) provided by the MMC.
PLCCUST.MDB
This database contains all customer-specific data
(configuration data) provided by the PLC.

C:\tcommc\exe MDE.MDB
Machine data register
ATM.MDB
Automatic startup logs
C:\tcommc\exe USERDLG.MDB
Texts in all languages for dialog programming
C:\TCOMMC\XYZ XYZ.MDB
Machine-dedicated database
PLC error texts for machine XYZ* in all languages
I/O settings in the languages GER, ENG, FR (from
schematics)
* XYZ: placeholder for:

TC600L, L2530, L3030, TLC, TC2000R, L2502,
Tubematic, .....
4.4 Database directories
Working directory
The working directory for the databases is c:\tcommc\exe, except

for machine-specific databases such as TC600L.MDB. Databases
of this kind are located in the directory with the machine name, for
example c:\tcommc\TC600L
Backup directory
c:\tcommc\save These specific databases, which change during the runtime, are
backed up to the directory c:\tcommc\save every 24 hours, when
the system starts up again:
• LTT.MDE
• MDE.MDB
• PLCCUST.MDB
• TCOCUST.MDB
The backed up database is assigned the file extension *.md0.

*.md1 or *.md2. This means that the oldest backup is erased so
that the c:\tcommc\save directory only ever contains two backup
versions of a particular database.
If the c:\tcommc\save directory contains backups with the file
extension *.mdb, then these backups have been made manually
on the hard disk using function 1 Operation, 5 Maintenance/Setup,
2 Data backup, Customer data.

Directories during DB update
c:\tcommc\dbupdate\old In the case of MMC software update, all the databases for the old
software version are first copied into the directory
c:\tcommc\dbupdate\old.
From there, the data is imported into the new databases during the
database update.
c:\tcommc\dbupdate\new During an MMC software update, the new databases are loaded
into the directories c:\tcommc\dbupdate\new and c:\tcommc\exe.
In the directory c:\tcommc\dbupdate\new nothing is done with
these databases. They are just stored there with their original
/standard contents.
c:\tcommc\exe After an MMC software update, the databases are located in

directory c:\tcommc\exe with their original /standard contents.
Not until the database update are the specific database contents of
the old software version imported from directory
c:\tcommc\dbupdate\old into the databases in directory
c:\tcommc\exe. This ensures that they once again contain the
specific data.
In directory c:\tcommc\dbupdate\new, the databases still contain

the original/standard data.
Schematic representation of DB-Update

an MMC update
c:\tcommc\exe c:\tcommc\dbudpdate\old
tcolink.mdb tcoupd.mdb
import
new spec. DBs old spec. DBs

Fig. 23772E

5. ODBC interface
The ODBC interface (Open Database Connectivity) allows the

operation environment software (BOF) to access the databases
without the need for an application program such as ACCESS. The
ODBC interface is internationally standardized and uses SQL
(Structured Query Language). This interface is realized by means
of an ODBC driver which is automatically loaded during Windows
initialization. The driver must be informed as to the name and
location of the database and the password for access.
Database ODBC driver BOF
Fig. 17675E
These settings can be made using an ODBC administrator

auxiliary program.
5.1 ODBC administrator
The ODBC administrator can be started in two different ways:

st
1 Possibility: From the operation environment
1. Operation (1)
2. Maintenance/Start-up (5)
3. Data backup (2)
4. Press the <ODBC-Admin> softkey
5. Enter the password: “minutes530”
6. Press <ENTER>
nd
2 Possibility: From Windows
Exit the operation environment (BOF) so that no further database

access takes place:
1. Diagnostics (2)
2. Service (4)
3. Development (2)
4. Close (6)
5. Enter the password: “minutes530”
6. Press <ENTER>
7. Press the <Close> softkey
8. Open the “Main” group in the program manager
9. Control panel
10. ODBC

6. Database errors
Database errors can result if Windows is closed incorrectly.

Turning the machine OFF (main switch OFF), before Windows has
been properly closed is the most frequent cause of database
errors. A system crash (protection violation), however, can also
damage the databases.
Automatic backup Further protection is offered by storing databases containing

mechanism customer data (TCOCUST.MDB, LTT.MDB and PLCCUST.MDB)
automatically after 24 hours if the machine has been turned off.
If the operating environment is not shut down properly, a database

backup is automatically performed the next time the system is
booted up.
A database backup is executed only if a repair and compress has

been successfully completed. This procedure assures that only
such databases that are properly structured can be saved. The
backup is made to the C:\TCOMMC\SAVE directory. The number
of current backups is limited to 2 whereby extensions can contain
the names “MD0“ or “MD1“ or "MD2". The current backup can be
identified by the date and time.
6.1 Automatic database backup
A C:\TCOMMC\ EXE\BOFEXIT.LOG file is created when the

operating environment is started.
Fig. 23996
If the operating environment (BOF) is closed down properly, the

system deletes this file.
When the BOF starts up, the system checks whether the
BOFEXIT.LOG file is present. If yes, this shows that the BOF
software was not shut down properly, and the system then starts
the database backup function.
During the backup, the system first attempts to repair and
compress the databases. If it succeeds - the database structure is
therefore OK – it backs up the database to directory
c:\tcommc\save.

If the database cannot be repaired, the user is prompted to confirm
that the system should copy the most recent backup from the
directory c:\tcommc\save to directory c.\tcommc\exe.
The size of the database is also checked. If it has an invalid size,
the database is reported as being defective and stored under
*.FLT. In a dialog, the operator can copy back the last database
backup.
File "DBREPAIR.LOG" in the c:\tcomm\exe directory records when

the database backups were made.
File DBREPAIR.LOG also logs the number of times the

MMC/operating environment crashes.
Note:
In addition to this, the cause of a possible system crash is also
recorded in monitoring file coroner.log.
See 8.5 Monitoring tools/files
6.2 Database backup by the operator
The operator can execute a database backup himself:
1. Select „Operation (1) – Maintenance / Start-up (5) – Data

backup (2)“
2. Press the Save data group softkey
The backup is stored to C:\TCOMMC\SAVE as standard
procedure. These backups have the extension *.MDB and are
overwritten by the next backup by the operator.
A floppy disk or the network serve as further backup options.

These media are preferred to a backup to the MMC hard
disk, as a defective MMC hard disk will result in the loss of
such backup files.
6.3 No connection to a database
If the message “No text received from database” appears during

the operating environment boot-up phase or if no table contents
are displayed, a faulty ODBC connection can be the cause. In this
case the settings must be checked with the ODBC administrator.

Opening the ODBC 1. Select „Operation (1) – Maintenance / Start-up (5) – Data
administrator backup (2)“
2. Press the ODBC-Admin softkey
3. Enter the “Minutes530” password
4. Press ENTER:
As the ODBC administrator can only be used when databases
are not being accessed, the latter are automatically closed.
The following dialog is displayed:
Fig. 18367
Check database driver for Check if all database drivers displayed in Fig. 18367 are installed.
completeness Additional database drivers will be displayed if ToPs 100 lite is
installed. Machines with MDE (machine data register) have an
additional driver named MDE.
Connect database driver If all database drivers are available check to insure that these are
with database linked to their respective databases:
1. Mark the respective database driver (e.g. B. LTT)

2. Press "Setup"
/77
Fig. 18515
3. Check the path and database name entry listed behind the
“Database: entry. If this entry is incorrect, press “Select”.

Fig. 19928
4. Select the correct path and database name

5. Click "OK"
The dialog field will be closed.
/77
Fig. 18515
6. Click "Advanced..."

Fig. 19929
7. Check login name (trumpf)

8. Check password (secret)
9. Click "OK"
The dialog field will be closed
/77
Fig. 18515
10. Press "Options>>"

Fig. 18516
11. Check buffer size (512)

12. Click "OK"
Fig. 18367
13. Press "Close"

The ODBC administrator will be closed
The databases must be reconnected to the operating

environment after closing the ODBC administrator. This is
accomplished by pressing the Link database softkey!

Adding missing database The "TCOLINK". database driver is missing in Fig. 18370
drivers
Fig. 18370
This database driver must be added in the following manner:
1. Press "Add"
Fig. 18373
2. Mark "Microsoft Access Driver (*.mdb)"

3. Click "OK"
Fig. 18374

4. Enter the name of the database driver in the "Data Source
Name" field, here: TCOLINK
5. Press "Select..."
Fig. 18369
6. Select the correct path and database name

7. Click "OK"
Fig. 18368
8. Press "Advanced..."

Fig. 18371
9. Enter login name (trumpf)

10. Enter password (secret)
11. Press "OK"
Fig. 18368
12. Press "Options>>"

Fig. 18372
13. Check buffer size (512)

14. Click "OK"
Fig. 18367
15. Press "Close"

The ODBC administrator will be closed
After closing the ODBC administrator, the database must be

re-linked to the operating environment. This is accomplished
by pressing the Link database softkey!

6.4 Corrupt database
A damaged database which cannot be automatically repaired

during operation environment (BOF) bootup can be repaired by the
service technician by means of a “Repair”. The ODBC
administrator must be opened for this procedure:
Open ODBC-administrator 5. Select „Operation (1) – Maintenance / Start-up (5) – Data

backup (2)“
6. Press the ODBC-Admin softkey
7. Enter the “Minutes530” password:
8. Press ENTER:
As the ODBC administrator can only be used when databases
are not being accessed, the latter are automatically closed.
The following dialog is displayed::
Fig. 18367
Database repair 1. Mark the respective database driver (here: LTT)

2. Press "Setup"
/77
Fig. 18515

3. Press "Repair..."
Fig. 17676
4. Mark the respective database (here: TCONC.MDB).

5. Press "OK"
The database repair will be started.
The repair is successfully ended when the following message
appears:
Fig. 17677
6. Acknowledge by clicking "OK"
/77
Fig. 18515

7. Important: Select the "Cancel" button. An incorrect database
link can result if the database is closed with "OK"!
Fig. 18367
8. Press "Close"
The ODBC administrator will be closed.
After having closed the ODBC administrator, the databases

must be re-linked to the operation environment. This is
accomplished by pressing the Link database softkey!
Copying stored databases If a database is so badly damaged that it can no longer be

to the respective directory repaired, a backup of the database (if available) can be copied to
the respective directory:
Databases may only be copied with the DOS command

XCOPY /V. There is a risk of data loss if the COPY
command is used!
Note:
• The most current backup of (TCOCUST. MDB, LTT.MDB,

PLCCUST.MDB) can be copied from the C:\TCOMMC\SAVE
directory or from a diskette if these customer specific files have
been damaged. The backup extension might have to be
changed to *.MDB.
• If a backup is not available, the respective database can also

be transferred to the MMC from the C:\TCOMMC\ DBUPDATE\
NEW directory or by means of pcAnywhere.
• Important: The databases in the C:\TCOMMC\

DBUPDATE\NEW directory have the supply status of the most
recently installed software version.

• The LTT_TCx.MDB (x = a random number) database in the
C:\TCOMMC\“Maschine“ directory represents the LTT.MDB
database status at delivery. This means that customer
changes have not yet been made in this database. If an
original LTT database is required the LTT_TCx.MDB file can
be copied to the C:\TCOMMC\EXE directory and subsequently
renamed to LTT.MDB. All customer changes to the laser
technology tables, however, will be lost in this case!
Following a software change, no data backups may be

restored as the data structure most likely will have changed.
Existing database backups must be deleted after a software
change and new backups must be made.

7. Complete files
7.1 Management
ToPs MMC NCK
Complete file C:\DH\TOPS.DIR Main program and sub-

*.LST routines, plus the tables,
Automatic splitting of are transferred to directory
complete file into master WKS.AKT and processed
program and subroutines, from there.
and of tables.
C:\DH\TOPSMANU.DIR
Operator must initiate

splitting.
Main program and sub-

routines are stored in a
subdirectory of
C:\DH\WKS.DIR.
The tables are entered
in TCOCUST.MDB .
Fig. 18389
The programming system generates a complete file with the

extension *.LST. These files are managed on the MMC hard disk
and transferred to the NCK for processing. Following is a
description of the directory structure for program management:
MMC directory structure
C:\DH\ TOPS.DIR\
TOPSMANU.DIR\ 1098.LST
FOCUS5_1.LST
st
WKS.DIR\ 1 DIR\ P1.LST
P2.LST
P3.LST
nd
2 DIR\ P1.LST
P2.LST
n.DIR\

7.2 Structure of a complete file
A complete file consists of three sections:
• Unit identification:
Unit identification establishes which measuring system is
relevant for the following NC code.
• Table header:
The table header serves as an information transfer medium.
The following, for example, are transferred:
• Set-up plan information
• Tool technology tables
• Sheet handling tables
• Laser technology table calls
• Processing code (NC text):
The actual processing code is listed after the unit identification
and table header.
Important data for the program is evaluated from the table header.
The following is an example of a SHEET_TECH table evaluation:
BEGIN_SHEET_TECH
C ------------------------------------------- Commentary
ZA,MM,15-------------------------------- Number of characteristic
description blocks (here: 15)
MM,AT,1,40,1,1,,,,’mm’,Z ------------ Identification number 40
MM,AT,1,20,1,1,,,,’mm’,Z
MM,AT,1,30,1,1,,,,’mm’,Z
MM,AT,1,50,1,1,,,,,Z
MM,AT,1,70,1,1,,,,’Bool’,Z
MM,AT,1,100,1,1,,,,,Z
MM,AT,1,110,1,1,,,,,Z
MM,AT,1,120,1,1,,,,,Z----------------- Characteristic description
MM,AT,1,130,1,1,,,,,Z blocks describe table
MM,AT,1,160,1,1,,,,,Z parameters
MM,AT,1,170,1,1,,,,,Z
MM,AT,1,180,1,1,,,,,Z
MM,AT,1,190,1,1,,,,,Z
MM,AT,1,210,1,1,,,,,Z
MM,AT,1,10,1,1,,,,,T
C
ZA,DA,1 ---------------------------------- Number of characteristics
blocks (here: 1)
DA,3.0,1000.0,1000.0,0,0,5,11,17,0,0,0
* ,4,11,-1,’SHT-1’---------------------- This block is generated from
the above characteristics
description blocks.
ENDE_SHEET_TECH A data block is generated from
the DA block.

7.3 Splitting a complete file
Complete (master) files destined for manual splitting are stored in

the C:\DH\TOPSMANU.DIR directory.
If files are stored to TOPS.DIR, the operation environment
automatically splits the file after maximum 60 seconds (automatic
MMC check cycle on available *LST files). The complete file is
subsequently deleted.
Complete file
Values are entered Main program and subroutines

in the corresponding are transferred to corresponding
tables directories
e.g. TCOCUST C:\DH\WKS.DIR\2.DIR

SheetTech P1.lst, P2.lst
NCP_Stückliste
Manual splitting of a complete file Fig. 18385E
1. Select "Operation – PROGRAM – File management"

2. Select the desired file using the cursor
3. Press the Split master file softkey
Splitting of the complete file will be started:
• Table values from the table header are entered to the
tables in the operating environment. A SQL command is
generated for each block of the header for this operation.
The newly entered values of the just split program are

entered in the first line of the SheetTech table:
Fig. 17674
• The processing code is transferred. The first sub-routine is

transferred to the C:\DH\WKS.DIR\2.DIR directory as
P1.LST and the main program (for example), as P2.LST to
the same directory. A corresponding entry is made to the
NCP_STUECKLISTE table of the TCOCUST.MDB.

Fig. 17673
This entry makes it possible to subsequently locate and

process the program.
With this, the splitting procedure is finished. When a program is to

be processed at the machine, it must first be transferred from the
MMC to the NCK:
1. Select "Operation – PRODUCTION – Single job"

2. Press the Select program softkey:
The respective program parts are transferred to the NCK:
• Main programs and subroutines are transferred to the
\DH\WKS.DIR\AKT.DIR directory with the original program
names (P1, P2, Pn) and the extension *.MPF.
• Sheet handling tables are copied from the database to the
\DH\WKS.DIR\AKT.DIR directory and assigned respective
extensions (*.SHL, *.SHT, *.SHU, *.PTT, *.PAU, *.RPO)
according to the table type.
• Laser technology tables are copied from the database to
the \DH\WKS.DIR\LTT.DIR directory and assigned the
extension *.LTT.
NC directory structure
\DH\ WKS.DIR\ AKT.DIR\ 1.MPF

2.MPF
SHT-1.SHT
LTT.DIR\ 4950.LTT

8. Diagnostic possibilities
8.1 MMC 7-segment display
The MMC has a 7 segment digital display to indicate the progress

of internal checks during system boot-up. If an error is recognized,
the routine (together with the display of the routine which
recognized the error) will halt. Because the display can only
indicate one character at this time, two-digit hex value are
differentiated by the varying display duration.
Display duration Long: a high Hex value

Short: a low Hex value
When an error has been recognized, the Hex values will be

repeated in an exactly defined cycle.
The MMC102’s 7-Segment display is normally OFF. The

MMC103’s 7-Segment display shows “8” (Pentium 200) or
"3" (Pentium 133) following a correct boot-up. The decimal
point lights up for both the MMC 102 and the MMC 103
during a hard disk access.
HEX character display
Fig. 11725

8.2 Fatal System Error 1
If this error occurs, one or more of the following files in the

C:\TCOMMC\SYSTEM directory are missing:
• CHKFILES.BAT
• MENU.BAT
• PASSWORD.EXE
• WINPASSW.EXE
• SYSPASSW.EXE
The missing file or files must be copied back to the MMC hard disk
drive per floppy or the pcAnywhere remote diagnostics program.
The boot procedure cannot otherwise be correctly completed!
Upload missing files from 1. Insert a bootable floppy in the floppy drive. If you do not have a
floppy disk bootable disk, proceed as follows:
• Insert a new floppy disk in the floppy drive of an external
computer.
• Change to DOS.
• Enter the command "C:\SYS.COM A:"
All system files required to boot the computer will be
copied to the floppy disk. The floppy disk is now bootable.
• Insert the disk in the floppy disk drive of the controller.
2. Turn the main switch OFF/ON.
3. Press <CTRL> + <ALT> + <ESC> simultaneously when the
blue BIOS prompt appears.
4. Enter the password "SYSTEM".
You are now in BIOS.
5. Select "Boot Sequence" with the cursor.
6. Change the boot sequence with the Plus key from "C, A" to "A,
C".
7. Exit BIOS by pressing F10 and confirm the message with
“Store”.
The MMC will now boot from the floppy disk.
8. Load the missing files to the MMC hard disk.
9. Reset the boot sequence to the original "C, A" configuration.

8.3 Fatal System Error 2
If this error occurs, one or more of the following files are missing in
the directories:
C:\TCOMMC\SYSTEM: • ACCESSOR.GRP
• BEGRENZE.EXE
• CONTROL.ON
• DOSPRMPT.PIF
• HDCHECK.BAT
• HOST.BAT
• INI_FILE.EXE
• MAIN.GRP
• MESSAGE.BAT
• NETWORK.GRP
• NFS1.ON
• NFS2.ON
• PCANYWHE.GRP
• PROGMAN.OFF
• PROGMAN.ON
• REBOOT.EXE
• SCRIPT.GRP
• SERVICE.GRP
• SIEMENS.BAT
• SIEMENS.LOD
• STARTUP.GRP
• SYSTEM.ON
• TCOMMC.GRP
• TRUMPF.BAT
• TRUMPF.LOD
• WIN.ON
• WINDAT.BAT
C:\WINDOWS • CONTROL.INI
• PROGMAN.INI
• SYSTEM.INI
• WIN.INI
When "Fatal System Error 2" appears on the monitor you will be
automatically asked whether Teleservice is desired.
Proceed as follows:
1. Acknowledge the message

"Ready for Teleservice (don’t press any key)" will appear. The
cursor will blink at the bottom left of the monitor.
2. Enter the password "GOTO DOS"
3. Press ENTER
You are now in the DOS environment.
4. Check to see which files are missing from the above
mentioned directories.
5. Load the missing files to the hard disk.

The password must be entered in CAPITAL letters only. If
the password is incorrectly stated three times in succession
all further entry will be blocked and the main switch must be
turned OFF/ON again to continue.
8.4 Automatic start error messages
The purpose of the automatic startup is to ensure that bootup of

the operation environment (user interface) can be monitored.
Thanks to the automatic startup feature, the operation environment
is not offered until it has been initialized completely. One exception
to this is when the laser is initialized. This initialization can take
place while the user is entering commands. The reason for this
procedure is that it takes longer for a laser to start up and be ready
for operation than for a machine to power up. Hence the operator
is not hindered unnecessarily from making preparations for
production. Keep in mind, however that, for example, laser
machine data can be requested only when the laser has started up
completely. The automatic startup status can be checked at the
screen <2. Diagnose <4. Service <2. Development <5.Automatic
startup.
The following takes place during automatic start-up:
• general initializations
• a synchronous and
• an asynchronous step sequence
Once the general initializations have been completed, the

asynchronous step sequence is started. This step sequence is
responsible for tasks involving communication and must therefore
wait for return signals from the NC or PLC before further
transmission. This results in waiting periods, so that the
synchronous step sequence can be run at more or less the same
time.
Notes for Diagnostics
Error during general An error in general initialization usually means that the database
initialization could not be accessed. You can recognize this error because the
screen containing the automatic startup is incomplete.
This indicates that the TCOLINK database does not have a clean
connection to the ODBC administrator. In this case the best thing
to do is to activate the ODBC administrator in the Control Panel
and re-connect the TCOLINK.MDB database (first disconnect and
then re-establish the link).
You can also try and repair the customer databases and the
TCOLINK database manually.

Error in the synchronous If an error occurs in the synchronous step sequence, this is usually
step sequence a software or installation error. (For example, not all configuration
parameters were entered in the database).
This means that configuration parameters may be missing in the
PLCCUST.MDB or TCOCUST.MDB database.
Error in the asynchronous If an error occurs in the asynchronous interface, this suggests that
step sequence the MMC / NCK or MMC /PLC software versions are not
compatible, or that the communication is not working properly.
General problems If there are reports that the operating environment is not running
properly or that errors keep recurring during operation, you should
have a look at the automatic initialization log. Here you can check
the current status of the automatic startup. If there is an entry
“Hochlauf komplett” (bootup complete) then all initialization steps
have run correctly.
Initialization
If automatic start-up stops while the operating environment is

booting up, you can refer to the table below to determine why
automatic start-up was interrupted:
Step Functions executed by the system Function

Start • A connection is established to database
TCOLINK.
• The old diagnostics file dberror.log is deleted.
• The automatic startup is initialized and set to
step 10001 (equals "Init1“).
Init1 • In the ATM.MDB database another log is created GwMainInit1
for the system startup. You can use the log file to
check whether the system was shut down
correctly last time.
• The connection to the alarm server (MBDDE
server) is established by setting up a client to the
MBDDE server. A ring buffer is created so that
the messages can be stored in the MMC.
• For correct communication with the MBDDE
server, hotlinks still need to be set up:
• Hotlink for number of alarms (NrOfAlarm)
• Hotlink for set up alarm list (Alarmlist)
possible error message:
Cannot connect to MBDDE
Init2 • The backup paths are read from GwMainInit2
TCOMMC.INI.
• The system checks whether a file named
BOFEXIT.LOG exists. If it does, this means that
the last shutdown was caused either by a system
crash or by the user turning the main switch
OFF.
• Message texts that are needed for a database
repair are loaded from the database (provide that
the database can be accessed).

• If necessary, connection to the database is shut
down, and the database is repaired. In this
phase it can happen that no text is displayed for
messages arriving from the PLC or NCK (these
messages are not stored in the memory!).
• The repair function is applied to all databases
with customer data. Depending on the option /
machine configuration, these may include:
TCOCUST.MDB, PLCCUST.MDB, LTT.MDB,
MDE.MDB
For each of these databases there must be an
entry in the ODBC administrator. Otherwise they
cannot be repaired.
• The system first determines the database size. If
the size of the files is wrong, the database is
reported as corrupted and saved with file
extension *.FLT.
If an error occurs, the system can restore the
most recent backup of the database from the
backup directory once the user has confirmed
that he wants this to happen.
• All telegram channels are set up:
• channel for receiving alarms
• channel for sending switch element
telegrams
• channel for receiving switch element
telegrams
• channel for sending bitbus telegrams
• channel for receiving bitbus telegrams
• channel for synchronous actions
• channel for machine data
• channel for other DDE events which have to
be reported by telegram
Alarm telegram channel not connected to DDE
• Start event 10203 is set
Init3 • The client for general NCDDE messages, GwMainInit3
NcddeP, is set up
• The Hook server is installed
• The states of the LEDs in the operating panel
are set
• The telegram handler in the MMC is initialized as
well as the alarm function that belongs with it.
• The contents of file c:\dh\wks.dir\datei.nck are
loaded. This is the active main program in the
control system.
Now the system can check in the database which
program parts / tables are required for this program
(needed later for NCK synchronization)
• From the Tcommc.ini file, the system reads in
• The number of magazine stations
• The number of clamps
• The system evaluates the LASTLAS.DAT file.
This file contains details of the last laser program
that was processed (lens, nozzle, etc.).

• The system checks whether Trumatool is
implemented. The result (yes/no) is used for the
Define for screen display (relevant for menu
generation).
• Now the tool management function in the
database is initialized.
• The start event 10301 is set
• The MMC configuration data is loaded from the
database.
• The system checks which measurement unit has
been set (metric / inch).
• The start event 11101 is set
11101 • The system checks if automation components Src1init
have been installed.
• It loads the configuration data for src1 from the
Tcommc.ini file and the database
• It defines an instance for the measurement unit
manager (important for switching between metric
and inch)
• The number of lift component axes is loaded
• If a Trumalift is present, the module status is
initialized.
• The system checks if the AutolasPlus option has
been set.
• Event 11201 is set
11201 • The I/O texts are loaded from the database. Src2init
Depending on the option selected, these can be:
• texts for the basic machine
• texts for the laser
• texts for the Liftmaster
• For dialog programming, the hotlink
/Channel/Configuration/mmcCmd[u1] is set up
• The data in the program-specific tables is
loaded.
11301 • The system loads the configuration of the src3 Src3init
from the database and Tcommc.ini file.
11401 • Initialize the production plan Src4init
• Load configuration parameters
• Initialize the SQL interpreter
• Initialize the telegrams
11501 • The system carries out the complete initialization Src6init
of tool data.
11601 • A client is set up for the DDE debugger Src7Init

11701 • The Define TLFLASER is set in accordance with Src8init
the configuration. This is taken into account
during menu generation..
Only for laser machines:
Suppress autotelegrams to the laser until
initialization has been completed.
The time is set in the laser
11801 • Initialize MDE Srcainit
12201 • Reset the automatic startup for the synchronous
step sequence
• Create the hotlink to alarms GwMainInit3
• Create a hotlink to the channel for sending
switch element telegrams
• Create the hotlink to receive switch element
telegrams
• Request for offset for channel for sending bitbus
telegrams
• Hotlink to the access level (access rights for
machine data)
• Switch to automatic startup event (10203)
• Screen switching is enabled
• Load GUI file. To do this, the system starts a GwMainInit4
batch file. As long as this file is running, nothing
else happens
• Disabled menu options are now enabled
• The system issues a message that initialization GwMainInit5
has been completed
• Append ATM_PROTOKOLL
Asynchronous communication step

sequence in automatic startup
Step Functions executed by the system Function

21/12101 • The system creates a DDE client for general NC Src1Sequenz
messages Init

Cannot connect to NCDDE
• The time and date are set in the PLC/NCK
50/15001 • The system creates a hotlink to the active block Src1Sequenz
number of the main program. This is to Init
determine which block was last processed if the
program is re-entered: channel1, HP level.
Item: /Channel/ProgramPointer/blockNoStr[u1,1]
• possible error message:
Cannot connect to NC

51/15101 • Hotlinks and requests are set up to PLC/NCK Src1Sequenz
for: Init
• Reference position
• Program end
• RESET
• Read-in inhibit
• Feed disable
• Laser status
• PLC control type
• Teaching
(The items are compiled for this request as
described in the interface description)

Cannot connect to PLC
The items listed below are for the NCK:

• Operating mode
(Item: /Bag/State/opMode)
• Create variable for transfer status
• Create connection for tool management,
Item: /tco/wzv_nck_to_mmc
• Number of axes, item:
/channel/configuration/numMachAxes
• Comment on the currently processed record
/Channel/ProgramInfo/msg[u1]
Cannot connect to PLC
52/15201 Only for punching machines: Src1Sequenz
Transfer of rail assignment Init

Rail assignment cannot be transferred to NCK.
For laser machines:
Step is ignored.
53/15301 • The system checks the contents of the NCK Src1Sequenz
directories Init
DH-Server is not responding to command 10.
List of contents cannot be read by the NCK.
54 15401 The asynchronous sub-programs are communicated Src1Sequenz
to the NCK. Init
31/13101 Currently no function assigned Src1Sequenz
Init
23/12301 Siemens control system: src3SequenzI
nit
The Siemens machine data is loaded:
To do this, a step sequence is started which retrieves
all binary data of the machine data.
• General machine data
• Channel-specific machine data
• Axis-specific machine data
• Global user data
• General setting data
• Channel-specific setting data

• Axis-specific setting data
• Feed data

Machine data cannot be read by the NCK
The system retrieves laser machine data only during
laser initialization.
Bosch control system (only on TC2000R):
• Set target name for Type 3
• Initialize Bosch machine data
• Carry out one-time conversion from Unix
character set to Windows character set
Machine data cannot be read by the NCK
33/13301 Event 13301 is set
26/12601 Machine with punching functionality: Src6Sequenz
The system initializes tool management Init
Machine without punching functionality:

Event 12601 is set
• Tool synchronization between Trumatool and rail
36/13601 • The system checks if Autolas-Plus is present. If
not, event 13601 is set
• The focus offset is transferred to the PLC.

AutoLas Plus focus position offset cannot be
transferred to the PLC.
29/12901 • The system checks if there is a TC-CELL Src9Sequenz
connection Init
• The system checks if there is a TC-CELL server
connection
Ready/0 • The system loads the appropriate menu Switch
screen to
Production
menu
28/12801 Machine with laser: Src8Sequenz
Init
The system runs the initialization for the laser.
• Automatic telegrams are reported at the
telegram handler for:
Switch elements, alarms, operating messages

Machine without laser
Event 12802 is set

81/18101 • One-time request for laser alarms
• System initializes automatic telegram for laser
status
• Request for laser status and beam data
Telegrams reacting to laser alarms, laser status or
beam data not received.
83/18401 possible error message:
First telegram with laser machine data not received.
84/18402 • Get machine data from laser
Telegram with laser machine data not received.
85/18402 • Get machine data from laser
Telegram with laser machine data not received.
86/18602 • The system requests display control data from
the laser, via a step sequence.
Telegram with display control data not received.
87/18602 possible error message:
Telegram with display control data not received.
38/13801 Machine with laser:
• Laser machine datum number 0 is set to 1. This
activates the automatic telegrams.
Machine without laser:
Some messages are displayed in the operating environment:
Fig. 17678E

8.5 Monitoring tools/files
The following monitoring tools/files are used in the MMC:
DBERROR.LOG
BOFEXIT.LOG
DBREPAIR.LOG
LASTERROR.LOG
HDCHECK.LOG
PROTO.TXT
CORONER.LOG
SOFTWARE logbook
With the monitoring tools, error situations are logged.

These logs are written to the files assigned for this purpose, and
can then be analyzed.
As it is usually the software development department which carries

out this analysis, these files are made available to this department.
You can access the contents of the files by selecting the function
1 Operation
5 Maintenance/Start-up
2 Data backup
in the data group "System files".
Description
DBERROR.LOG Path: c:\tcommc\exe\dberror.log
SQL commands with errors are recorded in the DBERROR.LOG

file.
All SQL commands going to defective databases are also logged.
The following error message is displayed if a fault occurs:
Fig. 23994

DBERROR.LOG:
Fig. 23995
File DBERROR.LOG is deleted every time the operating

environment is rebooted.
BOFEXIT.LOG Path: c:\tcommc\exe\bofexit.log
Please also refer to Section 6.1 "Automatic database

backup".
The C:\TCOMMC\EXE\BOFEXIT.LOG file is used to check

whether the BOF operation environment was last shut down
correctly or not.
File not present when the operating environment boots up:

The operating environment was shut down correctly. A new copy of
the file is created after the bootup check. If the operation
environment is shut down correctly, the system deletes the file
from the hard disk.
The system performs a database repair if the system was last

booted up more than 24 hours ago.
The file is present when the operating environment boots up:

If this is the case, this means that the operating environment was
not shut down correctly.
This happens if:
• The system crashes
• The user turns the main switch OFF
This can result in a database crash. This happens if the database

was accessing data when the operating environment was switched
off. For this reason, when the MMC is started up, the system will
always carry out a database repair and compression, followed by a
database backup.

DBREPAIR.LOG Path: c:\tcommc\exe\dbrepair.log
Please also refer to Section 6.1 "Databases during operating

environment bootup"
In this file a log is kept of each time the operation environment is

booted up and shut down.
It also logs the times at which database repairs take place.
You can use this file to see how often a customer actually powers
up the operation environment. This can show whether or not the
customer is exaggerating when claiming that the operation
environment constantly crashes.
Contents of DBREPAIR.LOG:
Line Contents
1 24.11.1998, 14:44, dbSave: 0, <Power Up MMC, last exit of MMC OK>

2 24.11.1998, 14:45, dbSave: 0, <Saving by Time Control>
3 24.11.1998, 16:17, dbSave: 0, <Power Down MMC>
9 25.11.1998, 15:23, dbSave: 0, <Safing by Time Control>
10 26.11.1998, 14:56, dbSave: 0, <Power Up MMC, last exit caused ERROR>
11
Line 1:
The operation environment is being powered up. At this point in
time, in this case, the BOFEXIT.LOG file is not present on the hard
disk, so the operation environment was shut down correctly last
time.
Line 2:
The system main switch was last switched off over 24 hours ago.
The system creates a backup copy of the customer databases in
c:\tcommc\save.
Note: This line is part of the power-up process described in Line 1.
Line 3:
The system exits the operation environment.
Line 10:
When the operation environment boots up, the system finds that
the BOFEXIT.LOG file is present. It makes a database repair. The
error status is indicated with the comment <Power Up MMC, last
exit caused ERROR>.
To check whether there has been a system crash, you can

interpret the contents of the file in the following way:

If an entry like the one in Line 10 exists, there has either been a
general protection fault, or someone turned the main switch off
before the operation environment had completely shut down.
If there has been a system crash , this is usually also shown in the
c:\windows\CORONER.LOG file. You will find the starting point of a
system crash when you see the following lines:
Coroner exception report - 11/26/1998 14:50:50

Exception 13 at TCOMMC 2FA7:775F (0029:775F)
(TASK=TCOMMC)
In this example the Coroner.log file shows a system crash on 26

November 1998 at 14:50 hours. Since the Dbrepair.log file
contains an entry made at the same time, in line 10 (26 November
1998 at 14:56) it is clear that there has been a system crash.
However, if the Dbrepair.log file contains a line such as <Power Up
MMC, last exit caused ERROR> but the Coroner.log file has no
entry made at the same time, this means that the customer almost
certainly turned the machine off at the main switch.
CORONER.LOG Path: c:\windows\coroner.log

A system crash of the operation environment is logged in the
CORONER.LOG file.
The software development department can analyze this file to
determine the cause of the system crash.
For this, the CORONER.LOG file must be sent to the software
development department.
LASTERROR.LOG Path: c:\tcommc\exe\lasterror.log
This file is not created as default. To obtain this file you must first
change an entry in the c:\tcommc\exe\tcommc.ini file:
[Debug]
ddeLastError = 1
When the operation environment is rebooted after you have made

this change, the system opens a dialog box if a “Last error” event
occurs. The errors that occurred are then displayed in this box. The
data can be output to the c:\tcommc\exe\lasterr.log file.
To determine the meaning of lasterror.log files, send them to the

TCO Service department.

HDCHECK.LOG Path: c:\hdcheck.log
This file is generated by Scandisk. It contains the results when

Scandisk checks and fixes a data storage device such as a hard
disk.
Fig. 23984
This file excerpt shows that, on 30 March 1999, at 2.01 p.m.,

ScanDisk discovered that two clusters were lost in an MS-DOS file.
PROTO.TXT Path: c:\mmc2\proto.txt
The Siemens MBDDE server logs all incoming error messages in

the proto.txt file. This file can help you if the operation environment
crashes when it receives error messages. This can happen if
invalid translations have been entered in the database. You can
use the error time, which is also recorded in the log, to find the last
error that occurred.
The dashed line in the file marks the start and end of the file.
If there is a control character in the Proto.txt file, there will be

constant MBDDE general protection fault messages.
If you want to edit the Proto.txt, therefore, you should, for
example, copy it into the c:\tmp directory and edit it there.
If you start getting the MBDDE general protection fault error
message, delete the file in DOS: the system will re-generate
it next time MBDDE is re-started.
To determine the meaning of Proto.txt files, send them to the TCO

Service department.

Fig. 23985E
SOFTWARE logbook The SOFTWARE logbook is activated via Service – Development –

SW Logbook.
In the SOFTWARE logbook, a log is kept of software processes
and software states.
Log files are created for this purpose. Their name format is
"logboolx.log", where the "x“ is a number from 0 to 9. These files
are located in directory “c:\tcommc\log”.
These files can be analyzed by the software development

department if you send them the files
Fig. 23986E

There are three output methods:
1. Memory
The log is created in the RAM. The size of the memory buffer
is 32768 bytes. You can copy the log into the Windows
Clipboard by pressing the Show key. The advantage of this
method is that the log is created very quickly. The
disadvantage is that the memory is relatively small. The
system stops creating the log when the memory buffer is full.
You can press the Clear key to empty the memory buffer. The
system then starts logging again at the beginning of the
memory buffer.
2. Screen
The system creates a log directly in the additional MMC
window on the screen. Currently this only works for the 16bit
operation environment. Disadvantage: the buffer is too small.
3. File
The system creates a log in a file. This is the method that is
most commonly used. A maximum of 10 log files are generated
(logbook0.log to logbook9.log). Logging begins with
logbook0.log. Once the file has reached a pre-defined size
(tprint has been called up 1000 times), the system starts using
the next file, logbook1.log. The process continues in this
manner. Once the logbook9.log file has reached a pre-defined
size, the system uses file logbook0.log again. Advantage of
this method: permanent recording, so the log is still present
and available again after MMC crashes. Disadvantage: it slows
down the operation environment. In tcommc.ini you can see
which logging file is the current one.
The ID code is set or cancelled

• by clicking with the mouse on one of the 100 ID codes
• by entering the ID code in the "Set“ input field. For example,
you type 1,9-13,15,200-209 and press Enter.
In the "Selection“ field you choose one of the following:

• No log: Ignoring the set status of all ID codes, the system
creates no logs.
• Selection: Log as defined by the current settings of the ID
codes.
• Log all: Ignoring the set status of all ID codes, the system logs
everything.
In the "Active phases“ dialog, you can select or deactivate the

following options which can be combined with each other:
• Start up: Log only during the bootup phase.
• Operation: Log only after the bootup phase.

These settings can be saved in a configuration file called *.loc. This
stores the set modes and ID codes.
A configuration file that has been saved can be loaded. Once it has
been loaded, the new settings are immediately effective.
You use the option "Nächster Start“ (Next Start) to define which
configuration file will be loaded next time MMC is powered up. This
selection is automatically stored in tcommc.ini.
In the "Umschalten auf Default“ (Switch to Default) dialog, you

define whether the special default configuration DEFAULT.LOC file
will be used, and when. In the default configuration, logging is
usually switched off.
This selection is automatically stored in tcommc.ini.

9. Maintenance
9.1 Replacing the battery
Change the battery under power only as data loss will otherwise
result!
Observe EGB measures during battery change!
Procedure
1 Battery
Rear view of MMC Fig. 11851
1. Pull the X11 connector and remove the battery

2. Mount the new battery
3. Replace the X11 connector, being careful not to de-pole the
battery!
9.2 Replacing the complete MMC unit
If the complete MMC unit has to be replaced, a replacement unit

loaded with the up-to-date software version is required.
A MMC replacement becomes necessary if the Windows

environment becomes unstable. This can be caused by
unauthorized network drivers or other software or by problems
originating form the hard disk. A data backup should be made
(whenever possible), prior to replacement of the MMC. There are
several backup methods available:

ZIP drive • A disk with drivers is required for older software versions. The
MMC hard disk contains a directory named C:\IOMEGA with
drivers for a parallel IOMEGA-ZIP drive.
• To install the IOMEGA, the GUEST.EXE driver must be started
from DOS. A drive letter will automatically be assigned for the
ZIP drive. Data can now be stored or recovered from the ZIP
drive.
INTERLINK connection 1. Boot the MMC and start the “confidential selection menu”.
2. Select “TRUMPF Service with INTERSVR“.
3. Boot the computer (e.g. notebook) and save the data from
DOS.
Data which must be saved
Machine data 1. Important customer specific NC and PLC machine data (offset
values, reference point offsets etc.) must be written down and
later checked and corrected if necessary.
2. Store the C:\840D\MD\MASCHINE.INI file and copy this to the
new MMC.
Network • Standard Windows network:

1. Transfer the C:\WFW_NET.BAT file from the old to the
new MMC.
2. Computer name, protocols and respective parameters (e.g.
TCPIP addresses), network connections, enabled drives,
passwords etc. should be noted and transferred to the new
MMC.
• Novell network:
1. Copy the
C:\NETWORK.BAT
C:\NWCLIENT\NET.CFG
C:\NWCLIENT\STARTNET.BAT
C:\WINDOWS\SYSTEM.INI
C:\WINDOWS\WIN.INI
C:\WINDOWS\PROTOCOL.INI
files from the old to the new MMC.
2. Note the network connections and drives, transfer these to
the new MMC.
• NFS network:
A complete new installation from floppies or CD-ROM is
required.
Program data 1. Transfer the C:\DH\TOPSMANU.DIR and C:\DH\WKS.DIR with

all sub-directories from the old MMC to the new MMC:
C:\DH\WKS.DIR>xcopy *.* E:\SAVE\WKS.DIR /e /v

Database 1. First save and then copy the C:\TCOMMC\EXE\*.mdb from the
old MMC to C:\TCOMMC\DBUPDATE\OLD of the new MMC:
C:\TCOMMC\DBUPDATE\OLD>xcopy *.MDB
E:\SAVE\EXE\*.MDB /v
2. Open the "SCRIPTS FOR DATABASE" program group
Fig. 17679
3. Start DATABASE UPDATE

4. When the "DB-Update ready!" message appears (see Fig.
17679) close the application with "Exít".
PLC update 1. Open the "SCRIPTS FOR DATABASE" program group.

2. Start PLC UPDATE.
3. Close the application with "Exít".
9.3 Replacing the hard disk drive

(only possible with MMC 103)
The MMC 103 hard disk can be ordered separately as a spare part
“Hard disk with vibration buffer”.
An ELITE-BIOS 570870.7033.12_V3.xx (V3.04) is required for the

replacement.
Due the higher disk density, the new hard disks are more sensitive
to vibration and shock during transport and operation. Due to the
harsh machine operation environment, the hard disk is subjected to
ds
greater wear. To enable at least 2/3 of its life expectancy in the
PC, certain measures have been taken to protect the hard disk
from damage and the integrated vibration buffer during transport.

Transport safeties The transport safety is engaged during delivery. The transport
safety must be engaged if the machine or the equipment in which
the MMC is mounted is moved. The transport safety must be
engaged if the MMC or the hard disk is to be returned to the
service department or to the manufacturer. The original or at least
equally robust packing material must be used for this purpose.
Turning (engaging or disengaging) the transport safety

requires a bit of strength!
1 Transport safety engaged: non-

operating position
MMC 103 with transport safety engaged Fig. 17680

1
1 Transport safety not engaged:

“Operating” position
MMC 103 with transport safety disengaged Fig. 18382
Removing the hard disk 1. Power off

2. Loosen the 4 (captive) locking screws (1) of the hard disk trap
door plate.
3. Open the trap door (stays open), being careful not to bend the
hinges.
4. Press both ribbon cable connector (2) retainers to the side,
remove the hard disk and the cable from the connector.
Installing the hard disk 1. Mount the replacement hard disk.

2. Fully plug the ribbon cable connector (2).
3. Close the trap door and check to assure that the ribbon cable
is properly routed (3) and not pinched in between the hard disk
and the PCB!
4. Hand tighten the 4 trap door locking screws (1).

1
1 4 Mounting screws 2 Correct cable position 3 Hard disk cable connector
Removing/replacing the hard disk drive (MMC 103) Fig. 18383

If a “ DISK BOOT FAILURE” message appears following
hard disk installation, the transport safety lock is possibly still
in the “non-operating” position.
Fig. 23775
Storage Storage at normal room temperature is recommended. If this is not

possible, a waiting time is required before the hard disk can be
operated. This is solely for the protection of the hard disk:
Temperature differences between storage and installation site ≅
Wait time in hours.
No condensation allowed.
Switch cabinet/ machine DIN EN 60721 part 3-0 and 3-2 is valid: Vibration limits1g/9-200
transport Hz; Shock limits 10g/11ms.

Chapter 2
NCU
H274E2.DOC NCU 2-1

1. NCU
1.1 Mode of function
Time allocation The NCU processes different tasks:
• SERVO/position controller
• INTERPOLATOR, cyclical part
• INTERPRETER, look ahead part
• External communication
It also processes different services such as:
• Variables service
• Axis display
• Program display
• PI service
• Actions
• Reset
• Program selection
Following is a breakdown of the processor's time allocation:
Priority 1
Remaining Servo /
time position
controller
Priority 2
Interpolator
NCU time allocation
During the entire run time, the NCK operating system calls up the
position controller in cycles with priority 1. This time is defined by
machine data 10050 system clock cycle x 10060 position controller
cycle, e.g. 0.002 sec x 2 = 0.004 sec.
2-4 NCU H274E2.DOC

The system also calls up the Priority 2, the interpolator, in cycles.
This time is defined by machine data 10050 system clock cycle x
10070 interpolation cycle, e.g. 0.002 sec x 3 = 0.006 sec.
In the remaining time. additional functions are processed:
NCK Internal Structure (3)

Position regulator (cyclical high-priority) TASK Priorities
Interpolation (cyclical low-priority)
Interpreter, preparation, communication (non-cyclical)
Time
IPO cycle
Position regulator
cycle
Fig. 23774E
You can check the times of the interpolation cycle and of the
position regulator cycle in the NCU diagnostics.
H274E2.DOC NCU 2-5

Interpreter An NC program is translated line for line and then processed.
This means that the system does not first compile the entire
program and thus detect errors. Instead, it detects and reports
errors during processing.
NC program
N10 G01 X0 Y0 F10000
N20 G02 I5 J5
N40 ...
N50
TC_LASER_ON(1,"1999",10,100)
N60 G91 X23.4 Y55.4
N70 ...
N80 ....
...
N900 M30
NC program (ASCII)
MMC
Interpreter
Load NC program (ASCII)
Convert to internal data structure
Create internal processing record
Manage look ahead buffer
Save modal/non-modal information
Transfer in calculation from NC program
Interpret jump commands (gotob, gotof, UP)
Resolve macros MPI bus
Synchronisation with interpolator
Start asynchronous sub-programs
Internal block
Preparation
Frames (TRANS, ROT, SCALE, G54, G55,...) External Communication
Rail correction Communication with MMC
Software limit monitoring Domain service (file transfer)
Working range limitation Variables service (variables access)
Speed monitoring PI service (actions)
Preparation of axis data for interpolation
Look ahead
Fig. 23987E
2-6 NCU H274E2.DOC

Interpolator /
Preparation
Position controller
Internal Block
Interpolator (low-priority cyclical task)
Load PLC interface signals and I/O
Load block from l ook ahead buffer VDI PLC

Load actual values from position regulator
Positioning axis interpolation
Rail axis interpolation
Concurrent movements
Transformations (BKS -> MKS)
Real time software limit monitoring NCK

Nominal values to position regulator
I/O
Write interface signals and I/O
Position regulator (high-priority

cyclical task)
Load current values from drive
Regulate position
Preliminary control Drive
Transfer nominal values to drive
Interpolator communication
Prepare the interpolation nominal values
Fig. 23988E
H274E2.DOC NCU 2-7

1.2 System components
The Siemens SINUMERIK 840D hardware comprises the:
• NCU 572 / NCU 573

• Bitbus module
• SIMATIC S7-300 (PLC periphery)
• SIMODRIVE 611D (digital drives)
4 5 6 6 6
1 SIMATIC S7-300 periphery 4 Power supply module

2 NCU terminal block 5 NCU 572 / NCU 573
3 Bitbus module 6 SIMODRIVE 611D
SINUMERIK 840D and SIMODRIVE 611D Fig. 19694
2-8 NCU H274E2.DOC

2. NCU Rack
2.1 Hardware
Layout The NCU rack consists of the following:
• NC module with cable distribution

• Power supply
• Ventilator / Battery unit
• Steel housing with integrated channels for mounting the
components and the ventilator/battery unit.
H274E2.DOC NCU 2-9

Location of interfaces,
operation and display
elements
1 16
15
2
14
3 13
12
4 11
10
9
5 8
6 7
1 MPI interface 9 PLC set-up switch (S4)

2 SIMATIC interface to PLC 10 NCK set-up switch (S3)
periphery 11 NMI switch (S2)
3 Periphery interface (NCK)
12 7 segment display
4 RESET switch (S1) 13 Error and status LEDs
5 I/O extension 14 PG-MPI interface
6 Unit bus interface
15 Reserved for developers
7 PCMCIA slot 16 Profibus
8 Drive bus interface
Fig. 13986
2-10 NCU H274E2.DOC

1 2
3 4 5 6 7
1 NCU box 4 COM-Module socket 7 Fan/battery unit

2 Power supply 5 PLC-Module socket
3 DRIVER module socket 6 NCK unit
NCU rack Fig. 13987
NCU 573
NCU unit Fig. 24048
H274E2.DOC NCU 2-11

NCU 573
Additional fan for NCU 573 Fig. 24049
Interfaces
X101 Operating panel interface (MPI)
Connector designation: X101

Plug type: 9pin Sub-D connector
Maximum cable length: 200 m
Special feature: Electrical isolation (safe isolation)
Pin assignment
1 Not assigned 6 2P5 VO

2 M24ext VO 7 P24ext VO
3 RS_BTSS B 8 XRS_BTSS B
4 RTSAS_BTSS O 9 RTSPG_BTSS I
5 2M VO
Signal designation
XRS_BTSS, RS_BTSS differential RS485 data-BTSS

RTSAS_BTSS Request to Send AS-BTSS
RTSPG_BTSS Request to Send PG-BTSS
2M Signal Ground, electrically isolated
2P5 +5V, electrically isolated
P24ext, M24ext 24V Voltage supply
2-12 NCU H274E2.DOC

Signal Type
B Bi-directional
O Output
VO Voltage Output
I Input
X102 L2-DP interface

Plug type: 9-pin Sub-D socket connector
Special feature: Electrical isolation (safe isolation)
1.5 MBaud
Pin assignment
1 Not assigned 6 2P5 VO

2 M24ext VO 7 P24ext VO
3 RS_L2DP B 8 XRS_L2DP B
4 RTSAS_L2DP O 9 RTSPG_L2DP I
5 2M VO
Signal designation
XRS_L2DP, RS_L2DP differential RS485 data - L2DP

RTSAS_L2DP Request to Send AS-L2DP
RTSPG_L2DP Request to Send PG-L2DP
2M Signal Ground, electrically isolated
2P5 +5V, electrically isolated
P24ext, M24ext 24V supply voltage
Type of signal
B Bi-directional
O Output
VO Voltage Output
I Input
X111 SIMATIC interface

Plug type: 25-pin Sub-D socket connector
Special feature: non-isolated (basic insulation)
H274E2.DOC NCU 2-13

X112 Serial interface RS232 (reserved for service)

Plug type: 9-pin Sub-D male connector
Special feature: non-isolated, no safe isolation
Pin assignment
1 Not assigned 6 Not assigned

2 RxD I 7 RTS O
3 TxD O 8 CTS I
5 M VO
Signal designation
RxD Receive Data

TxD Transmit Data
RTS Request to Send
CTS Clear to Send
M Ground
Type of signal
O Output
I Input
VO Voltage Output
X121 Periphery interface (cable distribution)

Plug type: 37-pin Sub-D male connector
Maximum cable length: 25 m for all functions
Special feature: Electrical isolation for binary I/O’s,
handwheel non-isolated
2-14 NCU H274E2.DOC

Pin assignment
1 M24EXT VI 20 P24EXT VI
2 M24EXT VI 21 P24EXT VI
3 OUTPUT 1 O 22 OUTPUT 3 O
4 OUTPUT 0 O 23 OUTPUT 2 O
5 INPUT 3 I 24 MEXT VI
9 MEPUS 0 I 28 MEPUS 1 I
10 MEPUC 0 I 29 MEPUC 1 I
11 MPG1 XA I 30 MPG1 A I
12 MPG1 5 V VO 31 MPG1 0 V VO
14 MPG1 XB I 33 MPG1 B I
15 MPG0 XA I 34 MPG0 A I
18 MPG0 XB I 37 MPG0 B I
19 Not assigned
Signal designation
MPG 0, 1 5 V Handwheel power supply 0, 1 5V

MPG 0, 1 0 V Handwheel power supply 0, 1, 0V
MPG 0, 1, A, XA Differential handwheel input 0, 1 A,
XA
MPG 0, 1 B, XB Differential handwheel input 0, 1 B,
XB
MEPUS 0, 1 Test pulse signal 0, 1
MEPUC 0, 1 Test pulse common (reference
ground) 0, 1
INPUT [0...3] Binary NC input 0...3
MEXT External ground (reference ground for
binary NC inputs)
OUTPUT [0...3] Binary NC outputs 0...3
M24EXT External 24V supply (-) for binary NC-
outputs
P24EXT External 24V supply (+) for binary NC
outputs
H274E2.DOC NCU 2-15

Type of signal
O Output
VO Voltage Output
I Input
VI Voltage Input
X122 PG-MPI interface

Plug type: 9-pin Sub-D female connector
Special feature: Non-isolated, non-safe isolation
Pin assignment
1 Not assigned 6 P5 VO
3 RS_KP B 8 XRS_KP B
4 RTSAS_KP O 9 RTSPG_KP I
5 M VO
Signal designation
RS_KP, XRS_KP Differential RS485 data-K-Bus from

PLC
RTSAS_KP Request to Send AS-K-Bus from PLC
RTSPG_KP Request to Send PG-K-Bus from PLC
M Ground
P5 5V
Type of signal
B Bi-directional
O Output
VO Voltage Output
I Input
X130A/B SIMODRIVE 611D interface and I/O extension (digitalization)
Connector designation: X130A / X130B

Plug type: 2x36-pin micro ribbon
Special feature: non-isolated, no safe isolation
2-16 NCU H274E2.DOC

X172 Unit bus interface

Plug type: 2x17 pin connector
Maximum cable length:
Special feature:
Pin assignment
1 HF1 VI 18 P27 VI
2 HF2 VI 19 M27 VI
3 HF1 VI 20 M VI
4 HF2 VI 21 Not assigned
5 Not assigned 22 M VI
7 Not assigned 24 M VI
9 P15 VI 26 M VI
11 P15 VI 28 Not assigned
14 Not assigned 31 SIM_RDY OC
16 I2T_TMP OC 33 Not assigned
Signal designation
HF 1, 2 ±57 V, 20 KHz power supply

P15 +15 V power supply
M Ground
P27 +27 V ventilator power supply
M27 Reference ground for P27
I2T_TMP I²t-Pre-warning (NC specific: ventilator
/temperature alarm
SIM_RDY Drives and NC ready
Type of signal
OC Open collector
VI Voltage input
X173 PCMCIA-Slot

Plug type: 68 pin PCMCIA card connector, male
connector
H274E2.DOC NCU 2-17

X121 diagnostics
With the aid of the PLC debugger or interface diagnostics PLC ó

NCK (see 3.0 Interface diagnostics PLC ó NCK), you can check
the logical states of the digital NCK peripheral devices.
Actual values of the digital ON-BOARD, X121, inputs:

• Input 1 DB10.DBX 60.0
• Input 9-16 DB10.DBB 186
• Input 17-24 DB10.DBB 187
Nominal values of the digital ON-BOARD, X121, outputs:

• Output 1 DB10.DBX 64.0
• Output 9-16 DB10.DBB 190
• Output 17-24 DB10.DBB 191
2-18 NCU H274E2.DOC

Operation and display elements
Designation Type Description Comment

RESET (S1) Pushbutton Triggers a control and driver hardware RESET with subsequent
complete re-boot.
NMI (S2) Pushbutton Initiates an NMI request to the CPU.
S3 Rotary switch NCM set-up switch
Position 0: Normal operation
Position 1: Set-up position
Position 2...7: Reserved
S4 Rotary switch PLC operation mode switch
Position 0: PLC-RUN
Position 1: PLC-RUN-P
Position 2: PLC-STOP
Position 3: MRES
H1 LEDs +5V: lights when the pow er supply is in the tolerance Green LED
(Left row) range
NF: lights when the NCK watchdog has tripped and Red LED
during the boot-up phase
CF: lights when the COM watchdog has tripped
Red LED
CB: lights when data transfer via the operation panel
interface is active
CP: lights when data transfer via the PG-MPI Yellow LED
interface is active
Yellow LED
H2 LEDs PR: PLC-RUN condition Green LED

(Right row) PS: PLC-STOP condition Red LED
PF: Lights when the PLC watchdog has tripped. Red LED
(When the PLC watchdog trips, all 4 LED’s light
up).
PFO: PLC-FORCE condition Yellow LED
 NCU 571 – 573 Yellow LED
- Lights up briefly during a Reset
NCU 573.2
Procedure on machines with Profibus:
LED must blink for approx. 5-15 s during the
bootup phase (searching for Profibus users). The
LED must extinguish when the Profibus users
have been found.
- LED is OFF: DP is not configured or DP is
configured and all slaves have been found.
- LED blinks: DP is configured, 1 (several)
slaves missing.
LED is illuminated: Error (e.g. bus short-circuit,
no Token cycle)
H3 7 segment Software protected output of test and diagnostics messages
Normal operation display value is "6".
Note: All LEDs (MSTT) blinking: Load software
PS blinking, PF illuminated: Load software
H274E2.DOC NCU 2-19

2.2 NCK boot-up diagnostics
Set-up switch The following boot-up variants can be set with the NCK Setup
switch (rotary switch S3) on the front plate of the NCU module:
Position Description
0 Normal mode: Boot-up runs with the configured data.
1 IBN mode: The data in the buffered RAM (SRAM) will be
deleted and the standard machine data will be loaded.
2-7 Reserved for internal use.
Status display during Various boot-up phases are displayed at the 7-segment status
boot-up display on the NCU module:
Boot-up phase Situation

. An error has been detected during cyclical operation.
0 A change from REAL to PROTECTED MODE was
possible.
1 Starting to load from the PCMCIA card.
Number with The number of the module presently being loaded is
decimal point indicated on the status display.
2 Loading from PCMCIA card successfully completed.
3 Debug monitor is being installed.
4 The operating environment was successfully loaded.
5 Operation environment was booted.
6 NC-Software is installed.
No display means:
The CPU self-test was unsuccessful. Component is
defective.
A blinking display means:
A FATAL ERROR occurred during system boot-up. The
cause of the error is identifiable by the blinking combination.
Please refer to the following “Error recognition during boot-
up” table for further information.
Error detection during If an error occurs during the boot-up phase, the status display will
boot-up begin blinking. The frequency of blinking identifies the cause of the
error. The frequency of blinking begins with a somewhat longer
display output. The time step in which the error occurred is
indicated by a value in the status display. Following this, the error
type is identified and sometimes, further characteristic parameters
are displayed. The blinking frequency is repeated.
2-20 NCU H274E2.DOC

NCU 572
Error type Error code 1st para- Error description

meter
0 0 - The portion-wise loading of the PLC or
COM module reports an incorrect
return signal.
0 1 Module No. The established cross check sum
does not correspond to the cross
check sum in the header.
0 2 - The FEPROMx manufacturer's code
on the PLC is incorrect.
0 3 - Timeout while erasing the FEPROMs
on the PLC..
0 4 - Timeout while programming the
FEPROMs on the PLC:
0 5 - Verify Error while reading from the
FEPROMs on the PLC.
0 6 - Invalid address range of a loading
module of the PLC module.
0 7 - Invalid address range of a loading
module of the PLC module.
0 8 - Component codes are not consistent.
0 9 - DRAM/SRAM memory check not
successful.
1 0 - Exception 0
1 1 - Exception 1
1 2 - Exception 2
1 3 - Exception 3
1 4 - Exception 4
1 5 - Exception 5
1 6 - Exception 6
1 7 - Exception 7
1 8 - Exception 8
1 9 - Exception 9
1 1 0 Exception 10
1 1 1 Exception 11
1 1 2 Exception 12
1 1 3 Exception 13
1 1 4 Exception 14
1 1 5 Exception 15
1 1 6 Exception 16
1 1 7 Exception 17
Error type 0 Inconsistent PCMCIA card

Error type 1 Processor exception
H274E2.DOC NCU 2-21

2.3 Software
PCMCIA card The PCMCIA card is a read/write data storage device. This card is
interfaced to a dedicated PCMCIA slot on the NCU rack. The card
carries the following software:
• Operating system and software for the NCK

• PLC operating system software
• Operating system and digital drive software for the SIMODRIVE
611d
• Communication software
If a software update is to be performed or if control data has been

lost, the following software modules can be uploaded to the control
from the PCMCIA card.
Directory structure
The directory structure can be viewed under 2 Diagnostics - 3 File

Function with option CNC control at source:
Fig. 23776E
Some directories are created by SIEMENS as default and are not

used by TRUMPF. These directories are usually empty.
2-22 NCU H274E2.DOC

MPF.DIR Contains:
* Diagnostic files such as TELE.COM
* Tool table, WZV.MPF
* Laser methods, LTMETH.TAB
* TC_TOOL_REMOVE
CST.DIR Contains TRUMPF cycles with transfer parameters
SPF.DIR Contains TRUMPF cycles not requiring any transfer
parameters
WKS.DIR\ Contains all active program parts except for the laser
ACT.WPD technology table:
* Main programs and subroutines
* Tables, e.g. PTT, SHL, SHU, PAU, RPO
WKS.DIR\ Contains the active laser technology table
LTT.WPD
DEF.DIR This directory contains the macro definitions MMAC.DEF

and variable definitions SGUD.DEF
VS.DIR Contains the Boot files for the drives; these files are loaded to
the drives when booting the NCU
HS.DIR Boot files for main spindles, not for TRUMPF
XFER.DIR Temporarily for Transfer functions
IBN.DIR Siemens standard for commissioning
COM.DIR From SIEMENS for comment functions
NCK-specific files on Path: c:\tcommc\exe

the MMC
tconc.mdb NCK database
tconck??.com Error texts
nckdiag.lay NCK Diagnose layout
savenck.dat NCK data backup MMC
ncfct.dat File for combi box in the Editor
Path: c:\840D
Please refer to Section 3.2 "MMC directory structure"
Cycles
Analog to the CPL programs of the BOSCH CC control generation,

machine functions are described in NCK cycles. They are called up
in the NC program with commands such as "TC_laser_On“.
The NCK cycles are processed in the NCK from the directories
SPF.DIR -> Cycles without parameter transfer

CST.DIR -> Cycles with parameter transfer.
H274E2.DOC NCU 2-23

The NCK cycles are no longer located on the PCMCIA card but are
copied from NC diskettes to the MMC hard disk.
They are located in MMC directory:
"c:\840d\md\<machine name>"
Fig. 23989E
In the MMC operating system, only file names with eight

alphanumerical characters are permitted. For this reason, the files
in the c:\840d\md\<machine name> directory do not bear their call-
up names such as „TC_laser_On“ but have the following format:
TCXX_YYY.SPF
TC stands for TRUMPF Cycle
XX Machine type code:
1 TC600L
10 TCL3030
11 HSL2502
13 TCL2530
15 TCL1005
20 Tubematic
YYY Cycle type code
shows the type of cycle involved.
In each machine-specific directory there is a file called "readme.txt"

with a list providing a cross-reference list between file names and
call-up names.
2-24 NCU H274E2.DOC

Fig. 23777E
During the software download ("NCK First Load") the files are
loaded into the corresponding NCK working directory.
The header for each cycle contains information on which directory
the cycle is loaded and the name of the cycle in the NCK working
directory.
Each block in the cycle has a nine-digit block number which you
can use to determine if an error has been found in a cycle.
If an error is found, you can use the selection box in the automatic
mode "Program Data" to determine the point in the NC program
where the cycle was called up.
Variables in the cycle Variables are used as placeholders for changeable data.
Variables can be
• global (GUD)
or
• local
Variables are like the markers in the old control generation.
Global User Data (GUD) in In the machine data there is a GUD machine data group.
the cycle Unlike the GUD, machine data are usually static values. The GUD
consists of dynamic values that can be accessed and changed by
all control components, i.e. also by the NCK cycles.
The GUD blocks are marked with "TG...“ (TRUMPF Global

Variable) in the NCK cycles.
H274E2.DOC NCU 2-25

Fig. 23778E
Individual GUD blocks can be linked to all possible commands in

the cycle, as shown here with the "IF" command.
This example also shows that GUD blocks can be modified by the
PLC as well (see Line 4).
Local variables in the cycle As the name "local variable" suggests, variables of this type are
only valid during the time that the cycle is running.
When the cycle ends, the values are deleted.
Fig. 23991E
Local variables are declared i.e. set up at the start of a cycle.

To do so, the syntax "DEF ..." is used.
2-26 NCU H274E2.DOC

TRUMPF NC commands Functions/commands within a cycle that are TRUMPF-specific are
identified with the syntax "CC....".
Fig. 23992E
These functions/commands are stored in machine code in the

NCK.
ASUP The NCK has digital inputs. If the level at one of these inputs
(asynchronous sub- changes, the NCK reacts.
program) A change to a digital NCK input causes the system to call up an
ASUP (asynchronous sub-program) in which the function of the
digital NCK input is described.
When an ASUP starts, this interrupts the current program. Once
the ASUP has been run, the interrupted program is resumed and
processing continues.
H274E2.DOC NCU 2-27

2.5 Routine upkeep and maintenance
Warnings
Temporary dangerous voltages normally occur in some

components during normal operation of electrical equipment.
Improper handling of such equipment or components can lead to

fatal situations, serious injury or serious damage to the equipment.
For this reason, always observe all safety precautions mentioned

in this chapter and on all label and decal warnings on the
equipment when performing any maintenance work.
• Only qualified personnel may perform maintenance work on

the equipment.
• Power down the equipment prior to any maintenance or routine
upkeep, with the exception of selective battery change.
• Only original spare parts approved by the manufacturer may
be used.
• The stipulated maintenance intervals, repair and replacement
instructions must always be strictly observed.
Caution: All modules retain dangerous voltage levels for 4 minutes

after having been powered down!
Labels and decals
Please indicate all relevant equipment nameplate data to your local

Siemens representative in case of service and technical inquiries.
Components and assemblies are marked with one of the following

labels:
PCBs, silk-screen Example: Component number: 570 573.9001.00

Manufacture version: B (last check mark)
2-28 NCU H274E2.DOC

BT, MMC, HD, ISA adapter, Example: Component name: OP 031
PCMCIA MLFB (Machine readable code):
6FC5203-0BA10-0AA0
Component number: GE.570 038.9001.00
NCU unit Example: Component name: NCU 572

MLFB: 6FC5357-0BC20-0AE0
Component number: GE.570038.9620.00
NCU 572 6FC5357-0BC20-0AE0 GE.570038.9620.00 ABC
NCU-Box Example: Component name: NCU-Box

MLFB: 6FC5247-0AA00-0AA0
Component number: GE.570038.9015.00
Manufacture version: A (last check mark)
Certain electronic equipment contain electrostatically sensitive

modules. It is advisable to ground yourself prior to touching such
equipment components. This can be done relatively easily by
EGB label grounding yourself to a grounded piece of equipment (e.g. blank
metal of a switch cabinet or socket ground).
H274E2.DOC NCU 2-29

Battery and ventilator replacement
Do not attempt to reactivate batteries by means of heating or other

means. Batteries may not be recharged as this can cause leakage
and/or explosion.
Failure to observe this advice can lead to injuries or damage to the

equipment.
The NCU carries battery-buffered SRAMs and clock chips in which

data is saved in case of a power failure. The buffer voltage is
monitored by the control which issues a monitor signal. The battery
must be changed within 6 weeks following issuance of the battery
monitor message. The NCU-Box battery can be changed after
powering the control down as the data is buffered for a period of
15 minutes.
Buffer time The buffer time for these batteries is minimum 3 years.
Battery and ventilator The battery/ventilator module is located beneath the intermediate
replacement: NC-CPU circuit bus bars
1. A latch is located on the underside of the module (3), see Fig.

11723. Press the latch (3) upward and pull the module out
toward the front.
2. Remove the battery plug by lightly pressing the clips outward.
3. Remove the battery by pulling it upward
Replace the battery in the reverse order.
Assure correct polarity (2) of the battery when replacing it.
2-30 NCU H274E2.DOC

1 Battery 3 Latch
2 Red cable (Polarity +) 4 Ventilator
Battery / Ventilator unit Fig. 11723
H274E2.DOC NCU 2-31

3. NCU Terminal block
Titel:
G:\GRAFIK13\13988.EPS
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Diese EPS-Grafik wurde nicht gespeichert
mit einer enthaltenen Vorschau.
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Diese EPS-Grafik wird an einen
PostScript-Drucker gedruckt, aber nicht
an andere Druckertypen.
1 Drive bus interface 5 Interface to next NCU terminal 7 DMP compact module interface
2 Equipotential bonding connector block
3 External 24V power supply 6 Status LEDs

Green: 5V o.k.
4 Cover (screening) plate Yellow: Internal terminal block
error.
Red: External error in drive bus
connection (this LED is hidden
behind the plastic cover).
Fig. 13988
Monitoring • +5 V monitoring
• Temperature monitoring 60°C ± 3°C
• Option status monitoring
• Sign of life monitoring
The binary and analog outputs are switched to a safe condition (0V
at the output) during error or interference conditions!
Number of NCU terminal A maximum of two NCU terminal blocks can be attached to the
blocks drive bus. Each terminal block has 8 slots for DMP modules.
DMP compact module Decentralized Machine Periphery module

A maximum of 8 compact DMP modules can be attached to a
terminal block.
2-32 NCU H274E2.DOC

X9 X21
X20 X11 X12 X13 X14 X15 X16 X17 X18
X9 Power supply interface X20/X21 Drive bus interface X11–X18 Module slots
Terminal block with 3 DMP compact modules Fig. 19674
Interfaces
Power supply DC 24V (20.4V DC to 28.8V DC)
Plug type: 4 pin terminal block, 2.5mm²
connector
Pin assignment
1 P24ext VI 3 M24ext VI
2 P24ext VI 4 M24ext VI
Signal designation
P24ext +24V external power supply

M24ext External power supply ground
H274E2.DOC NCU 2-33

Type of signal
VI Voltage Input
X20/X21 Drive bus interface

Connector designation: X20 (IN) X21 (OUT)
Plug type: 36 pin Micro Ribbon
Characteristic: Non-isolated, no safe isolation
Attention: Maximum length of drive bus is 10 m
X11-X18 Module plug
Connector designation: X11 ... X18 (Slot 1 ... 8)

Plug type: 30-pin ELCO Microleaf
3.1 DMP compact module 1E Analog

(slow) 6FC5 111-0CA04-0AA0
The DMP Compact Module 1E Analog (slow) is an encapsulated

module. It can be plugged into one of the terminal interfaces.
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1 (X3) interface connection terminal 4 30 pin (X1) interface

2 Status LED 5 Mounting screw
3 Designation label 6 6-fold (X2) terminal
6,1 Screen
2 Current source for PT100
3 Analog input In+
4 Analog input In-
5 Ground
Fig. 11850
2-34 NCU H274E2.DOC

Interfaces
• A 30 pin X1 plug for interfacing to the terminal block.

• 4-fold terminal X3 (Phoenix Co., type MSTB2.5/4-ST-5.08
GRAY, order No. for X3: 1848407) to connect the power
supply for the analog portion and 6-fold X2 terminal (Phoenix
Co., type MSTB2.5/6-ST-5.08 GRAY, order No. for X2:
1787076) to connect the analog input.
Display elements
1 LED as status display for the power supply.

LED lights when the internal power supply is OK.
Circuitry
S1 Test range set-up

1-2 closed: +10V
1-3 closed: + 500 mV
S2 Line frequency set-up

closed: for 50 Hz mains
open: for 60 Hz mains
Circuit example
X2
S M _ + S
6 5 4 3 2 1
U Single pole (standard)
Circuit example for analog voltage measurement Fig. 19675
If the power source is not required, it should be grounded.
H274E2.DOC NCU 2-35

Technical data
Number of inputs 1 Analog input

Electrical isolation Yes
Voltage supply V LOAD - Rated DC 24 V
- Permis. range 20.4 V to 28.8 V
- Ripple 3.6 Vpp
Rated input range ± 10 V or ±500 mV +
Tolerance range ±20 V or ± 1 V
Current load (24V) 45 mA
Iconst for PT100 2.5 mA
Primary detector connection See below
Digital display of input signal 12 Bit + prefix
Error message in case of tolerance violation Yes
(± 20 V; ± 1 V)
Basic error level ± 0.2%
Nominal error limits (0°C to 60°C) ± 0.5%
Cable length (screened) max. 30 m
Weight Approx. 150 g
Type of protection as per DIN 40050 IP20
Humidity rating as per DIN 40040 F
The DMP Compact Module 1E Analog inputs and digitalizes an

analog voltage value This voltage value is measured by an
electrically isolated differential input.
Resistance thermometers (PT100) can be attached in connection

with the installed constant current source (2.5 mA).
2-36 NCU H274E2.DOC

3.2 DMP compact module 1E NC Analog
(rapid) 6FC5 211-0AA10-0AA0
The DMP compact module 1E NC-Analog is an encapsulated,

rapid analog input module with 75 microseconds access time. It
can be plugged onto a socket on the terminal blocks (L2-DP and
NCU) as an extension module.
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1 X3 interface connection terminal 4 30 pin X1 interface

3 Designation label 6 6-fold X2 terminal
6,1 Screen
2 Current source for PT100
3 Analog input In+
4 Analog input In-
5 Ground
Fig. 13989
Interfaces
• A 30 pin X1 connector for interfacing to the NCU-terminal

block.
• 4-fold X3 (Phoenix Co. type MSTB2.5/4-ST-5.08 GRAY, order
No. for X3: 1848407) for connecting to the power supply for the
analog portion and 6-fold terminal X2 (Phoenix Co., type
MSTB2.5/6-ST-5.08 GRAY, order No. for X2: 1787076) to
connect the analog input.
• These are plug-in terminals.
H274E2.DOC NCU 2-37

Display elements
1 LED as status display for the power supply.

LED is illuminated when the internal power supply is OK.
Circuit example
X2
S M _ + M S
6 5 4 3 2 1
U Single pole (standard)
Circuit example for analog voltage measurement Fig. 19681
Technical Data
Number of inputs 1 Analog input

Power supply V LOAD - Rated DC 24 V
- Permiss. range 20.4 V to 28.8 V
- Ripple 3.6 Vss
Rated input range ± 10 V
Primary detector connector see below
Digital display of input signal 11 Bit + prefix
Error message in case of tolerance violation 0 .. 55°C ± 0.6%
including zero point errors
Length of screened cable max. 30 m
Type of protection according to DIN 40050 IP20
Humidity rating according to DIN 40040 F
The DMP compact module 1E NC analog inputs and digitalizes an

analog voltage value. This voltage is read by an electrically
isolated differential input.
2-38 NCU H274E2.DOC

3.3 DMP compact module 1A Analog
The 1A analog DMP compact module is an encapsulated module.

It can be plugged into a socket on the terminal blocks (L2-DP and
NCU).
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1 X3 interface connection terminal 4 30 pin X1 interface

3 Designation label 6 4-fold X2 terminal
1,4 Screen
2 Analog output Out+
3 Analog output Out-
Fig. 13984
Interfaces
• A 30 pin X1 connector to interface with the terminal block.

• 4-fold terminal X3 (Phoenix Co., type MC1.5/4-ST-3.81, order
No. for X3: 1828126) to connect to the power supply for the
analog portion and the X2 (Phoenix Co., type MSTB2.5/4-ST-
5.08 GRAY, order No. for X2: 1840942) serving as interface for
the analog outputs.
• These are plug-in terminals.
H274E2.DOC NCU 2-39

Display elements
1 LED as status display for power supply.

LED is illuminated when the internal power supply is OK.
Technical data
Number of outputs 1 Analog output

Power supply V LOAD - Rated DC 24 V
- Permiss. range 20.4 V to 28.8 V
- Ripple 3.6 Vpp
Rated output range DC ± 10 V
Output current ± 3 mA
Load resistance at current outputs min. 3.3 kΩ
Digital display of output signal 13 Bit + prefix
Short circuit protection Yes
Length of screened cable max. 30 m
Type of protection as per DIN 40050 IP20
Humidity rating as per DIN 40040 F
3.4 Diagnostics for the Analog NCK

Peripheral Devices
Using the PLC debugger or the interface diagnostics PLC ó NCK

(see 3.0 interface diagnostics PLC ó NCK) you can check the
analog values of the analog NCK peripheral devices (DMP
Module).
Actual values of the analog inputs:
1. Analog input 1 DB10.DBW194

2-40 NCU H274E2.DOC

Nominal values of the analog outputs:
1. Analog output 1 DB10.DBW210

H274E2.DOC NCU 2-41

4. Bitbus module
Each piece of TRUMPF equipment interfaced by Bitbus is fitted

with a Bitbus module (serial communication PCB), with a special
(8344) processor for data transfer and individual user program
processing.
The Bitbus consists of a controlling Master module and several

Slave modules. Slave modules have access to the Bitbus only
upon command by the Master module.
The transmission medium is an interference-free fiber optic cable.

The Bitbus PCB is fitted with additional electric interfaces for
communication with other equipment modules.
Fiber optic cables must be at least 3 meters long. The

bending radius of these cables must not be less than 5 cm.
The fiber core of these cables must be polished and fully
seated in their plug connectors.
Terminal block with mounted Bitbus module Fig. 18514
2-42 NCU H274E2.DOC

Titel:
C:\ARBEIT\7901.EPS
Erstellt von:
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1 Dual-Port-RAM 4 Serial interface processor 7 V24 interface (free, LSV2)

2 EPROM socket 5 Fiber optic receiver (blue) 8 Electrical connection (free)
3 8344 processor 6 Fiber optic transmitter (gray) 9 Function monitor LEDs
Bitbus module I (up to the fall of 1994) Fig. 7901
Titel:
19800.eps
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1 Dual port RAM 4 8344 processor 7 LED’s

2 Jumper array for transm. param. 5 Software IC 8 Fiber optic transmitter
3 Fiber optic receiver 6 Jumper array for module configur.
Bitbus module II (from the fall of 1994) Fig. 19800
H274E2.DOC NCU 2-43

Bitbus module LEDs
Two LED’s are mounted on the top of the Bitbus module. Use
these to check the Bitbus module and drive bus for function before
resorting to telegram diagnostics for help. A PIN reset is made at
the NCU for this purpose. The following sequence must be
observable at the LED’s:
1. The red and green LED’s light up briefly (PCB hardware reset)
2. Both LED’s light briefly a second time following initialization of
the bitbus module by the NC
3. The green LED lights up permanently indicating it is ready for
reception.
If, instead of a PIN reset, the main switch is turned OFF, then ON,
both LED’s light up briefly 3 times in quick succession.
If the above mentioned LED sequence cannot be observed in the

Bitbus module during the test, check the drive bus and Bitbus
module for function.
Green LED lights when the Bitbus module is ready for reception. Brief flickering
indicates that the Bitbus module is momentarily not ready for
reception. This is the case when a telegram has been received and
is in the process of being relayed further by the Bitbus module.
Red LED Flickers when the Bitbus module is in the process of telegram
transmission.
Technical data
Frequency 12 MHz
Length of fiber optic cable Approx. 30 m
Transfer rate, optical operation 2,5 MBit/s
Interfaces
X9 4-pin power supply connector located on the top of the mounted

module.
X20 Input from the 840D drive bus. The drive bus serves to transmit
data between the Bitbus module and the SINUMERIK 840D
control. The connector is located on the front of the mounted
module.
2-44 NCU H274E2.DOC

X21 Drive bus output. The terminal block for analog I/Os is connected
to this output. The connector is found on the rear of the mounted
module.
Fiber optic cable One blue (receiver) and one gray (transmitter) fiber optic cable
sockets are located on the front corner of the PCB. The fiber optic
cables form a ring circuit. The master module issues a signal to the
first slave (receiver) in the circuit. This slave relays the signal to the
next slave in the circuit (transmitter) and so on. This process is
continued for as many slave modules there are in the circuit until
the signal is eventually returned to the master as confirmation of
successful transmission.
Jumper configuration
Individual Bitbus module addresses are set by means of jumpers

(see circuit diagram excerpt on the following pages).
H274E2.DOC NCU 2-45

Fig. 14056E
2-46 NCU H274E2.DOC

Fig. 14017
H274E2.DOC NCU 2-47

5. SIMATIC S7-300 PLC periphery module
1 2
1 NCU 572 with PLC-Module 2 PLC periphery module
Fig. 19676
PLC module The PLC module is a sub-module of the NCU which supports
machine control. The PLC module represents a S7-300-compatible
PLC CPU. Three external lines of eight S7–300 periphery modules
each can be connected to the periphery bus.
2-48 NCU H274E2.DOC

Titel:
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1 Connector module 3 Release lever 4 Front cover

2 Digital module
Fig. 13978
Components The programmable SIMATIC S7-300 control consists of the

following components:
• PLC-CPU
• Signal modules (SM)
• Switching modules (IM)
Several S7-300’s can communicate across the PROFIBUS cable.
Components Function Illustration

DIN rail ... is the mounting rail for a S7-300
Accessories:
Screening element
Signal modules (SM) ... adapts various process signal levels

to the S7-300.
Accessories:
Front connector
Switching modules (IM) ... connects individual lines of a S7-300

with each other
Accessories:
Cable
H274E2.DOC NCU 2-49

5.1 IM 361 switching module
Characteristics The IM 361 switching module is characterized by:
• DC 24 V power supply
• Switching for module carries 1 to 3 of the S7-300
• Current delivery per S7-300 backplane bus max. 0.8 A
• Data transfer from the IM 361 to the IM 361 via connection
cable 368
• Distance between the IM 361 and the IM 361 maximum 10 m
Status and error display
Display elements Description Comments
SF Collective fault LED lights when:

• Connection cable is
missing
• The upstream IM
361 is OFF
• The network CPU is
OFF
• 24V de-poled
DC 5V DC 5V power supply for -

the S7-300 backplane
bus
2-50 NCU H274E2.DOC

Front view of the switching module Fig. 14099
Technical data
Size and weight

Size (B x H x T (mm) 80 x 125 x 120
Module specific data

Cable length
Maximal length to the next IM 10 m
Current consumption
from DC 24 V 0.5 A
Power loss Type. 5 W
Current data
At the backplane bus 0.8 A
Status and error display Yes
H274E2.DOC NCU 2-51

5.2 Switching module arrangement on
several carrier modules
Rules Please note the following rules pertaining to the arrangement of

individual modules on the carrier modules:
• The switching module always occupies slot 3, to the left of the

first signal module.
• A maximum of 8 modules (SM) may be attached to each
carrier module. The modules (SM) are always located to the
right of the switching module.
• The number of mounted modules (SM) modules is limited by
the permissible current supply from the S7-300 backplane bus.
The current consumption of each line may not exceed 1.2 A.
Switching modules Switching modules are required for extension to several carrier
modules. The task of the switching module is to relay the S7-300
backplane bus from one module to the next. The CPU is always
found on module carrier 0.
Switching module suitable for carrier modules
IM 361 Carrier modules 1 to 3
Maximum TRUMPF The following diagram shows the TRUMPF module assembly
extension arrangement on a maximum of three carrier modules. Individual
carrier module communication with the PLC CPU takes place
directly through the SIMATIC interface X111.
2-52 NCU H274E2.DOC

Module interface unit 3
Interface numbers IM 3 4 5 6 7 8 9 10 11
Fig. 11730E
H274E2.DOC NCU 2-53

5.3 Addressing the S7-300 modules
Slot-dedicated module addressing (Default

addresses)
Slot-dedicated addressing (default addressing) means that each

slot is assigned a module starting address. Depending on the type
of the module, either an analog or digital address is assigned. This
information is necessary to determine the starting address of the
modules used.
Module interface unit 0 Module interface unit 0 consists of the PLC-CPU on the NCU.
Signal modules cannot be integrated in this module interface. The
digital addresses of module interface 0 are displayed on the
machine control monitor.
Digital addresses 0 4 8 12 16 20 24 28
Module interface unit 1 The following diagram illustrates the starting addresses for the
digital modules on module interface 1.
The input and output addresses of I/O modules begin with the
same module start address.
Interface numbers 3 4 5 6 7 8 9 10 11
Digital address 32 36 40 44 48 52 56 60
Fig. 11731E
Module interface units 2 The following diagram illustrates the starting address for the digital
modules on module interface 2.
Digital address 64 68 72 76 80 84 88 92
Fig. 11732E
2-54 NCU H274E2.DOC

Carrier module 3 The following diagram illustrates the starting address of digital
modules on module interface 3.
Digital address 96 100 104 108 112 116 120 124
Fig. 11733E
Addressing the digital modules
The addressing of digital modules is described in the following.

This information is required to address the channels of a digital
module from an application program.
The I/O’s of a digital module are addressed with a combination of

Bit and Byte addresses.
e.g. E 1.2
Input Byte address Bit address
The Byte address is based on the module starting address.
The Bit addresses can be read on the module.
The following diagram illustrates the Bit and Byte structure on

which digital module addressing is based.
H274E2.DOC NCU 2-55

0
1
2
3
Byte address
4
5 Module starting address
6
7
0
1
2
3
4 Byte address
5
6
Module starting address +1
7
Bit address
I/O addresses of digital modules Fig. 11734E
5.4 Module replacement
Rules The following table indicates those items to note when wiring,
mounting or dismounting S7-300 modules.
Power CPU Signal

supply module
Screwdriver blade size 3.5 mm (cylindrical shape)
Torque:
Mounting modules on the 0.8 - 1.1 Nm 0.8 - 1.1 Nm
DIN rail
Attaching cables 0.5 - 0.8 Nm -
Main switch OFF during Yes No
replacement
Operation mode during - STOP
replacement
Load V OFF during change Yes Yes
Starting situation The module to be replaced is mounted and wired. A module of the
same type is to be installed.
If a module on a S7-300 carrier is pulled or mounted during a MPI

data transfer process, data can be corrupted by the resulting
interference.
Never pull or plug a S7-300 module when data transfer is active

across the MPI!
2-56 NCU H274E2.DOC

If you are not sure, pull the connector at the MPI!
Removing a (SM/FM/CP) To remove the module, proceed as follows:

module
1. Switch the PLC-CPU to STOP by turning the S4 keyswitch on
the NCU
2. Turn off the load voltage to the module
Titel:
Erstellt von:
Vorschau:
Kommentar:
1 Switching module 3 Release lever 4 Front cover

2 Digital module
Fig. 13978
3. Pull the label tag from the module

4. Open the front cover (4)
5. Unplug and remove the front connector:
• 20-pin front connector
Press release lever (3) down with one hand and pull the
front connector out (on the profiles) with the other hand.
H274E2.DOC NCU 2-57

Titel:
19798.eps
Erstellt von:
Vorschau:
Kommentar:
1 Fastening screw
• 40-pin front connector

Loosen the fastening screw (1) in the middle of the front
connector. Pull the connector out using the profiles
provided.
6. Swing the module out.
Removing the connector Prior to mounting the new module, the upper portion of the front
coding piece connector coding must be removed from the module.
Mounting a new module 1. Hang a new module of the same type in place and swing it
downward.
2. Screw the module down.
3. Slide the label from the old module into place on the new
module.
Set up the new module 1. Open the front cover (4)

2. Bring the front connector back into operating position.
3. Close the front cover.
4. Switch the load voltage back on.
5. Set the PLC-CPU back to RUN.
2-58 NCU H274E2.DOC

S7-300 module response After a module change the CPU will resume the RUN condition if
after replacement there is no standing fault. If the CPU should remain in the STOP
condition, the cause of the error can be displayed with STEP 7.
5.5 S7-300 power rating
The S7-300 and the various modules work with different rated
voltages. The following table contains the rated voltages and
respective tolerances of the S7-300.
Rated voltage Tolerance range
DC 24 V DC 20.4 to 28.8 V
AC 120 V AC 93 to 132 V
AC 230 V AC 187 to 264 V
H274E2.DOC NCU 2-59

5.6 SM 321; DI 16 x DC 24V digital input
module
Characteristics The SM 321; DI 16 x DC 24V module is characterized by:

• 16 Inputs, electrically isolated in groups of 8.
• DC 24V input power supply.
• Suitable for switches or 2-/3-/4-wire proximity switches.
Circuit and block diagram
1 3
1 Channel number 3 Circuit diagram

2 Status display - green 4 Backplane bus
Fig. 14098
2-60 NCU H274E2.DOC

Technical data
Size and weight

Size (W x H x D (mm) 40 x 125 x 120
Module-specific data
Number of inputs 16
Cable length
Unscreened Max. 600 m
Screened Max. 1000 m
Voltages, currents and potentials
Rated load voltage L+ DC 24V
Pole reversal protection Yes
Number of simultaneously addressable
inputs
Horizontal installation to 60°C 16
Vertical installation to 40°C 16
Electrical isolation
To backplane bus Yes (optocoupler)
Between channels No
Permissible potential differences
Between group M connectors -
Between input M connection and DC 75V
central grounding point AC 60V
Isolation checked with DC 500V
Current consumption
From backplane bus Max. 25 mA
From L+ Max. 1 mA
Power loss from modules Type. 3.5 W
Status, Alarms, Diagnostics
Status display Yes, green LED per channel
Alarms No
Diagnostic functions No
Encoder selection data
Input voltage
Rated voltage DC 24V
For signal "1" From 13 to 30V
For signal "0" From -3 to 5V
Input current
At signal "1" Type. 7 mA
Input delay time
Via parameter No
At "0" to "1" From 1.2 to 4.8 ms
At "1" to "0" From 1.2 to 4.8 ms
Connection of 2-wire proximity switches Possible
Permissible stand-by current ≤ 1.5 mA
H274E2.DOC NCU 2-61

5.7 Digital input module SM 321; DI 32 x
DC 24V
Characteristics The SM 321; DI 32 x DC 24V is characterized by:

• 32 inputs, electrically isolated in groups of 8
• DC 24V input load voltage
• Suited for switches and 2-/3-/4-wire proximity switches.
Fig. 18517
2-62 NCU H274E2.DOC

Technical data
Size and weight

Size (W x H x D (mm) 40 x 125 x 120
Weight approx. 260 g
Number of inputs 32
Cable length
Screened Max. 600 m
Unscreened Max. 1000 m
Voltages, currents, potentials
Pole reversal protection Yes
Number of simultaneously addressable
inputs:
horizontal installation to 40°C 32
horizontal installation to 60°C 16
vertical installation to 40°C 32
Electrical isolation:
to backplane bus Yes (optocoupler)
between channels No
Permissible potential differences:
between M connections in the -
group
between input (M connection) and DC 75V
Current consumption:
from backplane bus Max.15 mA
from L+ -
Power loss at modules Type. 6.5 W
Status, alarms, diagnostics
Alarms No
Encoder selection data
Input voltage
Rated value: DC 24V
for signal "1" From 13 to 30V
for signal "0" From -3 to 5V
Input current
at signal "1" Type. 7 mA
Input delay time:
via parameters No
at "0" to "1" From 1.2 to 4.8 ms
at "1" to "0" From 1.2 to 4.8 ms
Connection of 2-wire proximity switches Possible
Permissible stand-by current ≤ 1.5 mA
H274E2.DOC NCU 2-63

5.8 Digital output module SM 322; DO 32 x
DC 24 V/0.5 A
Characteristics The SM 322; DO 32 x DC 24V/0.5A is characterized by:

• 32 outputs, electrically isolated in groups of 8
• Output current 0.5 A
• Rated load voltage DC 24V
• Suitable for solenoid valves, DC breakers and LED’s
Special features Upon being energized by the 24V power supply, the outputs of the
SM 322; DO 32 x DC 24V/0.5A produce a “1” (high) signal for
approx. 50 µs. Keep this in mind if the SM 322; DO 32 x DC
24V/0.5A is used in conjunction with high speed counters!
Fig. 18518
2-64 NCU H274E2.DOC

Technical Data
Size and weight

Size (B x H x T (mm) 40 x 125 x 120
Number of outputs 32
Cable length
unscreened max. 600 m
screened max. 1000 m
Voltages, currents, potential

Pole reversal protection No
Sum current at outputs
(per group)
horizontal installation to 20°C max. 4 A
to 40°C max. 3 A
to 60°C max. 2 A
vertical installation to 40°C max. 2 A
between channels Yes
in groups of 8
Permiss. potential difference
Between the M connections of the DC 75V
group AC 60V
Between input (M connection) and DC 75V
central grounding point) AC 60V
Current consumption
from backplane bus max. 90 mA
from L+ (no load) max. 200 mA

Alarms No
Data for selecting an actuator

Output voltage
at signal "1" min. L+ (-0.8 V)
Output current
at signal "1"
rated value 0.5 A
permissible range From 5 mA to 0.6 A
at signal „0“ residual current max. 0.5 mA
Load resistance range 48 Ω to 4 kΩ
H274E2.DOC NCU 2-65

Output power
Lamp load max. 5 W
Parallel switching of 2 outputs
for logical connection Possible (must be outputs of the same
group)
For power gain Not possible
Gating a digital input Possible
Switching frequency
At Ohmic load/lamp load max. 100 Hz
At inductive load according to IEC max. 0.5 Hz
947-5-1, DC 13
Limit (internal) of inductive shut down Type. L+ (-48 V)
voltage to
Short circuit protection of output Yes, electronically
Gating threshold Type. 1 A
2-66 NCU H274E2.DOC

DC 24V/0.5A
Characteristics The SM 322; Do 16 x DC 24V/0.5A is characterized by

• 16 Outputs, electrically isolated in groups of 8
• Output current 0.5 A
• Rated load voltage DC 24 V
SM 322; DO 16 x DC 24V/2A produce a “1” (high) signal for
approx. 50 µs. Keep this in mind if the SM 322; DO 16 x DC
24V/2A is used in conjunction with high speed counters!!
1 3

2 Status displays - green 4 Backplane bus
Fig. 14097
H274E2.DOC NCU 2-67

Technical Data
Size and weight

Size (B x H x T (mm) 40 x 125 x 120
Number of outputs 16
Cable length
Voltages, currents, potential

Sum current at outputs (per
group)
to 60°C max. 2 A
Between channels Yes
in groups of 8
Between M connections in the DC 75V
group AC 60V
central grounding point) AC 60V
Current consumption

Status display Yes, green LED per Channel
Alarms No

Output voltage
Output current
at signal "1"
rated value 0.5 A
Permissible range From 5 mA to 0.6 A
Load resistance range 48 Ω to 4 kΩ
Output power
Lamp load max. 5 W
2-68 NCU H274E2.DOC

For logical connection Possible (must be outputs of the same
group)
Switching frequency
947-5-1, DC 13
voltage to
H274E2.DOC NCU 2-69

DC 24V/2A
Characteristics The SM 322; DO 8 x DC 24V/2A is characterized by:

• 8 Outputs, electrically isolated in groups of 4
• Output current 2 A
• Rated load voltage DC 24 V
SM 322; DO 8 x DC 24V/2A produce a “1” (high) signal for approx.
50 µs. Keep this in mind if the SM 322; DO 8 x DC 24V/2A is used
in conjunction with high speed counters!
1 3

2 Status displays - green 4 Backplane bus
Fig. 14096
2-70 NCU H274E2.DOC

Technical Data
Size and weight

Size (B x H x T (mm) 40 x 125 x 120
Number of outputs 8
Cable length
Voltages, currents, potentials

Sum current at outputs (per group)
to 60°C max. 4 A
Between channels Yes
in groups of 4
Between channels DC 75V
in groups of AC 60V
Current consumption

Status display Yes, green LED per Channel
Alarms No

Output voltage
Output current
at signal "1"
rated value 2A
Permissible range From 5 mA to 2.4 A
At signal "0"
residual current max. 0.5 mA
Load resistance range e 12 Ω to 4 kΩ
Output power
H274E2.DOC NCU 2-71

Lamp load max. 10 W
For logical connection Possible (must be outputs of the same
group)
Switching frequency max.
947-5-1, DC 13
voltage to
2-72 NCU H274E2.DOC

Chapter 3
PLC
H274E3.DOC PLC 3-1

1. Interface Overview
Communication between the PLC and the NCK flows across data
blocks to which the PLC and NCK have independent access
Data,
orders
Data, Passive file system

orders NC programs
COM module Data (wks.dir\act.wpd)
Tables
(wks.dir\act.wpd,
Orders
wks.dir\ltt.wpd)
Dual port ram NC cycles

DPR (spf.dir,
cst.dir)
Data blocs
Program
dbx.dbby selection
Active file system
VDI
interface
(dbx.dbby) Selected program
Tables
(datdpr.com)
PLC NCK
Bitbus Bitbus
telegrams handler
(tele.com)
PLC NCK
peripheral peripheral
devices devices
Fig. 23751e
The NC kernel accesses the Dual Port RAM (DPR) at an

interpolation cycle rate while the PLC accesses the DPR every
time a PLC cycle starts.
3-4 PLC H274E3.DOC

PLC/NCK Interface Fig. 14107
H274E3.DOC PLC 3-5

2. Alarms
Alarms are displayed in the operating environment. An alarm can

be either an error message or simply an information message.
Error messages An error message is a message, which leads to a machine stop.

Error messages are issued by the NC kernel, the PLC and by
SIEMENS modules
Messages Messages are alarms, which indicate the system status and only
serve as information. Only the TRUMPF PLC issues messages.
NCU 840D MMC
Error texts
NCK Error No.
Fehlernr.
NCDDE
*.com
PLC
MBDDE
Help texts
Error causes
BOF
MMC
(Operation maschine.
environment) mdb
Fig. 18390E
Error codes are transmitted through the NCDDE Server to the

MBDDE Server, which manages the pertaining texts in a COM file.
MMC texts: C:\TCOMMC\EXE\TCOMMCGR.COM

(GR stands for German)
NCK texts: C:\TCOMMC\EXE\TCONCKGR.COM
PLC texts: C:\TCOMMC\“Machine“\“Machine“GR.COM
The error code is also transmitted to the BOF operation

environment through the NCDDE Server. The operation
environment manages the pertaining help texts and error causes in
suitable databases, displaying the texts as required.
3-6 PLC H274E3.DOC

Databases or database tables (language dependent):
MMC: C:\TCOMMC\EXE\TCOMMC.MDB,
including the tables:
ERROR_MMC_DEU...._ENG
NCK: C:\TCOMMC\EXE\TCONC.MDB,
ERROR_NCK_DEU....._ENG
PLC: C:\TCOMMC\“Maschine“\“Maschine“.MDB,
ERROR_PLC_“Maschine“_DEU....._ENG
2.1 NCK and drive error messages
Error codes Error codes indicate if a SIEMENS or a TRUMPF module issued

an error message:
Error code Cause Documentation
to 70 000 SIEMENS CNC error Service error database

70 000 - 74 999 TCO CNC error Service error database
300 000 group SIEMENS drive error Service error database
TCO error codes The number range between 70 000 and 74 999 is sub-divided into
groups of 100. These groups are sorted into machine module
assignments (for example: laser, ram control etc.).
H274E3.DOC PLC 3-7

2.2 PLC alarms
The PLC is the only software module which issues both information
and error messages. The error number code indicates the
difference:
Alarm numbers
The PLC alarm number code (information or error message)

always consists of 8 digits::
01 1 007 01
Number
Module
Code
Unit
01 1 00102
Number
Code
Unit
Unit SIEMENS = 00
TC600L = 01
TCL2530 = 02
TLC = 03
TCL2502 = 04
TC2000R = 05
TCL3030 = 06
Laser 2D = 07
TUBE = 08
Laser = 11
MMC = 20
BOSCH TYP 3 = 30
TRL SM = 50
Liftmaster = 51
DIAS3 = 70
Library = 80
Lib HW Periphery = 82
Lib TLC = 83
Lib Special TLC = 90
3-8 PLC H274E3.DOC

Code Message = 0
Alarm =1
Module Each configuration file should have its own number. This number is
a reference to the configuration file in which the error has occurred
and therefore shows where you can find the alarm number again.
Number The two-digit number refers to Graph program.
The PLC alarm error texts are stored, per language, in the *:com
files in directory c:\tcommc\<machine>.
Error list
All error numbers are listed according to an 8-digit alarm

numbering system in the TRUMPF error message list. This list
includes information as to error location, cause and measures to
rectify the fault.
All above-mentioned information can be called up under

“DIAGNOSTICS - Error - Diagnostics” in the operating
environment.
2.3 PLC-NCK synchronization
During the boot-up process, the PLC boots faster than the NC
kernel and its periphery. The PLC would normally issue error
messages before the NC kernel is ready for operation. For this
reason, the PLC is synchronized with the NC kernel in such a
manner that error messages are only evaluated after 200 to 300
PLC cycles.
Problem If the control boots, issues a READY signal, crashes and

subsequently reboots, an error signal is issued. This error signal
cannot be ignored by the PLC as it has caused the crash. If this
problem occurs, TCO control service must be notified. The
engineer will need to know the contents of the following data
blocks:
DB 70, DBW 40: Data content indicates cause of crash

DB 70, DBD 42: Address of the module causing the crash
H274E3.DOC PLC 3-9

2.4 Diagnostics using error messages
In many cases the problem can be solved with the aid of the error
message and evaluation list. If this process is not successful in
solving machine problems, PLC diagnostics must be used.
3. PLC diagnostic possibilities
Machine function units are programmed with the aid of status

graphs and logic link sequence.
Status graphs A status graph is the graphic representation of a machine function.

Status graphs allow clear representation of complex
interrelationships.
Logic link sequences A logic link sequence describes the step sequence and
preconditions for executing machine functions.
The control offers several tools for diagnostics of machine

functions.
These diagnostic tools are activated via R-parameters or machine

data and write their information and data in PLC data blocks and
other R-parameters.
1. Diagnostics with the aid of data blocks:
DB Function TC 600L TC L2530 TC L XYZ

DB 110 SHEET_LOAD Table x x
DB 111 SHEET_UNLOAD Table x
DB 112 PART_UNLOAD Table x
DB 113 SHEET_TECH Table x x
DB 114 TOOL_TECH Table x
DB 115 REPOSIT Table x
DB 116 PLC actual position x x
DB 117 PLC nominal position x x
DB 125 TOOL_CHANGE x
DB 21 Punching / Nibbling package x
DB 87 Laser functions x x
DB 127 TYPE.H x x
3-10 PLC H274E3.DOC

2. Diagnostics with the aid of R parameters:
R-Param. Function TC 600L TC L2530 TC L XYZ

R 80 Rail layout check x
R 56-R 66 Tapping/Bitbus x
3. Diagnostics with the aid of machine data:

Diagnostics is activated via machine data MN_DIAG_
DEBUGINFO. The information/data is written to the mpf.dir in
the NCK.
File Function TC 600L TC L2530

DATDPR.COM Axis positioning x x
DATDPR.COM Table programming x x
WZW.MPF Tool management x
3.1 PLC Diagnostics
To start the interface diagnostics, select option 2. Diagnostics > 4.

Service > Interface PLC Ø NCK.
This is available for newer software versions.
The PLC Ø NCK interface diagnostics show you the interface

signals in a similar way to the PLC debugger.
Fig. 23752E
Pre-defined diagnosis data blocks can be selected from the

selection window.
H274E3.DOC PLC 3-11

The title of the selected diagnostics is displayed in the top line.
The settings are defined in the *.DEB files which are stored in the
C:\TCOMMC\<machine> directory.
Access values (e.g., db87.dbb60) cannot be changed nor can they
be overwritten.
’current line’ shows the access DB of the yellow highlighted line.
Switch to the next line by selecting “next line”.
If the value is •1, the background is white; otherwise, it is displayed
in gray. High and low values are clearly displayed in this manner.
The “Previous page” and “Next page” keys are used for scrolling
up or down in the display.
PLC <-> NCK interface diagnostics
The PLC <-> NCK interface diagnostics serves to display the

transfer signals.
Fig. 23753E
If a page contains axis-specific values, the system offers the

buttons for Axis + and Axis –. As the pages are sorted by title
(name), an axis-specific page only contains axis-specific data.
When you change axes, the system displays all the values on the
page for the next axis. You can recognize this because you see
db31. for axis 1, db32. for axis 2, etc.).
3-12 PLC H274E3.DOC

Languages
The PLC diagnostics are shown in German (DEUTSCH) and

English only. English is always displayed if the selected language
is not DEUTSCH. The translations are stored in the *.deb file. The
texts for English have been taken from the SIEMENS interface
documentation.
If there is no English text, the system displays the German text by
default.
Configuration file
The texts for the diagnostic pages are stored as *DEB files in
directory C:TCOMMC\<MACHINE>.
These files do not have a binary format, like in the PLC debugger,
but are of ASCII format (plain text) and therefore easy to change.
As this is a PLC file, it is loaded to the MMC with the PLC
installation diskettes.
Example of a deb-file Fig. 23754E
H274E3.DOC PLC 3-13

3.2 PLC-Debugger
Function The PLC debugger is the ”Operating element” for diagnostics using
R-parameters and data blocks.
The PLC Debugger mask appears after activating "Diagnose (2) –

Service (4) – Development (2) - PLC-Debugger (2)":
PLC-Debugger Fig. 18519e
The list is divided into five columns:
Number The sequential number of the displayed file entries is indicated.
Comments A brief description of the current error is commented in this column.
Command/Address The command field is an input field in which the service technician
must enter the command/address of the data block or the R
parameter, which allows him to view the contents of the data
blocks. This command consists of entries in the respective data
block:
1. Data block designation: DB127
2. Data format:
Designation in DB127 Addresses in the

command line
UBIT DBX (1 Bit)

UBYTE DBB (1 Byte)
UWORD DBW (2 Byte)
ULONG DBD (4 Byte)
3-14 PLC H274E3.DOC

3. Address number
Examples of display of Input/Output status in the PLC-

Debugger:
Comments Command Type Value
Output bit 21.5 A21.5 BL 1

Output byte 21 AB21 BL 00100000
Output word 20 AW20 BL 00000000 00100000
Regulation enable DB31.DBX2.1 BL 1

Regulation enable DB31.DBB2 BL 00000010
Regulation enable DB31.DBW2 BL 00000000 00000010
Regulation enable DB31.DBD2 BL 01000000 00000000
00000000 00000010
Start switch E20.3 BL 0

Start switch EB20 BL 11010000
Start switch EW20 BL 00000000 11010000
Start switch ED20 BL 00001000 10000000
00000000 11010000
Type The type field is also an input field in which the service technician
enters the data type of the value to be displayed. The data type
description is composed of two letters:
• First letter
B Binary (e.g. I/O)
D Decimal (for example, ladder logic with UWORD)
H Hexadecimal
• Second letter
No letter Big-ENDIAN
(default setting)
L Little-ENDIAN (always with binary)
D Normal (ladder logic)
H274E3.DOC PLC 3-15

Possible letter combinations:
• Big-ENDIAN (default setting) in combination with B (Binary):

type B
Byte 80 Byte 81
7-0 15 - 8
7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0
7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0
Byte 82 Byte 83
23 - 16 32 - 24
Fig. 11853
• Little-ENDIAN in combination with B (binary): type BL
Byte 83 Byte 82
31 - 24 23 - 16
7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0
7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0
Byte 81 Byte 80
15 - 8 7-0
Fig. 11855
• D in combination with D (decimal): DD (for ladder logic)
Low byte High byte
00001010 00000000 = 2560
• L in combination with D (Decimal): DL (for tables, for example

DB 110, SHEET LOAD-Table (SHL), exception: Bitbus tele-
grams → Big-ENDIAN)
High byte Low byte
00001010 00001010 = 10
3-16 PLC H274E3.DOC

The setting that must be made for the 2nd letter in order to
decipher the displayed value correctly cannot be taken from
the TYPE.H-file!
Editing R-parameters
Changing certain R-parameters in the PLC debugger activates

various diagnostic possibilities.
Example Activating the TELE.COM Bitbus diagnostic file:
Bitbus diagnostics R56 D 0.00000000
To activate Bitbus diagnostics files, set the value „0“ to „1“:
1. Select the „Bitbus diagnostics“ line so that the line is

highlighted in yellow.
2. Press the „Change Value“ softkey.
3. Enter „1“.
The input and output telegrams will now be written to the
TELE.COM file and can be viewed in menu „Diagnostics“ (2) –
„Program Management“ (3) – „Diagnostics Editor“ (2). To
select the data from the file selection window, a password must
be entered first.
3.3 Diagnostics with data blocks
DB127
To determine in which logic ladder the machine was active at the

time of the error you will first require data block 127. The system
always writes the status of the logic ladder and graphs to DB 127.
The value displayed in the PLC debugger for DB 127 can be
interpreted with the aid of the TYPE.H and the lsp_vss.h-files. The
logic ladder segment responsible for the error can be localized in
this manner.
The PLC debugger can be used to analyze the logic ladder

segment responsible for the error. For this purpose, the address of
the respective data block must be entered in the command line.
The value, which is then displayed, will indicate the location in the
logic ladder in which the error occurred. Interpretation of these
values is described in the following:
H274E3.DOC PLC 3-17

Command/Address To view the content of a data block, the respective address must
be entered in the PLC Debugger command line. This command
consists of entries in the respective data block:
1. Data block designation: DB 127

2. Data format:
Designation in DB 127 Address in the command

line
UBIT DBX (1 Bit)

UBYTE DBB (1 Byte)
UWORD DBW (2 Byte)
ULONG DBD (4 Byte)
3. Address number
TYPE.H-File
The TYPE.H-File contains different designations for each machine.

The structure, however, is always the same. The handling of this
file is described using a TC 600L basic machine without
automation periphery, as an example.
The enums "ELSP", "VSS" and "VSH" were removed from

the TYPE.H-File and (from software version 3.0 onward)
stored in a separate "ELSP-VSS.H" file.
Structure The TYPE.H-File is split into three parts:
Part 1:
All status graphs and logic ladders are sub-divided into 15 groups
with the addresses 00 to 454
• The data format for each address is determined in the first
column.
• A text describing the logic ladder or the status graph is found in
the second column. If a function is programmed with a status
graph, the endings (suffixes) have the following significance:
_zgr_zyl The actual status in which the component to be
addressed is currently found (very exact
information important for the source code).
_command Currently active command (nominal condition)
_status The Return-Value in the graph is displayed
(Information for the active process)
Values obtained when entering commands for graphs in the PLC
Debugger must be interpreted in different ways:
3-18 PLC H274E3.DOC

_zgr_zyl Interpretation of the value with the aid of status
graphs directly.
_command Interpretation of values by means of the
TYPE.H-File "enum command"
_status Interpretation of values by means of TYPE.H-
File "enum states"
• The address of the component or logic ladder being triggered
is displayed in the third column of the TYPE.H-File.
Part 2:
Enums, sub-divided into various functions groups in which each
module or status is assigned a Bit. The data significance of
individual addresses (i.e. operation modes, axis etc.) is stored in
these enums.
• Address 134 "refpkt_offset": Ram reference point offset
• enum Read disable Group 5/6 Address ULONG 80

• enum Feed disable Group 5/6 Address ULONG 84
• enum Feed hold Group 5/6 Address ULONG 88
• enum E-stop Group 5/6 Address ULONG 92
• enum Stroke ON ARLA-Con. Group 3 Address UWORD 52
• enum Stroke disable Group10Address UWORD 260
To display these enums in the PLC-Debugger, data type

"Binary Little ENDIAN (BL)" must be selected.
Part 3:
The parameters of I/O monitoring of status graphs are defined in
the last part of the TYPE.H-File. Of no interest for service!
H274E3.DOC PLC 3-19

3.4 Overview of data blocks used
Number Size Application

21 Punch/Nibble package diagnostics
59 Diagnostic module Laser telegram to/from Bitbus
60 Diagnostic module H+L telegrams from/to Bitbus
61 Diagnostic module Laser technology tables from NC
62 Diagnostic module Laser methods tables from PC
77 System applications
80 Diagnostic module Sheet handling tables from NC

81 Diagnostic module Tool management table from NC
82 Diagnostic module Positioning table from NC
83 Diagnostic module Data/tables to NC
84 Diagnostic module Tool technology tables from NC
85 Tapping
86 PLC Diagnostics
87 DB _init_laser_functions
88 L2530:On/Off Diagnosis
89 L2530: Pallet changer diagnostics
90 Operation data collection (BDE)
91 AutoLas Plus diagnostics
94 Welding diagnostics
100 R-Parameter, NC-Application data
read, write
109 DB_init_maschdaten (Application data)

110 SheetLoad
111 SheetUnload
112 PartUnload
113 Sheettech
114 Wzw (tool change)
115 Bht
116 PlcPos
117 PlcPos
120 128 Diagnostics for Automatic MMC <-> PLC

121 128 H&L <-> Punching
122 40 Automatic diagnostics
125
126 Communication MMC <-> PLC
127 Diagnostics
3-20 PLC H274E3.DOC

3.5 DB 21: Punch/nibble package
diagnostics
The NC interrupt I/O’s are used for rapid stroke execution as the
PLC input/output option would be too slow.
The states of the punching/nibbling package can be checked with
data block 21.
Assignment Data block 21, Byte 3, Data traffic from the PLC to the NCK:
0 Stroke enable
1 Manual stroke
2 Stroke suppression
3 Delayed stroke
4 Stroke disable
Data block 21, Byte 38, data traffic from the NCK to the PLC:
1 Stroke execution
2 Acknowledge manual stroke execution
3.6 DB 77: System applications
System application data is stored in this PLC data block.

The PLC reports with data block DB 77, the machine components
that are present in the (PLC) software. From MMC V05.02.2
onward, the so-called software machine components will also be
reported in this manner. to the PLC (Laser-Lib, Standard-Lib, HL-
Lib,...).
Only the hardware machine components are displayed in the
“Machine components” dialog. The software machine components
are displayed in the configuration data of the basic machine.
The dialog will then display a description of machine components
in plain text together with their status. This will take place with the
aid of the database (table “SYSTEM APPLICATIONS”).
If the data between the database and DB 77 are different, the
database data will automatically be transferred to DB 77.
3.7 DB 85: Tapping
The number of lubrication pulses can be determined in data block

DB 85.DBW118.
The actual number of lubrication pulses can be displayed in data
block DB85.DBW120 by activating the switch.
H274E3.DOC PLC 3-21

Address Variable
DB85.DBW0 Start address of structure
TS_PLCabKopf
Table header for tapping data
DB85.DBW 2 Start address of structure
TS_GEWDATEN
TS_PLCabKopf
Table header for gew_Kommando (tapping command)
TS_GEWKOMMANDO
TS_PLCTabKopf
Table header for gew_Status (tapping status
TS_GEWSTATUS
TS_PLCWztPuffer
TS_Gewinde_Var
DB85.DBW 16 Table type 06
Processing type 05
DB85.DBW 18 Method 01
Acknowledgment 00
DB85.DBW 20 height above sheet 0
DB85.DBW 24 lubrication container
DB85.DBW 28 lubrication pulses
DB85.DBW 32 ut_offset (TDC offset)
DB85.DBW 36 ot_offset (BDC offset)
DB85.DBW 40 reserved
DB85.DBW 44
DB85.DBW 46
DB85.DBW 48 gew-formen 01 gew-befreien 02
DB85.DBW 50 gew-aktiv 01 gew-inaktiv 02
DB85.DBW 52 Table type 06
Processing type 05
DB85.DBW 54 Method 03
Acknowledgment 00
DB85.DBW 56 rest position 01
DB85.DBW 58 available 01
verlassen_links 02
verlassen_rechts 03
referenz_fehlt 04
DB85.DBW 60
DB85.DBW 88
3-22 PLC H274E3.DOC

DB85.DBW 88 TS_Bit Var1
DB85.DBW 90 TS_Bit Var2
DB85.DBW 92 Step chain Status_right left ackn. assume position
DB85.DBW 94 Step chain Tapping reference position
DB85.DBW 96 Step chain Auto lubrication
DB85.DBW 98 Step chain Manual lubrication
DB85.DBW 100 Step chain Unlock Mt_thread lock
DB85.DBW 102 Step chain Mt_thread lock reference position
DB85.DBW 104 Counter of TC_TAB_ON
DB85.DBW 106 Counter ofTC_TAB_OFF
DB85.DBW 108 RESERVED
DB85.DBW 110 gew_offset_alt
DB85.DBW 112 gew_offset_status
DB85.DBW 114 Offset_neu_kleiner_alt = 1
Offset_neu_größer_alt = 2
Offset_neu_gleich_alt = 3
Offset_neu_undefiniert = 4
aktuelle anzahl_schmier_impulse_auto
DB85.DBW 116 gew_fkt_status_grundstellung
Reference position reached = 1
Center = 25
DB85.DBW 118 Default value for number of lube pulses is 3.
This value is designed for Start-up and can be modified, if
necessary
DB85.DBW 120 Actual number of lubrication pulses during Start-up
DB85.DBW 122 RESERVED
3.8 DB 86: PLC Diagnostics
The DB 86 serves for general PLC diagnostic purposes.
3.9 DB 87: Laser function diagnostics
Nominal and actual laser states are written to data block 87 for
diagnosis purposes. These states can be viewed in the PLC
Debugger.
DIAS height regulation states can also be checked with the aid of
the R parameters. Please read the “Diagnostics with R-
parameters” section on page 3-51.
H274E3.DOC PLC 3-23

Assignment
Address Variable
DB87.DBB20 active method element
DB87.DBB12 Laser nominal-status
DB87.DBB13 Laser actual status
0 LS_STRAHL_AUS (beam off)
1 LS_NETZ_AUS (power on)
2 LS_VSH (feed hold)
3 LS_VSH_QUIT (ackn. feed hold)
4 LS_EIN_CUT
5 LS_EIN_PIERCE
6 LS_ZYKLISCH
7 LS_STATUS
DB87.DBB16 DIAS nominal status
DB87.DBB17 DIAS actual status
AR_AUS
AR_EIN
AR_PIERCE
AR_CUT
AR_V0
AR_NICHT
AR_INPOS
AR_NICHT_INPOS
AR_ZUSTAND
AR_VSH
AR_QUIT_VSH
AR_ZYKLISCH
AR_DUMMY
DB87.DBB14 Gas nominal status
DB87.DBB15 Gas actual status
GAS_OEFFNEN (open gas)
GAS_SCHLIESSEN (close gas)
GAS_ZYKLISCH (gas cyclical)
DB87.DBB18 Z-Axis nominal status (not assigned)
DB87.DBB19 Z-Axis actual status
POSITION_ERREICHT (position reached)
ACHSE_FAEHRT (axis moving)
DB87.DBB22 UBYTE diag_las_status_resonator
DB87.DBB23 UBYTE diag_las_status_shutter
DB87.DBB24 UBYTE diag_las_status_beam
DB87.DBB25 UBYTE diag_las_status_error
DB87.DBB26 UBYTE diag_las_status_panel_mode
DB87.dbb143 active method element
Number of currently active laser function
DB87.dbb143 diag_last_method
previously selected laser process method
3-24 PLC H274E3.DOC

PLC Height regulation The height regulation module of the PLC and DIAS 3 parameters
module can be diagnosed with the following diagnosis variables:
Address Variable
DB87.dbb52 DIAS nominal status
The status to which the PLC height
regulation module is to be switched.
DB87.dbb53 DIAS actual status
Current status of the PLC height regulation
module.
The diagnosis variables can be assigned
the following values:
DIAS_OFF = 1,
DIAS_GOTO_OFF = 2,
DIAS_ON = 3,
DIAS_GOTO_ON = 4,
DIAS_PIERCE = 10,
DIAS_CUT = 11,
DIAS_INPOS = 20,
DIAS_NOT_INPOS = 21,
DB87.dbb54 diag_las_dias_start_up
All DIAS error messages can be
suppressed with this value e.g., to continue
working during the machine start-up
process.
To prevent the DIAS from being energized
if this value has been set, an error message
is issued which activates a Feed Hold.
DB87.dbb92 dias_las_dias_soll_zustand_int
Displays the internal nominal status of the
PLC height regulation module. This is
different from the above status in that e.g.,
the “Suppress DIAS” switch status is still
active here. Designation of values: as
above.
DB87.dbb94 vs_poti0_aktiv
Indicates if the DIAS has been momentarily
deactivated because the feed potentiometer
is set to 0%.
0 = Feed potentiometer not equal to 0%
1 = Feed potentiometer equal to 0%
DB87.dbb95 program stop during active Dias.
Indicates that a program stop has taken
place while the DIAS was active.
0 = no program stop
1 = program stop active
DB87.dbb96 drives_module_status
Indicates drives status.
0 = drives off
1 = drives on
H274E3.DOC PLC 3-25

DB87.dbb98 last_DIAS_NC_state
Indicates the last (current) NC status in
regard to the DIAS.
DB87.dbb99 tele_activ
Indicates if telegram transfer (to NCK) is
still active.
DB87.dbw84 dias3_sprintlas_pierce_hight
Sprintlas piercing height
DB87.dbb86 diag_las_dias_mode
DIAS operation mode
This diagnostic variable can be assigned
the following values:
LS_EIN_CUT = 4
LS_EIN_PIERCE = 5
DB87.dbb87 diag_las_dias_inpos
DIAS in position message
DIAS 3
It is possible to display DIAS-3 parameters via the Bitbus in the

PLC debugger. This is activated with its own diagnostic variable:
Address Variable
DB87.dbb55 dias3_diagnostic
0 : Diagnostics OFF
1 : Diagnostics ON
After this, values which are newly requested by the DIAS-3 after every 50 PLC
cycles are visible:
DB87.dbd56 UBYTE dias3_freg
DIAS 3 frequency
DB87.dbd60 UBYTE dias3_dist
DIAS 3 stand-off
DB87.dbd64 UBYTE dias3_z_position
DIAS 3 Z-position
DB87.dbd68 UBYTE dias3_desired_speed
Desired speed of DIAS 3
3-26 PLC H274E3.DOC

Gas module
The gas module can be diagnosed with the following variables:
Address Variable
DB87.dbb32 Gas-nominal-status
Status to which the gas control module is to
be switched to.
Gas-actual-status
DB87.dbb33 Current status of gas module
The following values can be assigned to the
variables:
GAS_ON = 0
GAS_OFF = 1
DB87.dbw34 diag_gas_pressure
Active gas pressure
DB87.dbb36 diag_gas_typ
Active gas
DB87.dbb37 diag_diag_gas_purging
Gas purge necessary
DB87.dbb37 diag_gas_purge_on_off
Switch for deactivating gas purge
Z-Axis module
Address Variable
DB87.dbb103 Z-axis actual status
The current status of the Z-axis module
The following values can be assigned to the
variable:
Z_IN_POS = 1
Z_IN_MOVE = 2
DB87.dbd106 z_position
the last programmed position
DB87.dbd110 z_nc_postion
current position reported by the NC
DB87.dbd114 diag_active_measuring_hight
measured sheet thickness
DB87.dbw148 calib_status_dias
DIAS calibration status (content of the total
response telegram)
H274E3.DOC PLC 3-27

3.10 DB 88: Diagnostics ON/OFF (TC L2530)
Switch ON and switch OFF machine cycles consist of a series of

functions which are called up sequentially by the handler for
“Machine ON/OFF”.
The active function for "Machine ON/OFF" can be viewed in data

block DB88.dbb24:
The following additional information is available:
Address Variable
DB88.dbb25 Mach_on_off_status
DB88.dbb26 On_off_function
DB88.dbb27 Estop_fault_active
DB88.dbb28 Feedhold_mach_on_delay
DB88.dbb29 Feedhold_doors_delay
DB88.dbb30 Feedhold_safety_doors
DB88.dbb31 Drives_handler_step
DB88.dbb32 Drives_diag
DB88.dbb33 Drives_enable
DB88.dbb34 Puls_enable
DB88.dbb35 Drives_status
DB88.dbb36 Drives_module_status
DB88.dbb37 Safety_status
DB88.dbb38 Drives_on_cmd
DB88.dbb39 Drives_off_cmd
DB88.dbb40 Refer_barrier_active
DB88.dbb41 Pallet_barrier_active
Machine reference cycle diagnostics
The machine reference cycles consist of a series of functions

which are called up sequentially by the reference cycle handler.
The active function for reference cycles can be viewed in data

block DB88.dbb24 (machine reference cycle step).
This byte can contain the following values:
3-28 PLC H274E3.DOC

• Pallet changer reference cycle active
• Drives ON active
• Delay active
• Operation group reset active
• Z axis reference cycle active
• DIAS reference active
• X and Y axis reference cycles active
Additional information is found in the following data blocks:
DB88.dbb6 X axis reference cycle step

DB88.dbb8 Y axis reference cycle step
DB88.dbb10 Z axis reference cycle step
DB88.dbb12 Pallet changer reference cycle step
These bytes contain numeric values which stand for an active step
number of a certain cycle.
H274E3.DOC PLC 3-29

3.11 DB 89: Pallet changer diagnostics
(TC L2530)
Guard door
Diagnostic information for the guard doors are found in the

following data blocks:
Address Variable Value

DB89.dbb13 Allow_error The following faults can be allowed:
1 Upper pallet in mid-position
2 Lower pallet in mid-position
DB89.dbb14 Desired_state
DB89.dbb15 State_before_fh
DB89.dbb17 Actual_state The guard door status can be
determined as follows:
1 DOORS_DOWN
2 DOORS_UP
10 DOORS_POS_MID
20 DOORS_POS_UNDEF
30 DOORS_VALVES_ON
40 DOORS_VALVES_OFF
130 DOORS_STOP_CMD
DB89.dbb12 Move_active
DB89.dbb16 Pos_reached
DB89.dbb18 Timstop_check
DB89.dbb19 Timcharge_check
DB89.dbb20 Tim_cmd_check
DB89.dbb21 Stop_active
DB89.dbb22 Feedhold_enable
DB89.dbb23 External_stop
3-30 PLC H274E3.DOC

Lift

DB89.dbb33 Allow_error The following faults can be allowed:
1 The lift lock pin is not unlocked
2 The upper pallet is not in the pallet
changer
3 Both valves for pallet in and out
have not energized.
4 The inside index is not locked
DB89.dbb35 State_before_f
DB89.dbb37 Actual_state The lift status can be determined as
follows:
1 LIFT_DOWN
2 LIFT_UP
10 LIFT_POS_MID
20 LIFT_POS_UNDEF
30 LIFT_VALVES_ON
40 LIFT_VALVES_OFF
130 LIFT_STOP_CMD
H274E3.DOC PLC 3-31

Lower pallet
Diagnostic information for the lower pallet is contained in the


DB89.dbb53 Allow_error The following errors can be allowed:
1 Guard door is not in position 2 or
not in the upper position.
2 The lift is not in lower position.
3 The access door is not closed.
4 The inside index is not unlocked.
5 The outside index is not unlocked.
DB89.dbb57 Actual_state The status of the lower pallet can be
1 LO_PALLET_OUT
2 LO_PALLET_IN
10 LO_PALLET_POS_MID
20 LO_PALLET_POS_UNDEF
30 LO_PALLET_VALVES_ON
40 LO_PALLET_VALVES_OFF
130 LO_PALLET_STOP_CMD
3-32 PLC H274E3.DOC

Upper pallet
Diagnostic information for the upper pallet is contained in the


1 Guard door is not in position 2 or not
in the upper position.
2 The lift is not in upper position.
3 The access door is not closed.
4 The inside index is not unlocked.
5 The outside index is not unlocked.
DB89.dbb77 Actual_state The status of the upper pallet can be
1 UP_PALLET_OUT
2 UP_PALLET_IN
10 UP_PALLET_POS_MID
20 UP_PALLET_POS_UNDEF
30 UP_PALLET_VALVES_ON
40 UP_PALLET_VALVES_OFF
130 UP_PALLET_STOP_CMD
H274E3.DOC PLC 3-33

Inside index
Diagnostic information for index “Pallet inside” is contained in the


1 The lift is neither up nor down.
2 The upper pallet is not in the machine
or in the pallet changer.
3 The lower pallet is not in the machine
DB89.dbb97 Actual_state The index status can be determined as
follows:
2 IN_INDX_LOCKED
1 IN_INDX_UNLOCKED
10 IN_INDX_POS_MID
20 IN_INDX_POS_UNDEF
30 IN_INDX_VALVES_ON
40 IN_INDX_VALVES_OFF
DB89.dbb98 Manual_step The active step of a manual locking or
unlocking cycle.
DB89.dbb99 Manual_lock_cmd
DB89.dbb100 Manual_unlock_cmd
DB89.dbb101 Pallet_handler_step Upper pallet loading cycle (standard
condition: both pallets are in the
changer).
0 START_DOORS_UP_CMD
1 BOTH_INDX_OPEN_CMD
2 CHECK_LIFT_PIN_CMD
3 LIFT_UP_CMD
4 LIFT_PIN_LOCK_CMD
5 CHECK_DOORS_UP
6 UP_PALLET_IN_CMD
7 PALLET_CICLE_DELAY
8 DOORS_INDX_CLOSE_CMD
9 CHECK_DOORS_DOWN
Cycle for pallet change/ driving pallet out
(start condition: upper pallet is in the
machine).
2 CHECK_DOORS_UP
3 UP_PALLET_OUT_CMD
4 CHECK_REMOVE_ACTIVE
5 LIFT_PIN_UNLOCK_CMD
3-34 PLC H274E3.DOC

6 LIFT_DOWN_CMD
7 LO_PALLET_IN_CMD
8 PALLET_CYCLE_DELAY
9 BOTH_INDX_CLOSE_CMD
10 LO_PALLET_VALVES_ON_CMD
12 DOORS_DN_LIFT_UP_CMD
13 LIFT_PIN_LOCK_CMD
14 CHECK_DOORS_DOWN
Cycle for pallet change/ driving pallet out
(start condition: lower pallet is in the
machine).
2 LIFT_DOWN_CMD
3 LO_PALLET_IN_CMD
6 CHECK_DOORS_UP
7 LO_PALLET_OUT_CMD
8 CHECK_REMOVE_ACTIVE
9 LIFT_UP_CMD
10 LIFT_PIN_LOCK_CMD
11 UP_PALLET_IN_CMD
14 CHECK_DOORS_DOWN
Loading the lower pallet during container
processing.
2 LIFT_DOWN_CMD
4 CHECK_DOORS_UP
5 LO_PALLET_IN_CMD
7 IN_INDX_LOCK_CMD
8 LO_PALLET_VALVES_ON_CMD
10 CHECK_DOORS_DOWN
DB89.dbb102 Start_allow
DB89.dbb103 Two_hand_active
DB89.dbb104 Safety_choice
DB89.dbb105 Pallet_command 0 EXCHANGE
1 REMOVE
2 BOX
3 CMD_NOT_ACTIVE
DB89.dbb106 Pallet_cycle_act
H274E3.DOC PLC 3-35

Outside index
Diagnostic information for index “Pallet outside” is contained in the


1 The upper pallet is not in the machine
DB89.dbb117 Actual_state The outer index status can be determined
as follows:
1 OUT_INDX_UNLOCKED
2 OUT_INDX_LOCKED
10 OUT_INDX_POS_MID
20 OUT_INDX_POS_UNDEF
30 OUT_INDX_VALVES_ON
40 OUT_INDX_VALVES_OFF
Freeing the pallet changer
With the PLC Debugger (Menu 2-4-2-2) it is possible to suppress

all collision monitoring of the pallet changer. The pallet changer
can therefore be freed from an undefined situation.
The data block "db89.dbb108" must be set to value “25” for this
purpose.
Following each RESET, this value changes back to “0”. Freeing

must then be reactivated again.
Warning Incorrect handling of the Debugger can result in serious damage.

For this reason, never disclose this freeing possibility to the
customer!
3-36 PLC H274E3.DOC

TC L3030 Lift frame: Module pal lift.c
Allow_error; /*db89.dbb20 */
Desired_state; /*db89.dbb21 */
State_before_fh; /*db89.dbb22 */
Pos_reached; /*db89.dbb23 */
Actual_state; /*db89.dbb24 */
Timstop_check; /*db89.dbb25 */
Timcharge_check; /*db89.dbb26 */
Tim_cmd_check; /*db89.dbb27 */
Stop_active; /*db89.dbb28 */
Lift_up_step; /*db89.dbw30 */
Lift_down_step; /*db89.dbw32 */
Index cylinder: Module pal indx.c

Move_actuve; /* db89.dbb40 */
Allow_error; /* db89.dbb41 */
Desired_state; /* db89.dbb42 */
State_before_fh; /* db89.dbb43 */
Pos_reached; /* db89.dbb44 */
Actual_state; /* db89.dbb45 */
Timstop_check; /* db89.dbb46 */
Timcharge_check; /* db89.dbb47 */
Tim_cmd_check; /* db89.dbb48 */
Stop_active; /* db89.dbb49 */
Pallet transport device: Module tr chain.c

Allow_error; /*db89.dbb60 */
Startcheck_mach; /*db89.dbb61 */
Startcheck_chg; /*db89.dbb62 */
Mot_vsh_extern; /*db89.dbb63 */
Mot_vsh_intern; /*db89.dbb64 */
Mot_block_r; /*db89.dbb65 */
Mot_224_state; /*db89.dbw66 */
Mot_224_cmd; /*db89.dbw68 */
Mot_224_msg_nr; /*db89.dbw70 */
Mot_224_erg_nr; /*db89.dbw72 */
Light barrier: Module lig curt.c

Initialized; /*db89.dbb80 */
Safety_ok; /*db89.dbb81 */
Diagnosis: Module pal diag.c

Pal_position; /*db89.dbb101 */
H274E3.DOC PLC 3-37

Function handler: Module pal fkta.c
Func_counter; /*db89.dbb121 */
Actual_step; /*db89.dbb122 */
Handler_active; /*db89.dbb123 */
Automatic cycles: Module pal auto.c

Active_cycle_type; /*db89.dbb141 */
ACK_needed; /*db89.dbb142 */
Waiting_for_LM_ack; /*db89.dbb143 */
Buffer_loadinglevel; /*db89.dbb144 */
ELSP_shl; /*db89.dbb145 */
New_pal_in_mach; /*db89.dbb146 */
Component master: Module pc mastr.c

Appl_changer_typ; /*db89.dbb161 */
Appl_LC_2; /*db89.dbb162 */
Appl_serv_func; /*db89.dbb163 */
Appl_ACK_needed; /*db89.dbb164 */
Appl_Liftmaster; /*db89.dbb165 */
Appl_Rotolas; /*db89.dbb166 */
3.12 DB 94: Welding diagnostics
Welding gas control can be governed by the following bytes.
Address Variable
DB94.DBB24 schutzgasEinKopf (shield gas on)
DB94.DBB25 schutzgasHeKopf (shield gas He)
DB94.DBB26 schutzgasArKopf (shield gas Ar)
DB94.DBB27 schutzgasN2Kopf (shield gas N2)
DB94.DBB28 schutzgasSonstKopf (other shield gas)
DB94.DBB29 weld_gas_nom
DB94.DBB30 weld_gas_act
DB94.DBB32 lasernennleistung (nominal laser power)
DB94.DBB36 laserLeistungInPromille (laser power)
DB94.DBB38 laserVorwaermleistungInPromille (laser
prewarm power)
DB94.DBB40 laserVorwaermZeit (laser prewarm time)
3-38 PLC H274E3.DOC

3.13 DB 109: Initializing the application data
Transfer to To transfer the applications to the TRUMALIFT-SHEETMASTER

Sheetmaster/LiftMaster and LIFTMASTER, a telegram is formed from each group of
applications (each line in the combo box is a group). This is then
transferred to the TRUMALIFT-SHEETMASTER or LIFTMASTER
(see “fktWerteUebertrgen” in the mas_komp.cpp file). As soon as
one telegram has been positively acknowledged, the next telegram
or next group is transferred. This continues until all telegrams have
been transferred. No messages are issued by the MMC. Only the
PLC (of the TRUMALIFT-SHEETMASTER) issues the start and
end as a message.
Transfer to PLC To transfer the applications to the PLC, all applications of the
activated machine component (without those components
belonging to the LIFT), are written to a data block in the PLC. For
example, these are the components TC600L, TRL-SM, GRIP and
TOOL; the TC600L, GRIP and TOOL applications are written to the
DB but not those of the TRUMALIFT-SHEETMASTER or
LIFTMASTER. After this, a re-boot is executed so that the PLC can
st
take the information from DB109, 1 Byte. This determines how
many applications can be written. The MMC then writes to DB109
the maximum number of applications of 8 bytes each.
Structure • 4 Bytes for the header (first byte: max. number of applications
must be 63 or 126!)
• Groups of 8 bytes each for the applications. This consists of:
• 2 Bytes for the number of applications (unsigned int)
• 2 Bytes for the type or format of the application (int)
• 4 Bytes for the application value (unsigned long)
• 2 Bytes (both `0`), as end Id. for the PLC.
H274E3.DOC PLC 3-39

3.14 DB 121: H&L <-> Punching
During the H&L Ø punching process a dedicated data block, DB
121, is created and managed.
For each configuration file within this process there is an individual
database structure which you can use for diagnostics.
Positions DB121.DBB52
Ram positions which have been transferred to H&L.
Address Format Variable

DB121.DBB 52 DL lage_fahren_erlaubt
DB121.DBB 53 DL lage_fahren_aktiv
DB121.DBB 54 DL angewaehlte_lage
DB121.DBB 55 DL lage_fahren_gesperrt_y_kleiner_100
DB121.DBW 56 DL merker_eintauchlage
DB121.DBW 58 DL merker_arbeitslage
DB121.DBW 60 DL merker_startlage
DB121.DBW 62 DL merker_klemmlage
DB121.DBW 64 DL merker_technologie
DB121.DBW 66 DL merker_zyklus
DB121.DBB 68 DL merker_fahrkurve
DB121.DBW 70 DL ut_pos
DB121.DBW 72 DL ot_pos
DB 121.DBW74 DL start_pos
DB121.DBW 76 DL klemm_pos
DB121.DBW 78 DL technologie
DB121.DBW 80 DL zyklen
DB121.DBW 82 DL fahrkurve
Setup DB121.DBW96

DB121.DBW 96 DL blechdicke
DB121.DBW 98 DL nachschleiflaenge
DB121.DBW100 DL werkzeugtyp
DB121.DBW102 DL niederhaltertyp
DB121.DBW104 DL max_ot_pos
DB121.DBW106 DL max_ut_pos
DB121.DBB108 DL multitool_typ
DB121.DBB109 DL HL_IB_aktiv
DB121.DBB110 DL lage
DB121.DBB111 DL schnelles_umformen
DB121.DBW112 DL ut_offset
DB121.DBW114 DL ot_offset
DB121.DBW116 DL stammdatum
DB121.DBB118 DL grst_anf_aktiv
3-40 PLC H274E3.DOC

DB121.DBB119 DL abwahl_erhoehte_lage
DB121.DBB120 DL m27_aktiv
DB121.DBB121 DL kratzarme_bearbeitung
DB121.DBW122 DL skz_ib_hl
DB121.DBW124 DL skz_ib_hl_alt
DB121.DBB126 DL skz
DB121.DBB127 DL fahren_erlaubt
Send telegrams DB121.DBB140
Address Formats Variable

DB121.DBB 140 HL letzt_tele_sendeliste
DB121.DBB 141 DL ringpuffer_initialisiert
Ram feed in percent DB121.DBB150

DB121.DBB 150 DL percent
Position tables DB121.DBW156

(Ram positions that
have been calculated)

DB121.DBW 156 DL blechdicke_lage_tab
DB121.DBW 158 DL nsl_lage_tab
DB121.DBW 160 DL wz_typ_lage_tab
DB121.DBB 162 DL lage_lage_tab
DB121.DBW 164 DL ut_offset_lage_tab
DB121.DBW 166 DL ot_offset_lage_tab
DB121.DBW 168 DL stammdatum_lage_tab
DB121.DBB 170 DL abwahl_erhoehte_lage
DB121.DBB 171 DL m27_aktiv
DB121.DBB 172 DL umform_wz_typ
DB121.DBB 173 DL bd_offset_tab
DB121.DBW 174 DL klemmlage_alt
DB121.DBW 176 DL startlage_alt
DB121.DBW 178 DL eintauchlage_alt
DB121.DBW 180 DL arbeitslage_alt
DB121.DBD 182 DL werte_ok
DB121.DBW 186 DL klemmlage_tab
DB121.DBW 188 DL arbeitslage_tab
DB121.DBW 190 DL startlage_tab
DB121.DBW 192 DL eintauchlage_tab
DB121.DBB 194 DL daten_pruefen_erforderlich
H274E3.DOC PLC 3-41

Read data from System DB121.DBW232
(Available data to
calculate the ram positions)

DB121.DBW 232 DL blechdicke
DB121.DBW 234 DL nachschleiflaenge
DB121.DBW 236 DL werkzeugtyp
DB121.DBW 238 DL ot_offset
DB121.DBW 240 DL ut_offset
DB121.DBW242 DL stammdatum
DB121.DBW 244 DL niederhaltertyp
DB121.DBB 246 DL abwahl_erhoehte_lage
DB121.DBB 247 DL m27_aktiv
DB121.DBB 248 DL kratzarme_bearbeitung
DB121.DBB 249 DL multitool_typ
DB121.DBB 250 DL grst_anf_aktiv
DB121.DBB 251 DL schnelles_umformen
DB121.DBW 252 DL max_ot
DB121.DBW 254 DL max_ut
DB121.DBB 256 DL hl_ib_aktiv
Oil temperature DB121.DBB266

DB121.DBB 266 DL skz_warm_up
DB121.DBB 267 DL warm_up_aktiv
DB121.DBB 268 DL status_hl
DB121.DBW 270 DL return_wert
Presser foot DB121.DBB276

DB121.DBB 276 DL skz_c_achs_sperre
DB121.DBB 277 DL tele_1_gesendet
DB121.DBB 278 DL tele_2_gesendet
DB121.DBB 279 DL lage_fahren_aktiv
DB121.DBB 280 DL c1_fahrbefehl
DB121.DBB 281 DL merker_not_aus
DB121.DBW 281 DL stangendruck_ein
DB121.DBW 284 DL stangendruck_aus
DB121.DBW 286 DL status
DB121.DBW 288 DL hub_ein_an_HL
3-42 PLC H274E3.DOC

M27 DB121.DBD298

DB121.DBD 298 DL m_fkt
DB121.DBW 306 DL niederhaltertyp
Telegrams status DB121.DBB336

DB121.DBB 336 DL step_bremsen_test_hl
DB121.DBB 338 DL skz_hl_init
DB121.DBB 339 DL eingang_bremse_kontrolle
DB121.DBB.340 DL hl_init_vorgenommen
DB121.DBB 341 DL timer_gestartet
DB121.DBB 342 DL state_hl
DB121.DBB 343 DL return_wert
Receive telegrams DB121.DBB140

DB121.DBW 204 DL alarmnummer
DB121.DBW 206 HL letzt_empf_tele
DB121.DBB 208 DL alarm_aufgetreten
DB121.DBW 210 DL empf_status
Reference point offset DB121.DBB356

DB121.DBB 356 DL refpkt_offset
Positions, max. values DB121.DBW366

DB121.DBW 366 DL max_blechdicke
DB121.DBW 368 DL min_blechdicke
DB121.DBW 370 DL max_nsl
DB121.DBW 372 DL min_nsl
DB121.DBW 374 DL max_ot_offset
DB121.DBW 376 DL min_ot_offset
DB121.DBW 378 DL max_ut_offset
DB121.DBW 380 DL min_ut_offset
DB121.DBW 382 DL max_stammdatum
DB121.DBW 384 DL min_stammdatum
DB121.DBW 386 DL max_bd_multitool
DB121.DBW 388 DL max_bd_schlitz
H274E3.DOC PLC 3-43

Tool types PLC DB121.dbw278
-1 No tool
0 Punching tool
1 Whisper tool
2 Forming tool
3 Multitool
4 Engraving tool
5 Slitting tool
6 Tapping tool
7 Clamp
8 Roller beading tool
9 Roller cutting tool
10 Punching tool with forming char. curve
11 Long punching tool
12 Rapid beading tool
Stripper types DB121.dbw50
-1 No stripper datum
0 No stripper
1 Self-stripping
2 Stripper Ø < 80mm
3 Stripper Ø > 80mm
3.15 DB 122: H&L punching
1.2.1 Diagnostics specification_struct (basis for computing ram

positions)

DB122.DBW0 D Sheet thickness
DB122.DBW2 D Regrind length
DB122.DBW4 D Tool type
DB122.DBW6 D Stripper (presser foot) type
DB122.DBW8 D Max_TDC
DB122.DBW10 D Max_BDC
DB122.DBB12 D Multitool type
DB122.DBB13 D Start-up active
DB122.DBB14 D Position
DB122.DBB15 D Rapid forming
DB122.DBW16 D BDC offset
DB122.DBW18 D TDC offset
DB122.DBW20 D Master datum
DB122.DBB22 D Referencing active
DB122.DBB23 D Cancel elevated height
DB122.DBB24 D M27 active
3-44 PLC H274E3.DOC

DB122.DBB25 D Scratch-free processing active
DB122.DBB26 D BDC dwell time
DB122.DBW27 D Tool length
DB122.DBB29 D Brush status
3.16 DB 123: H&L <-> Punching
1.2.2 Diagnostics status_struct (all H+L status data)
Address Format Variable Value

DB123.DBD 0 H Software version H+L (CPU) e.g. 0x00001700
DB123.DBD 4 HL H+L Library version
DB123.DBD 8 H H+L Library date
DB123.DBB 10 D Alarm issued by H+L
DB123.DBB 13 D Working ht. below toolchange
ht. with M27
DB123.DBB 14 D Working ht. below toolchange
ht. without _M27
DB123.DBB 15 D Work.ht. above toolchange ht.
DB123.DBB 16 D Toolchange height
DB123.DBB 17 D Uppermost height
DB123.DBB 18 D C reference position
DB123.DBB 19 D H+L reference position
DB123.DBB 20 D Position for laser guard
DB123.DBB 21 D Repositioning position
DB123.DBB 22 D Slitting position
DB123.DBB 23 D Service pos. 1
DB123.DBW 26 D TDC position Tele position
DB123.DBW 28 D BDC position
DB123.DBW 30 D START position
DB123.DBW 32 D CLAMPING position
DB123.DBW 34 D Technology
DB123.DBW 36 D Cycle
DB123.DBB 38 D Motion curve
DB123.DBB 39 D TDC dwell time
DB123.DBW 40 D Clamp. pos._tab_old
DB123.DBW 42 D TDC pos._tab_old
DB123.DBW 44 D Start pos. tab_old
DB123.DBW 46 D Penetr. height_tab_old
DB123.DBW 48 D Tool type_tab_old
DB123.DBB 50 D Data check required tab-old
DB123.DBB 51 D Rod pressure status 1 ON 2 OFF
H274E3.DOC PLC 3-45

DB123.DBB 52 D Rod pressure valve 1 ON 2 OFF
DB123.DBB 53 D Clamping valve 1 ON 2 OFF
DB123.DBB 54 D Init performed Initialization cycle
was run
DB123.DBB 55 D M27 active 1 active,
0 not active
DB123.DBB 56 D Lift tele running 1 stroke finished
(acc. to Tele)
DB123.DBB 57 D Operation message
DB123.DBB 58 D Reference point offset In 0.1mm
DB123.DBB 59 D Softpunch or speed 1 Softpunch
2 Speed
DB123.DBW 60 D Punching parameter value (acc. to selection
DB123.DBB55)
DB123.DBB 62 D Operation mode
DB123.DBB 63 D Warm Up
DB123.DBB 64 D Standardization run 0 NO 1 YES
completed 2 completed but
not acknowledged
with START
DB123.DBB 65 D Expectation window upper
limit
DB123.DBB 66 D Expectation window lower
limit
DB123.DBW 67 D Value of stripper above sheet Used for the tool
that follows a
forming tool
DB123.DBB 69 D Basic diagnostics status Cycle end of basic
diagnostics
DB123.DBW 70 D Total LP charge time [ms] Time for gener-
ating low pressure
after Hydraulic ON
DB123.DBW 72 D LP charge time rapid rise [ms] Time for gener-
ating LP from
Hydraulic ON until
gas precharge
DB123.DBW 74 D LP charge time slow rise [ms] Time for gener-
ating LP from gas
precharge until
final pressure
DB123.DBW 76 D LP gas precharge [Hpa] Gas precharge of
low pressure
accumulator
DB123.DBW 78 D LP switch point min. [Hpa] Lower pressure
point of
preservation
charge of LP
DB123.DBW 80 D LP switch point max. [Hpa] Upper pressure
point of
preservation
charge of LP
DB123.DBW 82 D LP charge cycle time [ms] Time for one cycle
to maintain the
preservation
charge of LP
DB123.DBW 84 D LP accumulator charge Charge time of LP
3-46 PLC H274E3.DOC

time [ms] accumulator in
preservation charge
DB123.DBW 86 D LP accumulator discharge Discharge time of LP
preservation charge
DB123.DBW 88 D Total LP charge time [ms] Time for generating
low pressure after
Hydraulic ON
DB123.DBW 90 D HP charge time rapid rise Time for generating
[ms] HP from Hydraulic
ON until gas pre-
charge
DB123.DBW 92 D HP charge time slow rise Time for generating
[ms] HP from gas pre-
charge until final
pressure
DB123.DBW 94 D HP gas pre-charge [Hpa] Gas pre-charge of
high pressure
accumulator
DB123.DBW 96 D HP switch point min. [Hpa] Lower pressure
point of preservation
charge of HP
DB123.DBW 98 D HP switch point max. [Hpa] Upper pressure
point of preservation
charge of HP
DB123.DBW 100 D HP charge cycle time [ms] Time for one cycle to
maintain the
preservation charge
of HP
DB123.DBW 102 D HP accumulator charge Charge time of HP
preservation charge
DB123.DBW 104 D HP accumulator discharge Discharge time of
time [ms] HP accumulator in
preservation charge
DB123.DBW 106 D Electr. basic diagnostics
Errorbyte 1
DB123.DBW 107 D Electr. Basic diagnostics
Errorbyte 2
DB123.DBW 108 D Hydr. basic diagnostics
Errorbyte 1
DB123.DBW 109 D Hydr. Basic diagnostics
Errorbyte 2
DB123.DBW 110 D Hydr. Basic diagnostics
Errorbyte 3
DB123.DBB 111 D Basic diagnostics data valid 0 Data not valid
1 Data valid
DB123.DBB 112 D Reserved
DB123.DBB 113 D Reserved
DB123.DBW 114 D Stripper pressure Stripper pressure set
by the proportional
valve
DB123.DBW 115 D Reserved
DB123.DBW 116 D Reserved
H274E3.DOC PLC 3-47

3.17 DB 126: Communication
Only one variable can be read or written via the PLC-Debugger.
The transfer interface is located in data block db126 (PLC<->MMC)
and can be accessed at the following addresses (controls):
• 840 or Typ3 PLC
• Liftmaster PLC (via telegram)
• Sheetmaster PLC (via telegram)
MMC transfer MMC –> PLC:

interface
db126.dbd620 Address
db126.dbw624 Type
db126.dbd626 Value (writing)
PLC –> MMC:

db126.dbd670 Value (reading)
with type 840D/T3:

0x0001 Read byte
0x0002 Read word
0x0004 Read long
0x8001 Write byte
0x8002 Write word
0x8004 Write long
Liftmaster:
0x0101 Read byte once
0x0102 Read word once
0x0104 Read long once
0x1101 Read byte in cycles
0x1102 Read word in cycles
0x1104 Read long in cycles
0x8101 Write byte
0x8102 Write word
0x8104 Write long
Liftmaster
Software version 1. Start the PLC debugger of the L3030.

display 2. In line "Address (DB126.DBD620)", use "Change value" to
enter value "68100".
3. In line "Type (DB126.DBW624)", use "Change value" to enter
value "104".
4. The software version is displayed in line "Read value
(DB126.DBD671)".
3-48 PLC H274E3.DOC

TC L1005 manual programming unit (PHG)
Integration of PLC functions is possible as of PHG version V1.1.0.
An ASCII file in the NC, which is managed by the PLC, is used as
the interface. It serves the PHG for input and display. With the F3
triangle key, the user selects the function he wants and activates a
certain action with a keystroke. Both sets of information – function
and action – go to the PLC via db126. Processing takes place
entirely in the PLC.
PLC enable signal to PHG: • Format: Bit

• Address: DB126.DBB660 Bit 6 (01000000)
When the menu is activated, the contents of file PHGPLC?.TAB

appear on the screen. Use the cursor and Page Up/Down keys to
select the desired function.
Data transfer There are two transfer methods.

1. By activating one of the softkeys sk1, sk2, sk3 or sk4, the ID is
copied into db126.dbw616 as a decimal value. After that, a bit
is set in datum db126.dbb618. Here, sk1 corresponds to Bit 0,
sk4 to Bit 3. The PLC acknowledges this bit when a function
implemented according to the ID has been executed. The PHG
deletes both the ID and the sk bits if another function is chosen
from the list and when you exit this screen.
2. Functions of longer duration, such as filler wire travel etc. can
be realized via the softkey. When the screen opens, this
softkey is marked "activ." (= activate). If this is confirmed, the
ID is copied as a decimal value to db126.dbw616. At the same
time, the softkey label changes to "deact." (= deactivate) and
sofkey bit db126.dbb618 Bit 4 is set. The F1 and F2 keys are
now enabled for evaluation via the PLC. The potentiometer
values in the PHG no longer change over. If the 5th softkey is
pressed again, the ID and softkey Bit 4 are reset. The label
changes to "activ.". Softkey 5 therefore functions as a Toggle
key.
The PHG deletes both the ID and the sk bits if another function is
chosen from the list and when you exit this screen.
The following applies to both methods:
Function ID as decimal value (0...9999):

Format: Word
Address: DB126.DBW616
Bit bar for 5 softkeys (Bit0...Bit4):

Format: Bit
Address: DB126.DBB618, whereby Bit 0...3 is acknowledged by
the PLC and Bit 4 is toggled by the PHG.
H274E3.DOC PLC 3-49

3.18 DB 125 / 127: Tool change diagnostics
Tool in tool adapter:

DB125.DBD 100 D Magazine number in adapter
DB125.DBD 104 D Magazine number in adapter unloaded
DB125.DBD 108 D Act. MT punch in adapter
DB125.DBD 112 D Act. tool type in adapter
DB125.DBD 116 D Act regrind length in adapter
DB125.DBD 120 D Act. MT type in adapter
DB125.DBD 128 D Act. stripper type in adapter
DB125.DBD 132 D Act. TDC position for forming tool in
adapter
Tool to be loaded:

DB125.DBD 136 D Diag. Magazine number to be loaded
DB125.DBD 140 D Diag. Tool type to be loaded
DB125.DBD 144 D Diag. Multitool type to be loaded
DB125.DBD 148 D Diag. Punch (in Multitool) to be loaded
DB 125.DBD 152 D Diag. Regrind length of tool to be loaded
DB 125.DBD 156 D Diag. Stripper type of tool to be loaded
DB 125.DBD 160 D Diag. Sheet type
DB 125.DBD 164 D TDC pos. sheet thickness for tool to be
loaded
DB 125.DBD 64 D Diag. Act. Y Pos
DB 125.DBD 68 D Diag. Act. C1 Pos
DB 125.DBD 168 D Diag. Act. C2 Pos
DB 125.DBD 72 D Act. PLC tool change acknowledgement
Errors or data on rapid toolchange:

DB 125.DBX 2.0 B Memory rapid tool change
DB 125.DBX 2.1 B Memory error Cycle Open tool clamping
An error has occurred which can be cleared
only in reference position by means of a
special cycle.
DB 125.DBX 2.2 B Y position greater than 40mm
DB 125.DBX 2.4 B Last_Ret_Position message
"1" means: LOAD TOOL AS TOOL
WORKING HEIGHT HIGHER THAN TOOL
CHANGE HEIGHT
3-50 PLC H274E3.DOC

DB 125.DBX 2.5 B Last_Ret_Ram pos._Status()
"1" means: UNLOAD TOOL AS TOOL
WORKING HEIGHT HIGHER THAN TOOL
CHANGE HEIGHT
DB 125.DBX 2.6 B Cancel elevated height (forming height)
1: Not cancelled: The tool will be used from
the elevated height
0: Elevated height cancelled: The tool will be
used from its specific working height
Tool change steps:

DB127.DBW 160 D STEP Organization
DB127.DBW 284 D STEP Tool change within a Multitool
DB127.DBW 286 D STEP Preconditions for unloading Multitool
DB127.DBW 162 D STEP Verification
DB 127.DBW 168 D STEP Management of tool adapter check
DB 127.DBW 166 D STEP Unload
DB 127.DBW 174 D STEP Remove tool after unloading
DB 127.DBW 172 D STEP Pinion lubrication
DB 127.DBW 164 D STEP Preconditions for load empty
DB 127.DBW 298 D STEP Unloading Open tool clamping
DB 127.DBW 178 D STEP Loading Close tool clamping
DB 127.DBW 182 D STEP Cycle 1 before loading tool
DB 127.DBW 176 D STEP Load tool
DB 127.DBW 184 D STEP Termination
DB 127.DBW 190 D STEP Assume tool change height
DB 127.DBW 170 D STEP Check preconditions for unloading
DB 127.DBW 296 D STEP Multitool lock unlocked
DB 127.DBW 308 D STEP Rapid toolchange
DB 127.DBW 278 D STEP Rapid tool change 7 Pos.
DB 127.DBW 188 D STEP Clear error
3.19 Diagnostics with R-parameters
With R parameters you can:

• Activate diagnostic possibilities
• Read out information stored in the R parameters
R parameters are set and modified in the PLC-Debugger.
Command/Address The parameter abbreviation is written in this field, e.g. R80.
Type As data type, “DL” is entered for decimal data.
H274E3.DOC PLC 3-51

Value If the value for a parameter needs to be changed (e.g. to activate a
diagnostic possibility), the “Change Value” softkey must be
pressed.
3.20 Diagnostics via machine data
Various diagnostic possibilities can be activated via machine

datum MN_DIAG_DEBUGINFO. Please refer to Chapter 5
“Modifying machine data” on how to edit this machine datum.
Axis positioning diagnostics
The PLC states the axis positions for various machine functions.
For this purpose, the NC transfers the actual position information to
the PLC. The PLC then transfers the new nominal position back to
the NC. The NC now drives the axis in an interpolated fashion.
If machine datum MN_DIAG_DEBUGINFO is set to a value other

than “0”, the data transfer between the NCK and the PLC is
recorded in the DATDPR.COM file (MPF.DIR in the NCK). This
information can be viewed in the diagnostics editor:
1. Select "Diagnose – File functions"
2. Select source "CNC control"
3. Select directory "MPF.DIR"
4. Select file "DATDPR.COM"
5. Press ENTER to confirm
The DATDPR.COM file is opened and the information

displayed.
Table programming diagnostics
All commands which access the tables transfer data from the
passive NCK file system to the PLC. The NCK table handler reads
the programmed file name, formats the data and sends it to the
PLC.
If machine datum MN_DIAG_DEBUGINFO is set to a value other

than “0”, the data transfer between the NCK and the PLC is
recorded in the DATDPR.COM file (MPF.DIR in the NCK). This
information can be viewed in the diagnostics editor:
3-52 PLC H274E3.DOC

4. Select file "DATDPR.COM"
The DATDPR.COM file is opened and the information
displayed.
Tool management diagnostics
A new tool is selected by means of the NC cycle command

TC_TOOL_NO. The actual tool change itself is accomplished with
the TC_TOOL_CHANGE NC cycle command. The MMC tool
manager creates an WZW.MPF file (MPF.DIR directory in the
NCK) when the rail assignment is changed. The CNC performs its
tool check according to the information in this file.
If the machine datum MN_DIAG_DEBUGINFO is set to a value

other than “0”, the data transfer between the CNC and the PLC is
recorded in the WZW.MPF file (MPF.DIR in the NCK) and can be
viewed in the diagnostic editor:

4. Select file "WZW.MPF"
The WZW.MPFDATDPR.COM file is opened and the
information displayed.
H274E3.DOC PLC 3-53

R80: Rail assignment check diagnostics
The rail assignment check compares the actual mechanical tool

placement on the rail with the assignment stated in the controller.
If R-parameter 80 is set to "10", the recognized rail assignment is
written to the PPLISTE.COM ("MPF.DIR" directory in the NCK).
This directory can be viewed in the diagnostic editor:
1. Select "Diagnose – File functions
4. Select file "PPLISTE.COM"
The PPLISTE.COM file is opened and the information
displayed:
Number 1: Rail position
Number 2: Nominal assignment according to tool management
Number 3: Actually recognized rail assignment
-1 Not occupied
1 Tool
2 Clamp
3 Empty position or empty cartridge
R80-R87: DIAS diagnostics
The DIAS height regulation sends the nominal speed value to the
NC. This is standardized, limited and added to the programmed Z-
axis value. This function is activated by the "TC_LASER_ON" cycle
and de-activated by the "TC_LASER_OFF" cycle.
The height regulation status is written to R-parameters for
diagnostic purposes. The diagnostics are activated by setting R
parameter 80 to “5”. DIAS height regulation status is displayed in
R-parameters 81-87:
R80 = 5:
R81 Status ON/OFF
R82 Status stop (not used at this time)
R83 Status selection (not used at this time)
R84 Analog value read in
R85 Correction speed
R86 Corrected path
R87 Standardized amplification factor for analog value
3-54 PLC H274E3.DOC

R56 – R69: Tapping diagnostics
The tapping status is written to R-parameters for diagnostic

purposes. Diagnosis is activated by setting R-parameter 56 to
value “10” or “12”. Depending on the setting, R-parameters 57-66
will contain different information which can be viewed in the PLC-
Debugger.
Manual C-Axis motion 1. R56=0

2. R65: Enter value for angle statement
3. R66: Enter value for speed statement
4. R56=Set 9
When R65 is set to a new value, the release cycle is started
automatically. If an angle statement of more than 10 revolutions is
stated, the sense of rotation is reversed. An entry of 3960000
results in a CCLW sense of rotation.
R56=10 R57 Tapping step counter

R58 Release cycle angle
R59 Release cycle start position
R60 Release cycle end position
R61 Position of C-axis one cycle ahead
R62 Position of C-axis at start of tapping
R63 Reduction at tapping
R64 Path in sheet
R65 Selected RPM
R66 Selected number of C-Axis rotations
R67 Actual C-axis position
R68 NewPos (internal NC calculation value)
R69 NewVel (internal NC calculation value)
R56=12 R57 Technology data are valid

R58 Technology
R59 Feed rate
R60 Oil container
R61 Number of lubrication impulses
R62 BDC-Offset
R63 TDC-Offset
R64 Reserved
R65 C-Axis revolutions
R66 Tapping RPM
H274E3.DOC PLC 3-55

3.21 ELSP_VSS.H files
If the operating environment displays an alarm (Read-in disable,

Feed disable, Feed Stop or E-STOP) without text, the ELSP-
VSS.H files can be used to determine which machine module has
caused the fault.
1. Switch to "PLC-Debugger"
Fig. 18519E
2. On page 1 of the PLC-Debugger, note down the figures

indicated in column „Value“ under „Read-in disable“, „Feed
disable“, „Feed stop“ and „E-STOP“. 4 blocks with a double
digit decimal number each are shown (8 digits). Each decimal
number represents one module.
In this example, 3 modules (modules 03, 12 and 14) are triggering
a Feed Stop.
In addition to this, a Feed disable is active at module 07, and an
Emergency Stop is being issued by Module 02.
The modules can now be allocated accordingly in file
ELSP_VSS.H under the „enums“ ELSP, VSS, VSH and
EMERGENCY STOP:
• In „enum“ VSS you will find VSS_Werkstueck_Klemmung
(Feed disable_workpiece_clamps) under 7, i.e. the machine
has a problem with the clamps.
• In „enum“ VSH you will find VSH_NCU under 3,
VSH_Schlitzen (Feed Stop Slitting) under 12 and
GRP1_VSH_5 (Lichtschranke) (light barrier) under 14. These
are all modules which trigger a Feed Stop.
• In „enum“ NOTAUS you will find NOTAUS_EIN_AUS (E-
STOP_ON_OFF) for 2, i.e. there is a problem associated with
switching the machine on.
3-56 PLC H274E3.DOC

3.22 Overview: PLC modules
Organization modules
OB No. Designation Name Set
1 CYCLE Cyclical processing GP

40 ALARM Process alarms GP
100 NEWSTART New start/Start-up GP
Function modules
FC No. Designation Name Set
0 Reserved for Siemens

2 GP_HP Operating program for cyclical portion GP
3 GP_PRAL Operating program for alarm driven GP
portion
7 TM_REV Transfer module for tool change with GP
turret
8 TM_TRANS Transfer module for tool management GP
9 ASUP Asynchronous subroutines GP
10 AL_MSG Alarms/Messages GP
13 BHG_DISP Display control for manual operation GP
unit
15 POS_AX Positioning axis, Z axis GP
16 PART_AX Partition axis GP
17 Y-D switchover GP
18 PLC spindle control GP
19 MCP_IFM Distribution of MSTT and MMC-signals GP
on the periphery (Milling machine)
22 TM_DIR Direction selection
25 MCP_IFT Distribution of MSTT and MMC-signals GP
on the periphery (lathe)
30-127 Free for user
65 C program call
0-29 Reserved for Siemens

1 RUN_UP Boot-up operating program GP
2 GET Read NC variables GP
3 PUT Write NC variables GP
4 PI PI services GP
H274E3.DOC PLC 3-57

Data block assignment
1 Dual-Port-RAM interface GP
2-4 PLC-MELD PLC messages GP
9 NC-COMPILE NC Compiler cycles interface GP
10 NC Central NC interface GP
INTERFACE
11 BAG 1 BAG interface GP
21-22 CHANNEL 1 NC channel interface GP
31-38 AXIS 1 Interfaces GP
39 AXIS 9 Reserved for axis-spindle interface No. GP
to AXIS 31 9 to 31
61 Or free for user
62-69 Reserved authority DBs in C-PLC- GP
programming
Or
Free for user
70 Reserved for C-PLC programming
or
Free for user
71-73 User tool management
74 Reserved for Siemens tool GP
management
75-80 Reserved for Siemens GP
Assigned times
Timer-No. Description
1-9 Reserved
3-58 PLC H274E3.DOC

4. Interface signals
General A literature reference is stated for each signal in the following

periphery signal list.
The reference is to a chapter number or Siemens functional

description, see
SIEMENS literature: /FB/, xx, "yyy"
xx Abbreviation of individual functional description (for example:

/A2/)
yyy Name of functional description (for example: "Diverse
interface signals")")
Inverse signals Signals marked with "*" are so-called inverse signals. The
response that such an inverse signal triggers is initiated with its low
(“0”) state, not its normal high (“1”) state. (for example: MSTT, Byte
n+2.0: *NC-STOP).
4.1 Signals to and from the manual

operating unit (e. g. for TLC 1005)
Signals from the manual operating unit (pushbuttons)

Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
EB n+0 Reserved
EB n+1 Reserved
EB n+2
T9 T7 T6 T5 T4 T3 T2 T1
EB n+3
T16 T15 T14 T13 T12 T11 T10 T9
EB n+4
T24 T23 T22 T21
EB n+5 Acknowl. Rapid/Feed rate correction switch
Character Key switch E D C B A
display
H274E3.DOC PLC 3-59

Signals to the manual operating unit (LEDs)
AB n+0 Always 1
AB n+1 New data Block
for selected selection
block
AB n+2
L8 L7 L6 L5 L4 L3 L2 L1
AB n+3
L16 L15 L14 L13 L12 L11 L10 L9
Character display on the manual operating unit
AB n+4
AB n+4 1st character (right) of selected line
AB n+5
AB n+5 2nd character of selected line
AB n+19
AB n+19 16th character (left) of selected line
The manual operating unit is connected to the SINUMERIK

840D at the PLC’s MPI interface.
The I/O range start addresses and the number of Bytes to

be transferred must be stated with the STEP 7-Set
Communication Configuration.
Note: the GD parameters automatically issued by the

communication configuration must be set at the manual
operating unit.
SIEMENS literature /BH/, "Operating components manual"
3-60 PLC H274E3.DOC

4.2 MMC and PLC interface signals
Area: DB126 (100 bytes)

MMC->PLC: Byte 600-649
PLC->MMC: Byte 650-699
MMC to PLC:
DB 126 Signals MMC • PLC

DBB 600 cont.Tip incr. Tip Ax Bit3 Ax Bit2 Ax Bit1 Ax Bit0
DBB 601 LED LED Sh-F8 LED Sh-F7 LED Sh-F6 LED Sh-F5 LED Sh-F4 LED Sh-F3 LED Sh-F2
Sh-F9
DBB 602 LED Sh-F10
DBB 603 Type 3 Type 3 only: Type 3 only: Type 3 only: Job table Program
only: Progr. Stop Skip block (PLC) active start
Single M01 re-start **********
block
DBB 604 (Ref. pt) (Repos) (TeachIng) JOG MDA AUTO
DBB 610 Trigger for Trigger for Camera Camera ON Height Height
transferring transferring OFF regulation regulation
camera DIAS nomi- (DIAS 3 ) (DIAS 3 )
feedrate nal standoff OFF ON
DBB 612 Nominal standoff for DIAS (MSB) - - in µm
DBB 613 „ „ „ „ (LSB) - - „
DBB 614 Feed- for Teach camera (MSB) - - in mm/min
rate
DBB 615 „ „ „ „ (LSB) - - „
DBB 620 PLC Address LSB
Debugger
DBB 621 „ „ ...
DBB 622 „ „ ...
DBB 623 „ „ MSB
DBB 624 „ Number of bytes (here add 0x8000 LSB
DBB 625 „ „ „ for writing) MSB
DBB 626 „ Contents (write) LSB
DBB 627 „ „ „ „
DBB 628 „ „ „ „
DBB 629 „ „ „ MSB
H274E3.DOC PLC 3-61

PLC to MMC:
DB 126 Signals PLC • MMC
DBB 650 End of RESET Re-start Program start Laser RESET Start button Overall reference
program button NCK/PLC button button position exists
DBB 651 BDE active Approach refer-
ence position
DBB 652 Read-in disable - - - whole byte
DBB 653 Feed disable - - - whole byte
DBB 654 Controller type - (0=840D) (FF=Typ3) whole byte
DBB 655
DBB 656 Ready for Shutter open Laser beam ON Laser ready
service
DBB 657 Beam lock
active
DBB 658 Setting - - - - - this and
value
DBB 659 Setting next byte
value
DBB 660 PHG has PHG in Editor Prompt from Teach file was Keyswitch for PHG
WKS or Teach PHG to save modified or has has been turned ON
status mode Teach file been saved
DBB 661 Reserved for PHG
...
DBB 669 Reserved for PHG

DBB 670 PLC-Debugger Contents LSB
DBB 671 „ ...
DBB 672 „ ...
DBB 673 „ MSB
...
DBB 678
DBB 679 Number of subsequent heads (for HSL2502 only)
DBB 680 Head 1 Laser power in watts LSB
DBB 681 Head 1 Laser power in watts MSB
DBB 682 Head 1 Pressure in 1/10 bar LSB
DBB 683 Head 1 Pressure in 1/10 bar MSB
3-62 PLC H274E3.DOC

4.3 PLC messages (DB 2)
DB 2 Signals for PLC messages (PLC → MMC) /P3/

Channel 1
0 510007 510006 510005 510004 510003 510002 510001 510000
Feed disable (Alarm No.: 510000-510015)
1 510015 510014 510013 510012 510011 510010 510009 510008
2-5 Feed and read-in disable (Alarm No.: 510100-510131)
6-9 Read-in disable (Alarm No.: 510200-510231)
10-11 NC-Start disable (Alarm No.: 510300-510315)
12-13 Feed stop GEO axis 1 (Alarm No.: 511100-511115)
Channel 2
18 520007 520006 520005 520004 520003 520002 520001 520000
Feed disable (Alarm No.: 520000-520015)
19 520015 520014 520013 520012 520011 520010 520009 520008
20-23 Feed and read-in disable (Alarm No.: 520100-520131)
24-27 Read-in disable (Alarm No.: 520200-520231)
28-29 NC-Start disable (Alarm No.: 520300-520315)
36-143 reserved
Axis/spindle
144 600107 600106 600105 600104 600103 600102 600101 600100
Feed stop/Spindle stop (Alarm No.: 600100-600015) for axis/spindle 1
145 600115 600114 600113 600112 600111 600110 600109 600108
146-147 Feed stop/Spindle stop (Alarm No.: 600200-600215) for axis/spindle 2
160-179 reserved
User range
180 700007 700006 700005 700004 700003 700002 700001 700000
... User range 0 (Alarm No.: 700000-700063)
187 700063 700062 700061 700060 700059 700058 700057 700056
188-195 User range 1 (Alarm No.: 700100-700163)
H274E3.DOC PLC 3-63

The relation between message and alarm numbers, text and
range recognition takes place in the DB2. Transfer of all
alarm or message bits to the user periphery (channel,
axis/spindle) is set by means of parameters. The transfer
must otherwise be programmed in the user program. The
user periphery can be additionally influenced after calling up
the error/operation message module. Only signals from the
channels and axes declared in the NC machine data can be
transferred and texts displayed.
Error messages must be acknowledged by the operator as
they are generated. Operation messages are only displayed
as long as the condition is active.
Definition of error and operation messages /P3/

Byte No. of DB 2 / Error message FM or operation message BM
7 / FM 6 / FM 5 / BM 4 / BM 3 / FM 2 / FM 1 / BM 0 / FM
15 / BM 14 / FM 13 / BM 12 / FM 11 / BM 10 / FM 9 / BM 8 / BM
23 / BM 22 / BM 21 / FM 20 / FM 19 / BM 18 / FM 17 / BM 16 / FM
31 / BM 30 / FM 29 / BM 28 / FM 27 / BM 26 / BM 25 / FM 24 / FM
35 / BM 34 / FM 33 / BM 32 / FM
151 / BM 150 / FM 149 / BM 148 / FM 147 / BM 146 / FM 145 / BM 144 / FM
159 / BM 158 / FM 157 / BM 156 / FM 155 / BM 154 / FM 153 / BM 152 / FM
187 / BM 186 / BM 185 / BM 184 / BM 183 / FM 182 / FM 181 / FM 180 / FM
195 / BM 194 / BM 193 / BM 192 / BM 191 / FM 190 / FM 189 / FM 188 / FM
Example Alarms from 510200 - 510207 can be generated across the DB 2,

DBB6 (read-in disable channel 1). These alarms are defined as
error messages.
3-64 PLC H274E3.DOC

4.4 Signals to/from NCK Compiler cycles
(DB 9)
DB 9 Signals to/from NCK compile cycles (NCK ↔ PLC)

...
The data block is 400 bytes long.

The ranges for signals to/from compile cycles can be stated
in MD 10400/10410..
All NCK compile cycles can exchange data or signals across
the DB 9 with the PLC on an equal status basis.
The data block is cyclically updated. This is indicated in the
compile cycle description
4.5 Signals to/from NC (DB 10)
DB 10 Signals to NC (PLC → NC)

DBB 0 Disabling the digital NCK inputs /A2/ (from SW 2)
Digital inputs without hardware #) On-Board-Inputs §)
Input 8 Input 7 Input 6 Input 5 Input 4 Input 3 Input 2 Input 1
DBB 1 Setting the digital NCK inputs from PLC (from SW 2)
Digital inputs without hardware #) On-Board-Inputs §)
DBB 2, 3
not
assigned
DBB 4 Disabling digital NCK outputs /A2/ (from SW 2)

Digital outputs without hardware #) On-Board-Outputs §)
Output 8 Output 7 Output 6 Output 5 Output 4 Output 3 Output 2 Output 1
DBB 5 Overwrite mask of the digital Outputs NCK /A2/ (from SW 2)
DBB 6 Setting value of digital NCK outputs from the PLC /A2/ (from SW 2)
H274E3.DOC PLC 3-65

DBB 7 Input mask of the digital NCK outputs /A2/ (from SW 2)
DBB 8-55 RESERVED
DBB 56 Key switch /A2/ E-STOP E-STOP
Position 3 Position 2 Position 1 Position 0 acknowl. /N2/
/N2/
DB 57-59
#) Bit 4-7 of the digital inputs and NCK outputs can be

processed by the PLC even though no hardware
periphery is available for this. These bits can therefore
also be used for information exchange between the NCK
and the PLC
§) The digital NCK inputs and outputs 1 to 4 are on-board

(hardware) the SINUMERIK 840D. No hardware
periphery is available for Bit 0 to 3 on the FM-NC. These
can be processed by the PLC according to #).
DB 10 Signals from the NC (NC → PLC)

DBB 60 Actual value of digital ON-BOARD-Inputs of the NCK
(from SW 2)
On-Board-Inputs §)
Input 4 Input 3 Input 2 Input 1
DBB 61-63
DBB 64 Nominal value for digital NCK outputs (from SW 2)
DBB 65-96
#) Bit 4-7 of the digital inputs and NCK outputs can be

processed by the PLC even though no hardware
periphery is available for this. These bits can therefore
also be used for information exchange between the NCK
and the PLC
§) The digital NCK inputs and outputs 1 to 4 are on-board

(hardware) the SINUMERIK 840D. No hardware
periphery is available for Bit 0 to 3 on the FM-NC. These
can be processed by the PLC according to #).
3-66 PLC H274E3.DOC

DB 10 Signals from the NC (NC → PLC)
DBB 97 Channel number for hand wheel 1 /H1/
MMC→PLC (from SW 2)
C B A
DBB 98 Channel number for hand wheel 2 /H1/
MMC→PLC (from SW 2)
C B A
DBB 99
MMC→PLC
DBB 100 Axis number for hand wheel 1 /H1/ (from SW2)
MMC→PLC Machine Hand wheel E D C B A
axis selected
DBB 101 Axis number for hand wheel 2 /H1/ (from SW2)
MMC→PLC Machine Hand wheel E D C B A
axis selected
DBB 102
MMC→PLC
DBB 103 MMC-101 AT-Box
MMC→PLC /102-Batte- ready
ry alarm
DBB 104 NCK-CPU
Ready /A2/
DBB 105 not assigned
DBB 106 E-STOP
active /N2/
DBB 107 Meas. probe activated
/M2/
Key 2 Key 1
DBB 108 NC-Ready MMC-CPU1 MMC-CPU1
/A2/ Ready /A2/ Ready /A2/
DBB 109 NCK battery Air tempe- Chiller NCK-Alarm
alarm rature alarm circuit alarm active
/A2/ /A2/ NCU 573 /A2/
DBB 110 Software limit Minus (from SW 2) /N3/
8 7 6 5 4 3 2 1
DBB 111 Software limit Minus (from SW 2) /N3/
16 15 14 13 12 11 10 9
DBB Not assigned
112-113
DBB 114 Software limit Plus (from SW 2) /N3/
8 7 6 5 4 3 2 1
DBB 115 Software limit Plus (from SW 2) /N3/
16 15 14 13 12 11 10 9
DBB Not assigned
116-117
Re MMC-CPU 1 READY (DBX 108.3 and DBX 108.2):

Bit 3 is set when connecting the MMC to the operating panel
interface (X101) as a standard measure. When connecting
to the PG-MPI interface (X122), Bit 2 is set.
H274E3.DOC PLC 3-67

DBB 122 Disabling digital NCK inputs (from SW 2)
DB 10 Signals to NCK (PLC → NCK) /A2/ (from SW 2)

DBB 130 Disabling digital NCK outputs (from SW 2)
DBB 131 Overwrite mask of digital NCK outputs (from SW 2)
DBB 132 Setting value of digital NCK outputs from PLC (from SW 2)
DBB 133 Input mask for digital NCK outputs (from SW 2)
3-68 PLC H274E3.DOC

DB 10 Signals to NCK (PLC → NCK) /A2/ (from SW 2)
DBB 146 Disabling analog NCK inputs
DBB 147 Analog value statement for NCK from PLC
DBW 148 Setting value from PLC for analog input 1 of NCK
DBB RESERVED
164, 165
DBB 166 Overwrite mask for analog NCK outputs
DBB 167 Input mask for analog NCK outputs
DBB 168 Disabling analog NCK outputs
DBB 169 RESERVED
DBW 170 Setting value from PLC for analog output 1 of NCK
Re NCK-CPU Ready (DBX 104.7)

This signal is the activity monitor of the NC. This signal is to
be incorporated into the machine safety circuit.
H274E3.DOC PLC 3-69

DB 10 Signals from the NCK (NCK → PLC) /A2/ (from SW 2)
DBB 186 Actual value of digital NCK inputs
DBB 190 Nominal value of digital NCK outputs
DBW 194 Actual value of analog input 1 of NCK
DBW 210 Nominal value of analog output 1 of NCK
3-70 PLC H274E3.DOC

4.6 Signals to/from BAG (DB 11)
DB 11 Signals to BAG (PLC → NCK) /K1/

DBB 0 BAG-Reset BAG-Stop BAG-Stop Operating Operating mode
mode
Axes plus Change JOG MDA AUTO-
spindle disable MATIC
DBB 1 Machine function
REF REPOS TEACH IN
DBB 2-3 not assigned
DB 11 Signals from the BAG (NCK → PLC) /K1/

DBB 4 Operating mode-Strobe
MMC→PLC JOG MDA AUTO-
MATIC
DBB 5 Machine function-Strobe
MMC→PLC REF REPOS TEACH IN
DBB 6 all channels BAG Active Operating mode
in Reset Ready JOG MDA AUTO-
condition MATIC
DBB 7 Digitize Active Machine function
/FBD/ (from REF REPOS TEACH IN
SW 2)
4.7 Signals to/from control panel (DB 19)
Currently not used by TRUMPF.
DB 19 Signals to/from control panel (PLC → MMC)

DBB 0 Actual value Pushbutton Darken Control
in WKS, 0 = disable /A2/ screen /A2/ panel-
MKS /A2/ disable
DBB 20 MKS/WKS Darken
switchover screen /A2/
/A2/
H274E3.DOC PLC 3-71

4.8 Signals to/from NCK channel
(DB 21 - 28)
DB 21-28 Signals to NCK-channel (PLC → NCK)

DBB 0 Activate test Activate Activate Activate External
run feed M01 /K1/ single block DRF /H1/ processing
/V1/ /K1/ (in
preparation)
DBB 1 Activate Enable Activate
program protection referencing
test areas /R1/
DBB 2 Suppress
block /K1/
DBB 3 Nibbling and punching
Delayed No stroke Stroke Manual Stroke
stroke suppression stroke enable
release
DBB 4 Feed rate correction /V1/
H G F E D C B A
DBB 5 Rapid feed correction /V1/
H G F E D C B A
DBB 6 Feed rate Rapid feed Program. Delete rest Read-in Feed
correction correction level abort distance disable /K1/ disable /V1/
active /V1/ active /V1/ /K1/ /A2/
DBB 7 Reset /K1/ NC-Stop NC-Stop NC-Stop at NC-Start NC-Start
Axes plus /K1/ block limit /K1/ disable /K1/
Spindle /K1/ /K1/
DBB 8 Activate machine relevant protection areas /A3/ (from SW 2)
Area 8 Area 7 Area 6 Area 5 Area 4 Area 3 Area 2 Area 1
DBB 9 Activate machine relevant protection areas /A3/ (from SW 2)
Area 10 Area 9
DBB 10 Activate channel specific protection areas /A3/ (from SW 2)
DBB 11 Activate channel specific protection areas /A3/ (from SW 2)
Area 10 Area 9
DBB 12 Geometry axis 1
Jog key /H1/ Rapid feed Disable Feed Activate hand wheel /H1/
+ - override / Feed key Stop /V1/ 2 1
H1/ /H1/
DBB 13 Geometry axis 1 machine function /H1/
Var. INC 10000 INC 1000 INC 100 INC 10 INC 1 INC
DBB 14 OEM signals Geometry axis 1

Jog key /H1/ Rapid feed Disable Feed Stop Activate hand wheel /H1/
+ - override / Feed key /V1/ 2 1
H1/ /H1/
3-72 PLC H274E3.DOC

DB 21-28 Signals to NCK-Channel (PLC → NCK)

Jog key /H1/ Rapid feed Disable Feed Stop Activate hand wheel /H1/
+ - override / Feed key /V1/ 2 1
H1/ /H1/
Feed rate correction active (DBX 6.7)

Setting position 0% still active even if feed rate correction is
not active (=100%).
Feed rate correction (DBB 4)
Either 31 positions (Gray code) with 31 MD for % evaluation,
or 0-200% corresponding to the dual value in Bytes (201-
255 = max. 200%)
Rapid feed correction (DBB 5)
Either 31 settings (Gray code with 31 MD for % evaluation,
or 0-100% corresponding to the dual value in Bytes (101-
255 = max. 100%)
Activate single block (DBX 0.4)
Select variables with "Write variables”
Delete remaining distance (DBX 6.2)
Effective only for path axes and not for positioning axes
H274E3.DOC PLC 3-73

DB 21-28 Signals from the NCK-Channel (NCK → PLC)
DBB 24 Test run M01 DRF Processing
MMC→PLC feed selected selected from
activated /K1/ /H1/ external
/V1/ selected (in
preparation)
DBB 25 Program- Rapid feed
MMC→PLC test rate
selected correction
/K1/ selected
/V1/
DBB 26 Block
MMC→PLC suppression
selected
/K1/
(from SW 2)
DBB 27-31
DBB 32 M00/M01 Processing
active /K1/ from
external
selected (in
preparation)
DBB 33 Program Transform- M02/M30 Block Hand wheel Rotation Referencing
test active ation active active /K1/ search run override feed rate active /R1/
/K1/ /K1/M1 active /K1/ active active
(from SW 2)
DBB 34 OEM channel signals feedback
DBB 35 Channel status /K1/ Program status /K1/

Reset Interrupted active Aborted Interrupted Stopped Waiting Running
DBB 36 NCK alarm NCK alarm, All axes All
active with channel stopped compulsory
process specific is /B1/ ref. point
stop /A2/ active /A2/ axes are
referenced
/R1/
DBB 37 ASUP-Status /K1/
Error Interrupt Running
No. not
assigned
DBB 38 Nibbling and Punching
Acknowledg Stroke
e manual trigger
stroke active
Feed rate correction for rapid motion selected (DBX

25.3)
The PLC operation program copies the federate correction
to the rapid feed correction in the channel-specific periphery,
depending on this signal.
Program test selected (DBX 25.7)
Program test selected means axis disable for all axes and
spindles of the channel.
3-74 PLC H274E3.DOC

DBB 39 Protection
areas not
assured
Travel command /H1/ Hand wheel active /H1/
plus minus 2 1
DBB 41 Geometry axis 1 active machine functions /H1/
DBB 44 Geometry axis 1 selected machine function (from SW 2)

MMC→PLC Var. INC 10000 INC 1000 INC 100 INC 10 INC 1 INC
plus minus 2 1
DBB 47 Geometry axis 2 active machine function /H1/

plus minus 2 1
DBB 53 Geometry axis 3 active machine function /H1/

DBB 57
DBB 58 M-Fct. 5- M-Fct. 4- M-Fct. 3- M-Fct. 2- M-Fct. 1-
change /S5/ change /S5/ change /S5/ change /S5/ change /S5/
DBB 59 M-Fct. 5 not M-Fct. 4 not M-Fct. 3 not M-Fct. 2 not M-Fct. 1 not
decoded decoded decoded decoded decoded
DBB 60 S-Fct. 3- S-Fct. 2- S-Fct. 1-
change /S5/ change /S5/ change /S5/
H274E3.DOC PLC 3-75

DBB 61 T-Fct. 3- T-Fct. 2- T-Fct. 1-
(from SW 2) (from SW 2)
DBB 62 D-Fct. 3- D-Fct. 2- D-Fct. 1-
DBB 63 E-Fct.-
change
DBB 64 H-Fct. 3- H-Fct. 2- H-Fct. 1-
DBB 65 F-Fct. 6- F-Fct. 5- F-Fct. 4- F-Fct. 3- F-Fct. 2- F-Fct. 1-
change /S5/ change /S5/ change /S5/ change /S5/ change /S5/ change /S5/
DBB 66 Auxiliary
function
Quick
DBB 67
DBW 68 Extended address M function 1 (dual) /S5/
215 28
31
DBD 70 2
: M function 1 (dual) /S5/
:
DBD 73 20
DBD 76 M function 2 (dual) /S5/
DBW 98 Extended address S function 1 (dual) /S5/
DBD 100 S function 1 (REAL-Format) /S5/
DBW 116 Extended address T function 1 (16 Bit-Int)
DBW 118 T function 1 (dual) /S5/
DBW 120 Extended address T function 2 (16 Bit-Int)
DBW 122 T function 2 (Int)
DBW 124 Extended address T function 3 (16-Bit-Int)
DBW 126 T function 3 (Int)
DBB 128
DBB 129 D function 1 (dual) /S5/
3-76 PLC H274E3.DOC

M functions are programmed in the INTEGER format (8
decades plus prefix)
"REAL-Format" means: 24 Bit mantissa and 8 Bit exponent.

DBB 130 Extended address D function 2 (8 Bit-Int)
DBB 131 D function 2 (8 Bit-Int)
DBB 132 Extended address D function 3 (8 Bit-Int)
DBB 133 D function 3 (8 Bit-Int)
DBW 134 Extended address E function (16 Bit-Int)
Programmed T functions with names (for example

T=5564732.00A) cannot be transferred to the PLC in ASCII
format.
Programmed D functions with names (for example

D=SCHNEIDE_1) cannot be transferred to the PLC in ASCII
format
The REAL format corresponds to the floating point position

in STEP 7 (24 Bit mantissa and 8 Bit exponent).

DBD 136
DBW 140 Extended address H function 1 (dual) /S5/
DBD 142 H function 1 (REAL-Format) /S5/
DBW 158 Extended address F function 1 (dual) /S5/
DBD 160 F function 1 (REAL-Format) /S5/
H274E3.DOC PLC 3-77

F functions are programmed in REAL format in a part
program. The extended F function address contains a code
with the following designation: 0 = path feed, 1-18 = machine
axis number for positioning axis feed rate.

DBB 194 Dynamic M functions
M07 M06 M05* M04* M03* M02 M01 M00
DBB 195 Dynamic M functions /S5/
M15 M14 M13 M12 M11 M10 M9 M8
M23 M22 M21 M20 M19 M18 M17 M16
M31 M30 M29 M28 M27 M26 M25 M24
M39 M38 M37 M36 M35 M34 M33 M32
M47 M46 M45 M44 M43 M42 M41 M40
M55 M54 M53 M52 M51 M50 M49 M48
M63 M62 M61 M60 M59 M58 M57 M56
M71 M70* M69 M68 M67 M66 M65 M64
M79 M78 M77 M76 M75 M74 M73 M72
M87 M86 M85 M84 M83 M82 M81 M80
M95 M94 M93 M92 M91 M90 M89 M88
M99 M98 M97 M96
DBB 207
M functions marked with * will not be decoded in this Bit field

if a spindle is configured in the channel!
In this case these M functions will be presented as
extended M functions in DB21-28.DBB68 ff. and in the
respective axis DB DB31-48.DBB86 ff..
Dynamic M functions (M00 to M99) are decoded by the PLC

operating program.
Static M functions must be generated by the PLC user from
the dynamic M functions.
3-78 PLC H274E3.DOC

DBB 208 Number of active G function of G function group 1 (dual) /K1/
...
Number of active G function of G function group n-1 (dual) /K1/
Number of active G function of G function group n (dual) /K1/
DB 21-28 Signals from the NCK-Channel (NCK → PLC) (from SW 2)

DBB 272 Machine specific protected area pre-activated /A3/
DBB 273 Machine specific protected area pre-activated /A3/
Area 10 Area 9
DBB 274 Channel specific protected area pre-activated /A3/
DBB 275 Channel specific protected area pre-activated /A3/
Area 10 Area 9
DBB 276 Machine specific protected area violated /A3/
DBB 277 Machine specific protected area violated /A3/
Area 10 Area 9
DBB 278 Channel specific protected area violated /A3/
DBB 279 Channel specific protected area violated /A3/
Area 10 Area 9
H274E3.DOC PLC 3-79

4.9 Signals to/from Axis/Spindle
(DB 31-48)
DB 31-48 Signals to Axis/Spindle (PLC → NCK)

DBB 0 Feed rate correction /V1/
Axis and H G F E D C B A
Spindle
DBB 1 Correction Position Position Tracking Axis/ Sensor Acknowl. Drive test
Axis and active /V1/ measuring measuring regulation Spindle mechanical mechanical enable
system 2 system 1 /A2/ disable /A2/ stop /F1/ stop
spindle
/A2/ /A2/ (from SW 2) reached
7F1/ (from
SW 2)
DBB 2 Reference point value /R1/ Clamping Delete rest Regulation- Cam
Axis and 4 3 2 1 Cycle active distance / enable/A2/ Activation
Spindle /A3/ Spindle- /N3/
Reset (from SW 2)
/A2, S1/
DBB 3 Speed/ Enable Adopt
Axis and Spindle drive to external NV
spindle RPM limit mechanical /K2/ (from
/A3/ stop F1/ SW 2)
(from SW 2)
DBB 4 Jog keys /H1/ Rapid feed Jog key Feed Stop Activate hand wheel /H1/
Axis and plus minus override disable /H1/ Spindle 2 1
Spindle /H1/ Stop /V1/
DBB 5 Machine function /H1/
Axis and Continuous Var. INC 10000 INC 1000 INC 100 INC 10 INC 1 INC
Spindle
DBB 6 OEM Axis signals
Axis and
Spindle
DBB 7
DBB 8 Request Activate Assign NC axis channel
PLC Axis/- assignment
spindle With D C B A
positive
flank
DBB 9-11
DBB 12 Proximity. 2nd software limit switch Hardware limit switch /A3/
Axis Switch: /A3/
Referencing
With delay plus minus plus minus
/R1/
DBB 13-15
DBB 16 Delete S- No Re- Re- Gear Actual gear step /S1/
Spindle value monitoring synchronize synchronize switched
/S1/ in gear spindle 2 spindle 1 over /S1/ C B A
switching /S1/ /S1/
/S1/
3-80 PLC H274E3.DOC

DB 31-48 Signals to Axis/Spindle (PLC → NCK)
DBB 17 Invert Spindle Spindle
Spindle M3/M4 /S1/ feed rate feed rate
correction is correction is
valid valid for
positioning
DBB 18 Nominal rotation direction Oscillation- Oscillation
/S1/
Spindle left right RPM by PLC
DBB 19 Spindle correction
Spindle H G F E D C B A
DBB 20 Smoothing Moment HLGSS
611D of RPM limit 2 /A2/ /A2/
nominal
value /A2/
DBB 21 Pulse Integrator- Motor Motor selection /A27 Selection of drive parameter block /A2/
611D enable /A2/ disable- selected
Regulator /A2/ B A C B A
/A2/
DBB 22 (in Speed limit Speed limit Deselect Deselect
preparation) Bit value 1 Bit value 0 safe stop safe speed
and stop
DBB 23 (in Activate test Activate Translation Translation Translation
preparation) stop End position Bit value 2 Bit value 1 Bit value 0
pair 2
DBB 24-25
DBB 26
DBB 27
DBB 28 PLC checks Stop /P5/ Stop at next Change Set reversal
Oscillation axis /P5/ (from SW 2) reversal reversal point /P5/
(from SW 2) point /P5/ point /P5/ (from SW
(from SW 2) (from SW 2) 2)
DBB 29 Start gantry
synchron-
ization /G1/
(from SW 2)
DBB 30-59
NST "Delete rest distance" (DBX 2.2) has an axis-specific

effect only for the positioning axes. NST “Delete rest
distance” (DB 21-28, DBX 6.2) is channel-specific. NST
"Spindle-Reset" (DBX 2.2) has a spindle-specific effect.
H274E3.DOC PLC 3-81

DB 31-48 Signals from Axis/Spindle (NCK → PLC)
DBB 60 Position reached /B1/ Referenced/ Referenced/ Encoder Encoder Spindle/
Axis and With exact With exact Synchron- Synchron- frequency frequency No axis /S1/
Spindle stop fine stop coarse ized 2 /R1/ ized 1 /R1/ exceeded exceeded
2 /A3/ 1 /A3/
DBB 61 Current RPM Position Axis/ Tracking Travel
Axis and regulator regulator regulator Spindle stop operation request
spindle active /A2/ active /A2/ active /A2/ /A2/ active /A2/
DBB 62 Mech. stop Activate Reverse Hand wheel Software
reached travel to feed active override limit active
/F1/ (from mech. stop active /H1/ /N3/ (from
SW 2) /F1/ (from SW 2) SW 2)
(from SW 2)
DBB 63
DBB 64 Travel command /H1/ Hand wheel active /H1/
Axis and plus minus 2 1
Spindle
DBB 65 Active machine function /H1/
Axis and Continuous Var. INC 10000 INC 1000 INC 100 INC 10 INC 1 INC
Spindle
DBB 66 OEM axis signals
Axis and
Spindle
DBB 67
DBB 68 PLC Axis/ Neutral New Type New Type NC Axis/Spindle in channel
Spindle Axis/ requested requested D C B A
Spindle by PLC
DBB 69-71
DBB 72 Selected machine function (from SW 2) /H1/
DBB 73-75
DBB 76 Division Positioning Lubrication
Axis axis in axis /P2/ impulse /A2/
position /T1/
DBB 77
DBD 78
Axis F function (REAL-Format)
for positioning axis /V17
DBB 82 Gear Nominal gear step /S1/

Spindle switching C B A
/S1/
3-82 PLC H274E3.DOC

DB 31-48 Signals from the Axis/Spindle (NCK → PLC)
DBB 83 Actual RPM Spindle in Contact Geometry Nominal Nominal RPM limit
Spindle rotation monitor nominal range limit monitoring RPM RPM limited exceeded
direction /W1/ (from range /S1/ violated /W1/ increased /S1/ /S1/
right /S1/ SW 2) /S8/ (from (from SW 2) /W1/
SW 2) (from SW 2)
DBB 84 Active spindle operation mode /S1/ Synchron- Tapping CLGON
Spindle Control Oscillation Positioning ized mode without active /S8/
mode mode mode /S3/ compensati (from SW 2)
(from SW 2) on chuck
/S1/
DBB 85
DBW 86 M function (dual) for spindle /S1/
Spindle
DBD 88
Spindle S function (Floating point) for spindle /S1/
DBB 92 Nominal Moment. HLGSS Set-up

611D RPM limit 2 active /A2/ mode active
smoothing active /A2/ /A2/
active /A2/
DBB 93 Pulse Integrator Drive Active Motor /A2/ Active drive parameter block /A2/
611D enabled n-controller Ready /A2/ B A C B A
/A2/ disabled
/A2/
DBB 94 Variable nist = nsoll nist < nx nist < nmin Md < Mdx Boot-up Temperature warning /A2/
611D report fct. /A2/ /A2/ /A2/ /A2/ process
/A2/ ended /A2/ Heat sink Motor
DBB 95 UZK <
611D Warning
limit /A2/
DBB 96, 97
DBB 98 Superimpos Actual value Synchronous run (from
Synchron- ed motion coupling SW 2) /S3/
ized spindle /S3/ /S3/ Coarse Fine
DBB 99 Follower Lead
Synchron- spindle spindle
ized spindle active active
/S3/ /S3/
DBB 100 Oscillation Oscillation Sparking Oscillation Oscillation
Looping /P5/ motion out active error /P5/ non-start
(from SW 2) active /P5/ /P5/ /P5/
DBB 101 Gantry axis Gantry lead Gantry Gantry Gantry- Gantry shut
Gantry /G1/ axis /G1/ group is synchron- Warning down limit
(from SW 2) synchronous run limit exceeded
ized /G1/ ready /G1/ exceeded /G1/
/G1/
H274E3.DOC PLC 3-83

DB 31-48 Signals from Axis/Spindle (NCK → PLC)
DBB
102, 103
DBB 104 Active feed axis /P5/
Looping Axis 8 Axis 7 Axis 6 Axis 5 Axis 4 Axis 3 Axis 2 Axis 1
(from SW 2)
DBB Reserved
105-107
DBB 108 Axis End position Speed limit Speed limit Impulse Safe stop Safe speed
(in correctly pair 2 active active Bit active Bit delete per active or stop
preparation) referenced value 1 value 0 external active
circuit
DBB 93 Impulse Integrator Drive Active motor /A2/ Active drive parameter block /A2/
611D enabled n-controller Ready /A2/ B A C B A
/A2/ disabled
/A2/
DBB 109 SC 4- SC 4+ SC 3- SC 3+ SC 2- SC 2+ SC 1- SC 1+
(in Actual position > Cam position
preparation)
DBB 110 Reserved
SISITECH
DBB 111 Reserved
SISITECH
3-84 PLC H274E3.DOC

Chapter 4
Data Communication
H274E4.DOC Data Communication 4-1

1. Communication systems
Different communication systems are employed for data exchange

between the various components of a controller or with its
periphery.
ToPs
computer
Network
Modem link link
TCO remote Network

diagnostics Modem MMC adapter
computer
MPI interface
NCU
COM-
Modul
CNC PLC
Dual-Port-
RAM
Bitbus-Modul
Bitbus
Bitbus
user
Schematic structure of different communication routes: Fig. 18425E
2. MPI interface
The MPI interface permits data communication between NCU and

MMC using the NCDDE Server. The pushbuttons on the control
panel blink if communication is disrupted.
Transmission speed: 1 MB/s

3. Modem connection
3.1 Software for remote diagnostics
For modem link between the customer’s machine controller and

the TRUMPF service computer, the software program
„pcANYWHERE“ from Norton is supplied with the control system
as a standard.
Depending on which operating system is installed on the controller,

different versions of pcANYWHERE are employed:
• For WINDOWS 3.11, 16 bit: pcANYWHERE Version 2.0

• For WINDOWS NT, 32 bit: pcANYWHERE Version 8.0
Since TRUMPF Service must Diagnostics both operating systems

if service is required, Version 8.0 is recommended for the TRUMPF
Service computer as this version allows you to connect to both
operating systems.
3.2 Establishing a connection
1. The customer phones the TRUMPF engineer.

2. The customer activates the Teleservice software:
• At the control operation environment: Select "Diagnostics –
Remote Diagnostics" and press softkey Start
• In case of problems with WINDOWS or with the operation
environment: Activate the Teleservice software in DOS by
entering "t"
3. The TRUMPF engineer calls the customer's machine via
modem
4. The TRUMPF engineer logs in with the user identification and
password
5. The machine checks the identification and password
6. Teleservice connection between TRUMPF and the controller is
now active
This strictly regimented method of establishing communication

contact is intended to prevent unauthorized data access in public
telephone networks..
4-4 Data Communication H274E4.DOC

3.3 Primary setup at the machine control
(pcANYWHERE-Version 2.0)
To configure the software on the controller MMC, certain settings

must be made by the customer:
1. Start Windows
2. Activate the Program Manager
3. Open program group "pcANYWHERE"
4. Start "pcANYWHERE service"
Fig. 11859E
5. Select „Configure – System Hardware“

6. Enter Master password „fpmurt“
Fig. 11805E

7. Select „Modem“
8. Click „Edit...“
Fig. 11806E
9. Select „Custom modem“

10. Click „Define...“
Fig. 11807E
11. In the „Dial Prefix“ field, enter „ATDT“ for touch tone dialing
and ATDP“ for pulse dialing
12. Click „OK“

Fig. 11806E
13. Click the „Advanced...“ button
Fig. 11808E
14. Make the settings as shown in Fig. 11808e

15. Click „OK“ until the main menu appears again

Fig. 11859E
16. Select "Configure – System Setup"
Fig. 11809E
17. Field „Computer Name“ can either be left blank or you can
enter here the name of the computer in the network. The
master password is „fpmurT“.
18. Click „OK“ to confirm
19. Enter the password again as confirmation

Fig. 11859E
21. Select „Configure – Prefix/Suffix“
Fig. 11856E
A prefix or suffix is a pre-setting. In this case, a standard code is

used, “0” for long distance or “0049” as the country code for
Germany. A prefix or suffix can be corrected or new ones entered:
22. Select the „Prefix/Suffix Description“ you want to change

23. Click „Edit“
Fig. 11857E

24. In the „Number“ field, enter the desired code which, for
example, is needed to access an outside line. Please ask the
customer what code he uses to access an outside line in his
company.
25. Click „OK“ until the main menu appears again.
26. Select „Action – Host Mode“
Fig. 11858E
27. Select „Callers Have Individual Privileges“ under „Allow

Control Options“
28. Click „Settings...“
29. Enter Master password „fpmurT“
Fig. 11860E

30. From the caller list, choose the TRUMPF employee who will
call back if service is needed
31. Click „Edit“ or „New...“ if a new caller needs to be entered
Fig. 11861E
32. In the „Description“ field, enter:

TRUMPF extension number (reference or department), e.g.
TRUMPF568 (TK)
33. In the „Login Name“ field enter:
TRUMPF extension number, e.g. TRUMPF 568
34. In the „Password“ field, enter the same string as in „Login
Name“
35. Confirm the password again
36. Click the „Advanced...“ button

Fig. 11862E
37. Make the settings as shown in Fig. 11862e

39. Exit pcANYWHERE

4. Network connection
The MMC can exchange data with other computers (e.g. ToPs
computers) through the network adapter.
The settings of this adapter can be modified with the aid of special
software.
4.1 Basics of network technology
The ISO / OSI model
ISO (International Standardization Organization)

OSI (Open Systems Interconnection)
The OSI layer model is used as the basis for communications

technology. The principle is that computers use standardized
interfaces (seven layers) to communicate with each other.
Structure:
Breakdown of Creation of frame to

received frame be sent
Application program Application program
Layer 7 Layer 7
Application Application
Layer 6 Layer 6
Application-
functions
Presentation Presentation
oriented
Layer 5 Layer 5
Session Session
Layer 4 Layer 4
Transport Transport
Layer 3 Layer 3
Transport-
functions
Network Network
oriented
Layer 2 Layer 2
Data link Data link
Layer 1 Layer 1
Physical Physical
Physical communication medium

Cable types / connections
Layer 1 • Twisted pair (S-UTP) (RJ45)

Image • AUI for connecting to a Thick Lan connection unit
transmission • Coaxial cable (thin LAN) (BNC) (RG58)
Fig. 23755
Network topologies
Bus topology In a network of this kind, all users (subscribers) are connected to a
shared, passive medium, the bus. Each user can communicate
with all other users.
185m
ToPs 250 ToPs 250
Fig. 23756

In bus topology application, the network adapter’s BNC connection
is used.
Characteristics:
• BNC T-adapter
• RG58 cable
• Connections to network components always via T-adapter
• 50 Ohm terminating resistor
• 15m range from control panel to machine
• Maximum segment length 185m
1 2 3
1 RG58 cable 2 T-adapter 3 50 Ohm terminator

Fig. 23757
3K\VLFDOGLDJQRVWLFVSRVVLELOLWLHV
• Remove all T-adapters from the network cards. Attach a

terminating resistor to both ends of the cable and measure the
resistance. Normal value around 25 Ohms from the central
conductor to the outside of the plug.

Star topology This topology is most commonly used when networks are set up
using twisted pair cabling.
In star topology application, the RJ45 connector on the network

adapter is used.
HUB
100
m
ToPs 250 ToPs 250

Fig. 23758
Characteristics:
• Patch cable
• Maximum 100m cable length
1 2 3
1 Patch cable 2 RJ45 connector 3 HUB

Fig. 23759
Physical diagnostics possibilities:
• Check the activity LEDs on the hub and on the network card. If
necessary, replace the cable.

Ring topology A ring network, like the bus system, uses a shared data transfer
medium. The difference, however, is that the connection is in the
form of a ring.
The disadvantage of this system is that if connection between two

users is disrupted (e.g. due to cable breakage), the entire ring
closes down.
Fig. 23760
Access control
Layer 2 Ethernet :
Data Link
Bus structure with CSMA/CD (IEEE802.3)
Response time cannot be calculated exactly. Implemented on the
network card (hardware).
Token Ring:
Ring structure (IEEE802.5) with access rights passed between

users.
Response time can be accurately calculated.
Token Passing:
Bus structure (IEEE802.4) with defined access rights.

Response time can be accurately calculated.
TRUMPF supports the IEEE802.3 standard only.

Connection, for example, to a token ring network can be
established in the following manner:
Token Ring Network

Ethernet
PC with NT4.0
and 2 Network-cards
(Gateway)
Fig. 23761E
Network protocols
The NetBEUI protocol (NetBIOS Extended User Interface)
Layer 5 LAN transport protocol, developed by IBM and extended by

Session Microsoft.
Layer 4 Suitable for small networks.
Transport
Layer 3 + Easy to configure and address.
Network - No routing capability
- Many packets sent periodically for browsing.
- Addressing over several segments not possible.
Test in MS-DOS box
net view Displays a list of the computers in the current domain.
'DWDUHTXLUHGWRFRQILJXUHWKHQHWZRUN
Machine with Win 3.11 and PC with Windows 3.11/95:

• Cable type
• Computer name for machine
• Name of the work group
Machine with Win 3.11 and PC with WindowsNT 3.51/4.0:

• Cable type
• Computer name for machine
• Name of the work group / domain
• User name on NT computer / domain

The TCP/IP protocol (Transmission Control Protocol / Internet Protocol)
Developed by the US Department of Defense in the 1970s
This protocol is used world-wide in Unix systems. Suitable for large
networks
+ Possesses routing capability

+ Easy diagnostics with ping command
+ Universal application
- Configuration is a bit more complicated. Network know-how
necessary.
Important terms used in the TCP/IP protocol:
IP addressing
The IP address always comprises 4 bytes and consists of a

network ID and a host ID.
The network ID is defined through the subnet mask which
determines where the network ID ends and the Host ID begins.
Masking of the subnet mask is achieved using a binary format.
Example:
255. 255. 255. 0
11111111. 11111111. 11111111. 00000000
Network ID Host ID
Depending on the IP class, the following addresses are available:
Class From To Network ID Host ID

A 1 126 126 16.777.214
B 128 191 16.385 65.534
C 192 223 2.097.152 254
Network ID 127 is reserved for internal mechanisms by TCP/IP and

may not be used.
DHCP (Dynamic Host Configuration Protocol)
The DHCP mechanism is used to assign IP addresses centrally in

the network.
Advantages:
• Address conflicts are avoided
• Facilitates management of IP addresses in big networks

WINS (Windows Internet Name Service)
The WINS server maintains a central table which is used to resolve

the Net.BIOS name and IP address. For security reasons, a
primary and secondary server can be defined.
DNS (Domain Name Server)
The DN Server provides a function for running dynamic updates for

DNS, so that the necessary information from other network
services such as Active Directory, DHCP and WINS can be
entered automatically.
Test in MS-DOS box
Ipconfig /all Shows all current TCP/IP network configuration

values. This command is especially useful in
systems that run DHCP. You can use this
command to find out which TCP/IP configuration
values have been configured by DHCP.
Ping your
own address Carry out a self-test on your network card.
Ping another
address Simple diagnostic command that can periodically
send packets to a computer which can then
immediately send them back to the address of
the sender. Used for checking whether a
computer can be reached with the TCP/IP
protocol.
Data required to configure the network:
Machine with Win 3.11 and PC with Windows NT 3.51 / 4.0:

• Cable type
• Name of the work group / domain
• User name on NT computer / domain
• IP address / Subnet mask for machine
Machine with Win 3.11 and UNIX server

• Cable type
• Login name from the machine
• Name of server
• IP address of the machine and of the server
• Directory exported by server
The IPX/SPX protocol Protocol for Novell NetWare
+ Possesses routing capability

+ Packets are small
- High volume of network traffic when communicating with other
systems.

Data required to configure the network:
Machine with Win 3.11 and Server with Novell V3.XX / 4.XX
• Cable type
• Login name at the machine
• Name of Novell server
• Drive should be included in login script (Novell administrator)
Coupling devices
Repeater A repeater receives data signals, amplifies them and passes them
on. Repeaters work at level 1 of the ISO/OSI layer model.
Repeaters perform no logical separation of networks. Signals from
one segment are passed on with virtually no restrictions to all other
network segments connected by a repeater.
Bridge Bridges are used to connect several LANs and transport data
packets between them.
A bridge works on the MAC (Media Access Control) level (lower

level of Layer 2. In the case of Ethernet and Token Ring, the MAC
address is permanently programmed into the network card and is
unique. For this reason, the upper protocol levels are of no
relevance for bridges and are protocol-transparent.
The task of a bridge is to filter and pass on packets. For this
purpose, the bridge automatically generates an address table after
power-up. Based on this table, it decides where to send the data
packet.
Router Routers have the same function as bridges but work at different
levels of the layer model and therefore work in a completely
different way. Routers establish connections between sub-
networks on Level 3. Routers are therefore protocol-dependent.
Protocols with routing capability:

TCP/IP
IPX
Protocols that cannot do routing:

NetBIOS
With routers a LAN can be split into subnetworks with different

network addresses. For this reason, routers have to be configured
during installation.

Bridging Router A brouter is a combination device that works like both a bridge and
(Brouter) a router.
This system can process protocols that are capable of routing, as
well as those that are not. Depending on the situation, the brouter
handles data packets like a bridge or like a router. It is not
necessary, therefore, to implement bridges and routers at the
same time.
Gateway Using a gateway it is possible to combine different protocols and

character sets. A gateway works at the top level of the ISO/OSI
layer model.
Layer 2 switch With switches, the full bandwidth can be used to transport data
packets between the sender and recipient. This allows data
packets to be transmitted simultaneously between a large number
of ports.
There are two types of switches: cut-through switches and store-
and-forward switches.
Cut-through switches
Cut-through switches transport data packets onwards as soon as
the target address in the header is recognized.
Advantages:
Little delay in forwarding data packets, no matter how long each

data packet is.
Disadvantages:
Errors in a data packet are not detected.

It is not possible to connect different network types, as this requires
that the complete data packet be received before it can be
converted for another topology.
No filtering possible. This, too, requires that the entire data packet
be received first.
Store-and-forward switches
These switches store each complete data packet before forwarding
it.
Advantages:
Filter mechanisms are possible.

It is possible to connect different topologies.
Error detection is possible.
Disadvantage:
Processing time is slightly longer.

Hub The task of a hub is to act as an active, intelligent component and
set up star-shaped topologies.
1 2 3
1 Uplink BNC 2 Power 3 Uplink switch

Fig. 23762
Troubleshooting
Error / Fault Action

Network slows down when the machine is Check segment length, replace NETBEUI protocol with
connected TCP/IP
Only the machine but no other computer Check cable, terminator resistance, check cable for
appears in the browser physical damage. Check media type of the network card.
Ping command to the server times out. Ping Check cable, terminator resistance, check cable for
to self runs OK physical damage. Check media type of the network card.
Ping works on some computers, but not on Check cabling topology. Are there any gateways,
others bridges, routers?
Windows startup message "Network cannot Check if incorrect network card type was selected.
be loaded...:"
The shared drives on an NT server are not The user name that this machine uses to log into the
displayed. On other computers you can see network does not exist on the NT computer or in this
these shared drives domain.

4.2 Configuring the network adapter
1. When the controller is booting up, activate the „Confidential

selection menu“
2. Choose menu function "4 DOS-Shell"
3. Change to directory ETHERIII.ISA
4. Call up program 3C5X9CFG.EXE
Fig. 18489
5. Select "Install – Configure Adapter"
The settings on the Ether LinkIII card are displayed.

For the IRQ, the 3COM factory setting of the network card is
10. This value, however, is used by the SIEMENS MPI card.
For this reason, the settings for „Interrupt Request Level
(IRQ)“ and „I/O Base Address“ must be changed:
6. Using the Cursor keys, choose "Interrupt Request Level"

7. Press the ENTER key
Fig. 18490
8. Using the cursor keys, select "5"

9. Press ENTER
10. Using the cursor keys, select "I/O Base Address"
11. Press ENTER
12. Set the "I/O Base Address" to "300h"

When replacing network cards, always check and, if
necessary, correct the settings!
13. Using the cursor keys, select "Transceiver Type"

14. Press ENTER
Fig. 19610
15. Select the Transceiver type used in the company

16. Click "OK"
Fig. 19785
17. Click "OK"
Fig. 18492

Testing the Ether Link III card
Fig. 18493
1. Select "Test – Run Tests..."
Fig. 18494
2. Click "Start"
• If the test is run successfully ten times, message
"completed successfully" is displayed
• An error message is issued if a fault occurs
Fig. 18495

3. Click "Cancel"
Fig. 18496
4. Select "Quit – Exit"

The network adapter has been configured and tested
Configuring network adapter for a Windows

3.11 network with NETBEUI protocol
1. In DOS, change to directory C:\

2. Type EDIT WFW_NET.BAT
3. Change the following lines:
SET WIN_WITH_NET =
must be changed to
SET WIN_WITH_NET = 1
Customer-specific settings
4. Start Windows
5. In the Program Manager, change to the "Network" group
6. Choose "Network Setup"
7. Press ENTER
Fig. 18497
8. Click button "Networks"

Fig. 18498
9. Compare the settings with those in Fig. 18498 and make any
corrections that may be necessary
10. Click "OK"
11. Click "Sharing..."
Fig. 18499
12. Select the first box (a cross means it is active) in Fig. 18499 in
order to allow access to files
13. Click "OK"
14. Click "Drivers..."
Fig. 18500

15. Check whether the following entries exist:
• 3Com EtherLink III (network adapter)
• Microsoft NetBEUI (Protocol)
16. If the wrong network adapter was selected, click the "Remove"
button to remove it from the list
17. If there is no entry for a network adapter, click the "Add
Adapter..." button
Fig. 18501
18. Select 3Com EtherLink III

19. Click "OK"
Fig. 18502
20. Select IPX/SPX Compatible Transport with NetBIOS"

21. Click the "Remove" button (This protocol must be removed as
it is needed for Novell networks only)
22. Click "Cancel"
The TCPIP protocol can be installed by a network

administrator of the customer’s. The protocol is added using
function "Add Protocol...". The necessary drivers are located
in directory C:\TCPIP.
23. Click "OK"

Fig. 18497
24. If a message box now appears, close it by clicking button "Yes

to all". All necessary files are then copied to directory
C:\WINDOWS
25. Confirm all other messages with "OK"
26. Press ENTER to confirm the prompt "Restart Computer"
The MMC boots up.
27. In Program Manager, select the "Main" group
28. Select "Control Panel"
Fig. 18503
29. Select "Network"

Fig. 18504
30. The customer must fill out the lines "Computer Name",
"Workgroup" and "Comment"
31. Type "TC600L" in line "Default Logon Name"
32. Where applicable, enter a password after activating the
"Password" button
Fig. 18505
33. Click "OK" to adopt the password
The customer may also have to configure the settings for

logging on to a domain. He can do so after activating button
"Startup".

Fig. 18506
34. Make the necessary settings and click "OK" to adopt them
Sharing directories
In order to allow other network users access to various MMC

directories, these directories must be released for sharing:
1. Change to the File Manger
Fig. 19786

2. Select the directory you want to release for shared network
access
3. Press key combination ALT + D to activate the menu bar
4. With the cursor keys, choose „Share As...“
5. Press ENTER
Fig. 19787
6. Select Access Type "Full“. In required, a password can also be

assigned for Full Access.
In order to cancel network access to a shared directory later,

press <ALT+D>, open „Stop Sharing...“ and select the
directory for which you no longer want to share access.
Fig. 19788

Connecting to a computer Proceed as follows to link up from the MMC to a computer in the
in the network network:
1. Change to File Manager

2. Press key combination ALT + D to open the menu bar
3. Using the cursor keys, select "Connect Network Drive...“
4. Press ENTER
Fig. 19789
5. In the "Drive" selection box, select the drive letter you wish to
assign to the connected computer.
6. In box "Show Shared Directories on", select the work group
and the desired computer.
The enabled folders on the chosen computer are now
displayed.
7. Select the folder you want
8. Click "OK"

Disconnecting from 1. Change to File Manager
the network 2. Press key combination ALT + D to open the menu bar
3. Using the cursor keys, select "Disconnect Network Drive...“
4. Press ENTER
Fig. 19790
5. Select the network connection to be disconnected

6. Click "OK"

5. Dual-Port-RAM
Communication between the PLC and the NCK flows across data
modules to which the PLC and NCK have independent access
The NC kernel accesses the Dual Port RAM (DPR) at an

interpolation cycle rate while the PLC accesses the DPR every
time a PLC cycle starts.
1&8
NCK DPR PLC
DB
Fig. 18511

6. Bitbus
6.1 Principle of function
Communication between the various control units of a machine is

accomplished across a Bitbus communication circuit.
Depending on the machine and its complement of options, the

following control units can take part in the Bitbus communication
circuit.
• Machine controller SINUMERIK 840D

• Laser controller TASC 200
• Hartmann + Lämmle ram control
• SheetMaster controller TASC 100
All communicating parties are incorporated into a so-called closed-

loop communication circuit:
SINUMERIK 840D TASC 200

(Master) (Slave)
H + L ram control TASC 100

(Slave) (Slave)
Example TC 600L Fig. 12054E
6.2 Data flow
Each control unit is fitted with a Bitbus module. The Bitbus module
independently transmits and receives information in form of serial
telegrams. The various controllers transfer their information to the
Bitbus module which in turn processes and distributes this
information. The Bitbus module also receives information from
other modules in the loop, relaying this information upon request to
its own controller.
Advantage Individual control units are not required to synchronize themselves

for data transfer. This coordination is performed solely by the
Bitbus modules.

Coordination Coordination of information flow is assumed by the SINUMERIK
840D machine control (master control Bitbus). The master queries
the other Bitbus modules (slaves) for telegram transmission and
enables the transmission.
Telegram identification Every transmission telegram carries a destination address to

assure that the information reaches the correct recipient. Each
individual Bitbus module in the ring must therefore have its own
address and the designation “Master or Slave”. The latter is jumper
coded with the exception of the ram control which is software
coded for Master/Slave designation.
Fiber optic cable Information is transmitted in the form of serial telegrams. The
transmission line is a fiber optic cable which transmits information
in the form of light impulses to the receiver. The transmission
speed is 2 MBits/s.
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Data flow example: Between machine control and ram control Fig. 12055E
PLC - TASC 200 Individual controllers exchange information with the PLC. The
TASC 100 machine control Bitbus module is connected to the NCK drive bus.
H+L Telegrams from the PLC must therefore first flow across a Bitbus
handler and the Dual-Port-Ram. After this, the fiber optic cable can
transfer the telegram to the Bitbus module of the designated
control.
Acknowledgment When a telegram is received by a controller, the same telegram is

sent back to confirm that this information has been received.

Negative acknowledgment If a control party "misunderstands" an incoming telegram, it issues
a negative acknowledgment with information about this
"misunderstanding" to the transmitting party.
6.3 Telegram diagnostics
If data flow between individual modules is interrupted or faulty,

transmission telegrams can be recorded for diagnostics purposes
and later interpreted.
Communicating parties in SINUMERIK 840D Nodes 0 (Master)

Bitbus ring TASC 200 Nodes 1
H+L ram control Nodes 20
TASC 100 Nodes 2
DIAS III Nodes 4
Pallet changer Nodes 10
Recording telegrams
File TELE.COM Telegrams are recorded in file TELE.COM. This file is stored in
directory MPF.DIR on the NC and can be viewed:
Select "Diagnostics (2) Service (4) – Analyzer (4) – Telegram

Diagnostics (1)"
Fig. 18508E

Softkeys:
File TELE.COM is re-filled when you press softkey Update.
Update
Press softkey HEX to switch to hexadecimal display mode.

HEX
Press softkey Text to switch to text display mode.

Text
Text for a telegram can be displayed only if a "translation"
is present in the corresponding .tok file in directory
c:\tcommc\exe.
Press softkey Zoom ON to enlarge the text window.
Zoom ON
Press softkey Filter to open dialog field "Telegram filter".

Filter
Fig. 18509E
Softkeys:
When you press softkey Enable, telegrams are displayed for those
Enable components with a check mark.
When you press softkey Disable, telegrams for components with a

Disable check mark are suppressed.
Softkey Show allows you to toggle between "Display" and "Do not
Show display". The input telegram numbers are displayed / not displayed,
as selected.
When your press softkey Enter number, the focus is placed on
Enter input box "Telegram number".
number

R parameters
R-parameters can be used to determine which telegrams are

written to the TELE.COM file. R-parameters can be set or edited in
the PLC Debugger:
1. Select "Diagnostics (2) - Service (4) – Development (2) - PLC-

Debugger (2)"
2. In the comment column, enter the name of the R-parameter
you are going to change
3. In the "Command" field, enter the abbreviation of the R
parameter, e.g. "r56"
4. Enter “f” for floating in the "Type" field.
→ The value set for the R parameter is displayed in field

"Value" and can be modified there as required.
Checking Bitbus If two machine components cannot communicate with each other
communication (e.g. SIN840D and TASC200 laser controller) through the Bitbus, a
PLC-Alarm „Telegram Timeout“ is issued.
Possible source of error may be the laser controller, the Bitbus
module or the SIN840D. In order to narrow down the cause, the
Bitbus module of the laser control can be induced to react without
the laser control itself participating:
A RESET must be triggered at the MSTT prior to test in

order to ensure that the MMC does indeed display an
incoming Alarm 70300.
1. Set parameter R 56 to 1
Parameter R 57 changes to 9999
2. In parameter R 57, enter the address of the Bitbus module you
want to check, e.g. 1 for the laser controller.
→ The NCK sends a telegram to the Bitbus module of the
component being checked; the telegram is acknowledged
by this Bitbus module itself.
→ „Alarm 70300 with Parameter 369 and an additional
parameter":
369: Diagnostic telegram acknowledgement
"Additional parameter": Address of the component you
want checked (Bitbus module)
→ For the Service engineer, this means that the Bitbus ring is
ready and that the Bitbus modules of the SIN840D and laser
controller are functioning properly. The Bitbus ring is therefore
operational.
If this telegram is sent to the address of the Bitbus module of

SIN840D (1), only the internal communication of the SIN840D incl.
Bitbus module is tested.

Starting telegram recording The telegrams of all users are continuously recorded in a ring
manually buffer.
In order to be able to diagnose these telegrams, the recorded
information must be output to file TELE.COM, which can hold 80
telegrams, in directory MPF.DIR of the NCK:
R99 0 1 2
Do not output to file Copy the ring buffer to The telegrams are
tele.com file TELE.COM once immediately written
from the ring buffer to
→ R99 changes to 0 file TELE.COM (80
telegrams)
→ R99 changes to -2
If you want to record only the telegrams of one component in file

TELE.COM, you can define this with parameters R 56 and R63 :
R56 R63
Enter value "3" Enter the component address.

"255" causes all telegrams to be recorded
File TELE.COM can then be edited:
1. Select "Diagnostics (2) – File functions (3)"
FIg. 18510E

3. Select file TELE.COM in directory MPF.DIR

Defective Bitbus module Example:
resuming communication
The Bitbus module of a component is malfunctioning. This
participant (nodes) is then removed from the Bitbus network and
the address marked as being defective. The same happens when
you configure a machine component as being “not present” in
"Operation (1) – Maintenance/Start-Up (5) – Machine components
(4)". Otherwise, the MMC would keep getting the same error
message „Telegram exchange error Nodes xyz“.
When the component is ready for operation again, the entire

system must be switched OFF and ON again, so that the
components can be addressed again.
The same can be achieved by setting R parameter 56 to 7. This
erases the “defective” mark, so that Bitbus telegram
communication with the component can be resumed.
Telegram structure file TELE.COM
A telegram always consists of a header (8 bytes) and user data.

Both header and user data are shown in hexadecimal mode.
Header The header contains telegram management data such as

transmission and reception addresses, priority of telegram content
etc.
Byte 1: 0 = Low priority

1 = High priority
Byte 2: Reserved
Byte 3: 20 = Transmission telegram
40 = Reception telegram
60 = Autostatus telegram
Byte 4: 00 = Information telegram
01 = Error telegram
10 = Negative acknowledgement
Byte 5: Address of telegram recipient
Byte 6: Address of telegram transmitter
0 = SINUMERIK 840D
1 = Laser controller TASC 200
2 = SheetMaster control TASC 100
4 = DIAS height regulation
0a = Palletmaster
14 = Hartmann + Lämmle ram control
90 = PLC
A0 = NC
B0 = MMC
F0 = Network
FE = To all
Byte 7: Telegram number / Command number
Byte 8: Number of data bytes in user data

User data The user data contains the actual information of the telegram. The
respective functions description is necessary to decipher this data.
Examples of telegram diagnostics
The interpretation of telegrams in the TELE.COM file is clarified in

the following examples:
Example 1: Machine Communication after pressing the RESET button:

referencing
201. PLC → H+L:

01 78 20 00 - 14 90 04 01 - 01
01 Byte 9: Reset
01 Byte 8: Number of user bytes (1 byte)
04 Byte 7: Telegram number for Reset
90 Byte 6: Telegram transmitter (PLC)
14 Byte 5: Telegram recipient (H+L)
00 Byte 4: Acknowledgement (none with transm. telegram)
20 Byte 3: Transmission telegram
78 Byte 2: Reserved
01 Byte 1: Telegram has high priority
202. **RESET BUTTON**

00
203. H+L → PLC:

01 00 40 00 - 90 14 04 01 - 01
01 Byte 9: Reset
01 Byte 8: Number of user bytes (1 byte)
04 Byte 7: Telegram number for Reset
14 Byte 6: Telegram transmitter (H+L)
90 Byte 5: Telegram recipient (PLC)
00 Byte 4: Positive acknowledgement
40 Byte 3: Reception telegram
00 Byte 2: Reserved
01 Byte 1: Telegram has high priority
Communication after pressing the MACHINE OFF button
209. PLC → H+L:

01 E9 20 00 - 14 90 03 06 - 29 09 96 02 - 00 00
00 1Byte 4: Reserved (user bytes 5)
00 1Byte 3: Reserved (user bytes 4)
02 1Byte 2: Cycle for hydraulic OFF (user
bytes 3)
96 1Byte 1: Year 96 (user bytes 2)
09 Byte 10: Month 09 (user bytes 1)
29 Byte 9: Day 29. (user bytes 0)
06 Byte 8: Number of user bytes (6)
03 Byte 7: Telegram for Initialization

210. H+L → PLC:
00 00 40 00 - 90 14 03 06 - 29 01 96 00 - 00 02
02 Byte 14: Start for hydraulic OFF cycle
(user bytes 5)
00 Byte 13: Reserved (user bytes 4)
00 Byte 12: Reserved (user bytes 3)
96 Byte 11: Year (user bytes 2)
01 Byte 10: Example for negative
acknowledgement:
01: User data format error
29 Byte 9: Date (user bytes 0)
06
03 Byte 7: Telegram for initialization
14
90
00 Byte 4: Positive acknowledgement
211. H+L → PLC:

00 00 60 00 - FE 14 06 01 - 02
02 Byte 9: Enable Hydraulic OFF
01
06 Byte 7: Telegram for operation messages
14 Byte 6: Telegram transmitter (H+L)
FE Byte 5: Telegram recipient (FE: to all)
212. PLC → H+L:

01 00 40 00 - 14 90 06 01 - 02
00 Byte 4: Positive acknowledgement for oper. message
Hydraulic OFF
Communication after pressing the MACHINE ON button:
215. PLC → H+L:

00 E9 20 00 - 14 90 03 06 - 29 09 96 01 - 00 00
01 Byte 12: Standard (user bytes 3)
03 Byte 7: Telegram for initialization
216. H+L → PLC:

00 00 40 00 - 90 14 03 06 - 29 01 96 00 - 00 01
00 Byte 4: positive acknowledgement
for initialization
219. H+L → PLC:

00 00 60 00 - FE 14 06 01 - 01
01 Byte 9: Enable Hydraulic ON
06 Byte 7: Telegram for operation message)

220. PLC → H+L:
01 00 40 00 - 14 90 06 01 - 01
00 Byte 4: Positive acknowledgement for message
Hydraulic ON
Communication after pressing the REFERENCE MACHINE button:
222. PLC → H+L:
00 F0 20 00 - 14 90 09 02 - 00 25
25 Byte 10: Reference point offset 25 mm
00 Byte 9: Reserved
09 Byte 7: Telegram number for reference point offset
223. H+L → PLC:
00 00 40 00 - 90 14 09 02 - 00 25
00 Byte 4: Positive acknowledgement for reference point
offset
Punching head position:
224. PLC → H+L:
00 26 20 00 - 14 90 44 0C - 03 26 05 22 - 05 22 05 22 - 01 00 01 00 -
00 Byte 20: Do not disable
BDC curve
switch
01 Byte 19: Cycles, reference
cycle only if TDC
and Clamping
position = 52.2
00 Byte 18: Cycles
01 Byte 17: Punching
22 Byte 16: Clamping pos.
05 Byte 15: Clamping pos. =
52.2
22 Byte 14: Start position
05 Byte 13: Start position=52.2
22 Byte 12: TDC position
2 single, 2 post
decimal point =
52.2
5 decades
26 Byte 10: BDC position
2 single, 6 post
decimal pt.= 32.6
3 decades
0C Byte 8: No. of user bytes
(13 bytes)
44 Byte 7: Telegram for ram
height
225. H+L → PLC:
00 00 40 00 - 90 14 44 0C - 03 26 05 22 - 05 22 05 22 - 01 00 01 00 -
00 Byte 4: positive
acknowledgement
for ram height

Rod pressure status:
228. H+L → PLC:

00 00 60 00 - FE 14 43 01 - 01
01 Byte 9: 01: Rod pressure ON
43 Byte 7: Telegram for rod pressure status
229. PLC → H+L:

01 00 40 00 - 14 90 43 01 - 01
00 Byte 4: Positive acknowledgement rod pressure status
Telegram for Referencing completed, cycle ended:
230. H+L → PLC:

00 00 60 00 - FE 14 45 0C - 03 26 05 22 - 05 22 05 22 - 01 00 01 00 -
00 Byte 20: Do not disable
BDC curve
switch
01 Byte 19: Cycles, reference
cycle only if TDC
and clamping
position = 52.2
00 Byte 18: Cycles
01 Byte 17: Punching
0C Byte 8: No. of user bytes
(13 bytes)
45 Byte 7: Telegram for
Cycle completed
231. PLC → H+L:

01 00 40 00 - 14 90 45 0C - 03 26 05 22 - 05 22 05 22 - 01 00 01 00 -
00 Byte 4: Positive
acknowledgement
for Cycle
completed
"Referencing" cycle completed!

Example 2: Bitbus The PLC keeps trying to send the same telegram to the laser
communication with TASC controller (TASC 200) but receives no acknowledgment. The laser
200 disrupted control node is missing:
26. PLC → LAS:

01 E6 80 00 - 01 90 4A 02 - 00 00
02 Byte 8: 2 user bytes
4A Byte 7: Telegram number
90 Byte 6: Telegram transmitter: PLC
01 Byte 5: Telegram recipient: TASC 200
27. PLC → LAS:

01 E6 80 00 - 01 90 4A 02 - 00 00
28. PLC → LAS:

01 E6 80 00 - 01 90 4A 02 - 00 00
29. PLC → LAS:

01 E6 80 00 - 01 90 4A 02 - 00 00
30. PLC → LAS:

01 E6 80 00 - 01 90 4A 02 - 00 00
:
:

Bitbus telegrams over the DDE interface
Telegrams are sent by the MMC to the NCK / PLC if particular

actions are to be synchronized. Since TRUMPF has been provided
only with the DDE interface, all telegrams must therefore first be
sent to the NCDDE server as DDE messages. This server
transfers the data to the MPI card from where it is sent in
transmission format by the Profibus to the NC/PLC. There the data
is written to a data block.
The NCK / PLC can then retrieve the telegram from this data block
and relay it to other control units as a Bitbus telegram.
Telegram diagnostics is possible in screen <Diagnostics>
<Service><Analyzer><MMC Telegrams>. This requires that the
MMC application datum "Diagnosis of Telegram channel"
(telegram channel diagnostics) be set to 1. After that, the operating
environment must be rebooted.
Telegram diagnostics Fig. 23770E
The data can be output to the BBTELE.LOG log file.

Chapter 5
Configuration and Machine

Data
H274E5.DOC Configuration and Machine Data 5-1

1. Configuration data
Configuration data are divided into two sections:
• Configuration data for the machine

• Configuration data of the operation environment software
(BOF)
1.1 Modifying machine configuration data
1. Select "Operation (1) – Maintenance/Start-up (5)– Machine

components (4) "
Fig. 18416E
The machine components you wish to re-configure are selected

from this menu.
Softkeys:
Press softkey not available in order to deselect the machine

not components.
available
Press softkey available in order to add machine components.

available

Pressing softkey warm start causes the data to be adopted and
warm start transferred to the PLC.
You are prompted for a password after pressing the three

above softkeys. Enter "Minutes"530 as the password.
2. Use the FOCUS key to select the machine components you

wish to reconfigure.
3. Select softkey Applications
Fig. 18417E
Softkeys:
Choose softkey Group to access the "Group" selection field. Using

Group the cursor keys, select the data group you want and press ENTER
to call it up.
Press softkey Applications to go to the right panel "Applications".
Applica- Use the FOCUS key to step from one application set to the next. If
tions
the configurations in one group cover more than one page, use the
PAGE UP and PAGE DOWN keys to scroll through the screen.
Press softkey Back to return to menu "Machine components".
Back
5-4 Configuration and Machine Data H274E5.DOC

Press softkey Save values to transfer the configuration data to the
Save PLC.
values
To note after a software If one or more configuration data have a red highlight, this means
update that these applications were added after a software exchange or
update. The values of the red-highlighted applications must be
checked and corrected, if necessary. The configuration is
confirmed by pressing softkey Checked current value.
The configuration data is stored in database PLCCUST.

MDB on the hard disk.
Menu "Operation – This menu is intended for the machine operator as it allows him to
Production – Machine disable a certain machine component. This may come in useful if a
components" component is malfunctioning. However, error messages issued by
these components will still be displayed.
1.2 Modifying configuration data for

operation environment software
1. Select "Operation (1) – Maintenance/Start-up (5) – MMC

Configurations (5)"
2. Enter "Minutes"530 as the password.
3. Press ENTER
Fig. 18418E

Softkeys:
Choose softkey Group to access the "Group" selection field. Using

Group the cursor keys, select the data group you want and press ENTER
to call it up.
Press softkey Applications to go to the right panel "Applications".
Applica- Use the FOCUS key to step from one application set to the next. If
tions
the configurations in one group cover more than one page, use the
PAGE UP and PAGE DOWN keys to scroll through the screen.
To note after a software If one or more configuration data have a red highlight, this means
update that these applications were added after a software exchange or
update. The values of the red-highlighted applications must be
checked and corrected, if necessary. The configuration is
confirmed by pressing softkey Checked current value

2. Machine data
2.1 Modifying machine data
The machine data can be edited from the TRUMPF operation

environment. Proceed as follows:
1. Select "Operation (1) – Maintenance/Start-up (5) – Machine

data (1)"
Fig. 19791E
Softkeys:
See 5-13 for description

Further
Functions
Press softkey Save to EEPROM to save the laser machine data to

Save to the EEPROM of the TASC 200.
EEPROM
2. Press softkey Selection

Selection
3. Press the TOGGLE key to open the selection list

Fig. 18420E
4. Select the desired machine group using the CURSOR keys

• MADA (general): general NC data
• MADA (channel-specific): The CNC can be divided into two
channels, but TRUMPF uses only one channel.
• MADA (axis specific): All axes-relevant data. Axes are
selected with "Axis+" and "Axis-".
• MADA (GUD): Global User Data: NCK and PLC relevant
data
5. Confirm your selection with ENTER
6. Search the desired machine data with PAGE UP / PAGE
DOWN keys and select with the FOCUS key
The desired machine datum can also be located by using the

Search Search for... softkey:
for...
Fig. 12068E

• Depending on the nature of the machine data information
you need, you can search either according to Text (Name
of MDs), Index (MD-Number) or Page. Press the
corresponding softkey and enter the appropriate search
string or the search number in the yellow highlighted field.
• Pressing the Browse keys << >> starts the search. << will
activate an UP and >> activates a DOWN-ward search
direction
• The machine data found will appear in the above field
• If the desired machine data file is already in the selection
field simply press OK to close the window. If not, use the
Browse key to search. When you have found the desired
selection confirm with OK
7. Press softkey Other parameters if necessary

Other
parameters
Fig. 12065E
All currently set machine data parameters are displayed in the

selected file window:
• The number and designation of the machine data file is

shown in the top line
• Lower limit: Minimum machine data value.
• Value: Currently set machine data value.
• Upper limit: Maximum machine data value
• Limit check: Shows if a check of the upper and
lower limits is to be carried out or not.
• Change active after: Shows when a machine data change
becomes active
Reset = RESET MMC interface
Power On = Main switch OFF or
Reset at NCU
Immediate = Effective immediately
after the change
New Conf = Power On (possible only
with SIEMENS user
interface)

• Protection level: Siemens write protect level:
0 and 7: No protection
1: Password "sunrise"
2: Password "ECHTZEIT" (master
password)
• Data type:
BOOLEAN: Machine data bit (1 or 0)
BYTE Integral value (from -128 to 127
DOUBLE Real and Integral values (from ±4.19 x
-307 308
10 to ±1.67 x 10 )
9
DWORD Integral values (from -2.147 x 10 to
9
2.147 x 10 )
STRING String size (max. 16 characters)
consisting of uppercase letters with
numbers and underlines
UNS. WORD Integral values (from 0 to 65536)
SIGNED WORD Integral values (from -32768 to 32767)
UNS. DWORD Integral values (from 0 to
4294967300)
SIGNED DWORD Integral values (from -2147483650 to
2147483649)
WORD Hex values (from 0000 to FFFF)
DWORD Hex values (from 00000000 to
FFFFFFFF)
-37
FLOAT DWORD Real values (from ±8.43 x 10 to
38
±3.37 x 10 )
CHARACTER One character (alphanumeric)
• Array elements: Number of values for the displayed
machine data
• Array size: Size of data field
8. Note the protection level for the machine data shown
9. Press OK to close the window
10. Press softkey Write password.
Write
password
Fig. 12066E
11. Input the password for that protection level e.g. master
password ECHTZEIT (REALTIME)
12. Press softkey OK
If the password is accepted, message "write level changed" is
displayed in the message line
13. Machine data can now be edited

2.2 Saving machine data
If machine date is edited, the changes will affect only the NCK. It is
absolutely necessary (for the sake of data safety) to store all
machine data outside the NCK as well.
TCOCUST.MDB Changes to the machine data are logged by the BOF operation
environment in database TCOCUST.MDB.
MASCHINE.INI If application "Save File Maschine.ini" in the configuration data for

the BOF has been set to 1, the logged data is written to file
MASCHINE.INI when you exit the "Machine data" menu. In this
way, the modified data is saved in file MASCHINE.INI in directory
C:\840D\MD on the MMC hard disk.
MASCHINE.INI
File: c:\840D\md
Content: Machine Data for TC600L
Date: 24.07.1997
Changes from Customer:
DATA (1)
INT_INCR_PER_MM=10000.000000
REFP_MOVE_DIST_CORR[0,AX5]=-23.280000
REFP_MOVE_DIST_CORR[0,AX4]=-29.510000
REFP_MOVE_DIST_CORR[0,AX3]=9.550000
TC_CORR_LASER_HEAD_X=-499.630000
TC_CORR_LASER_HEAD_Y=90.250000
TC_DIST_SHEET_THICK_TOL=-1.500000
Example of a MASCHINE.INI file
Logging and saving When changing machine data, you are immediately asked if these
changes changes should be logged and saved. This allows the user to
decide, in the test stage already, whether or not to save the
changes.
To save the changes made to a machine datum, you must press

the ENTER key first.

Fig. 19792
Softkeys:
Press softkey Cancel if you do not want to make any changes.
Cancel
Press softkey NCK if the changes should apply only to the NCK.
NCK These changes will not be saved to the TCOCUST.MDB database
nor to file MASCHINE.INI.
Press softkey NCK Database to make changes in the NCK and
NCK save them to both the database TCOCUST.MDB and to file
database
MASCHINE.INI.
modify
MaDa
save
changes? NCK
NCK
database
NCK memory NCK memory
TCOCUST .MDB
MASCHINE .INI
Fig. 19793E

Changes which must be active even after a subsequent
start-up must be saved in the NCK and database. Reason:
After the INITIAL.INI in a subsequent start-up, the contents
of the MASCHINE.INI file are loaded into the NC memory.
After editing machine data, do not exit the operation

environment directly as the changes will not otherwise be
entered in MASCHINE.INI. Entries are made in this file only
after changing menus (e.g. from menu „Machine data“ to
menu „Produce“).
The following menu is offered when you press softkey Further

Further functions:
functions
Fig. 19794
Press softkey Back to close the "Further machine data

Back functions/Database" menu.
Press softkey Modified machine data to view the machine data

Modified stored in file MASCHINE.INI.
mach. dat.

Fig. 19795E
Deleting an entry in file 1. Select the entry to be deleted

MASCHINE.INI 2. Press softkey Delete entry
When you press softkey Print File, the contents of the machine
Print data groups are written to files. These files are located in directory
File
C:\TCOMMC\EXE and can be copied from there, e.g.:
• General machine data: TEAGLOB.VAL
• Channel specific MADA: TEACHAN.VAL
• Axes data: TEAACHS.VAL
• GUD: GUD.VAL

2.3 Machine data overview
Machine data and setting data are divided into the following areas:
Area Designation
1000 – 1799 Machine data for drives
9000 – 9999 Machine data for operating panel
10000 – 18999 General machine data
19000 – 19999 Reserved
20000 – 28999 Channel specific machine data
29000 – 29999 Reserved
30000 – 38999 Axes-specific machine data
39000 – 39999 Reserved
41000 – 41999 General setting data
42000 – 42999 Channel specific setting data
43000 – 43999 Axes-specific setting data
51000 – 61999 General machine data for Compile cycles
62000 – 62999 Channel specific machine data for Compile cycles
63000 – 63999 Axes-specific machine data for compile cycles
Area 51000-63999 is reserved for TRUMPF cycles.
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Gen. MD Channel MD Axis MD Boot-files

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Machine drive data
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drive bus S
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Fig. 12069E

Machine data is buffered on the NCU at power-down. They
do not need to be re-transferred from the MMC to the NCU
at next power-up.
Drive machine data The drive machine data is not buffered and must be transferred
again to the drives from the NCU via *.bot files. Automatic transfer
of drive machine data during a reboot, for example, takes place
across the drive bus. There is one*.bot-file per drive. The *.bot-files
are also stored on the MMC hard disk in directory C:\840D\MD.
2.4 Individual machine data groups
n the following, the most important machine data of various data

groups have been selected for closer description. The values
assigned to the machine data presented here is for the TC 600L.
Literature In all machine data, a cross-reference to the SIEMENS "Setup

Manual" is provided in square brackets (e.g. [K2/4-1] behind the
designation. The SIEMENS Setup Manual is classified according to
these cross-references. The SIEMENS Setup Manual can be
obtained from SIEMENS (also on CD-ROM).
Data areas The prefix abbreviation assigned to each data file helps to
determine which machine data group the machine data belongs to:
$MM Control panel data

$MN General machine data/setting data
$MC Channel specific machine data/setting data
$MA Axes-specific machine data/setting data
$MD Drive machine data
Description:
$ System variable
1st M Machine datum
1st S Setting datum
2nd M, N, C, A, D Partial area
Axis data are addressed by axis designation. Axis designations are

the internal identifiers (AX1, AX2 ... AX8) or the assigned
designations stated in MD 10000: AXCONF_NAME_TAB.

Example:
$MA_JOG_VELO[Y1]=2000
JOG feedrate of axis Y1 equals 2000 mm/min.
If the content of a machine data is a STRING (for example X1) or a

hexadecimal value (for example H41), the content must be written
between apostrophes as follows (’X1’ or ’H41’).
Example:
$MN_DRIVE_INVERTER_CODE[0]=’H14’
VSA-Module 9/18 A on drive bus slot 1
To address different machine data contents, square brackets are

necessary.
Example:
$MA_FIX_POINT_POS[0,X1]=500.000
The 1st fixed point position of axis X1 equals 500
(0=1., 1=2., 2=3. etc.)
Please refer to files INITIAL.INI and MASCHINE.INI for

current values for the machine data.
Drive data
The drive data are described by example of the TC 600L.
0DFKLQH /RJLFDO
D[LV GULYH
;
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=
%LWEXV 7HUPLQDO
& PRGXO EORFN

; & < & =
&

%LWEXVPRGXOH

%LWEXVPRGXOH ,QWHUIDFH
7HUPLQDOEORFN
Overview of central drive data Fig. 12070E

Allocations The allocations
• Machine axis ↔ Logical drive ↔ Slot on the drive bus
and
• DMP modules on the terminal block
are always the same on standard machines.
These allocations can, however, be configured manually for

special machines (e.g. TCL1005)
The respective configuration tool is automatically activated for
every software exchange (from SW version 4.0 and higher).
Please refer to Section 5.2 "NC/PLC: Loading software" in

Chapter 6 “Setup/Update”.
Manual configuration
Configuration on Manual configuration of a simulator requires a special NCK disk

simulators which must be inserted in the floppy drive as Disk 1 during Copy
NCK from Disk. At the appropriate time, you will be prompted by a
screen message to insert the next NCK disk.
Running the 1. You can also run the configuration tool without a new
configuration tool installation of the NCK disks: To do so, activate
„INST_NCK.BAT“ in directory c:\840d.ins.
Syntax: inst_nck hd (Harddisk)
2. Choose the required language.
3. Press Y to confirm the machine type determined.
4. Decide whether the old NCK version should be saved to
directory c:\840d.bak.
5. Select (4) Machine data.
6. Press N in reply to the query Will "Kanji" language be used at
the machine? (In Japan, press Y)
The standard configuration for the machine type is then displayed.
Standard configuration Fig. 23687E
The left side of the screen shows the selected configurations while
the possible configurations are displayed on the right.

The numbers preceding the selected configurations indicate, for
example,
9/1: The 9th option on screen page 1
Use the PageUp and PageDown keys to scroll through the screen
pages.
Deactivating a 1. Press softkey Deactivate.

configuration 2. Enter the number of the option you wish to deactivate.
(e.g. 9 for metric system)
3. Confirm the page
Fig. 24443E
4. The configuration has been deactivated. (e.g. metric system)
Modified configuration Fig. 23690E
You can deactivate other options in this manner.
5. Press softkey Cancel when finished with deactivation

Activating a 1. Press softkey Activate.
configuration 2. Enter the number of the option you wish to activate. (E.g. 8 for
the Inch system)
Modified configuration Fig. 23693E
The selected configuration is now active and appears on the

left half of the screen, under "Selected configurations".
You can activate other options in this manner.
3. Press softkey Cancel when finished with activation.
Drive bus 1. Press softkey more.

configuration
The message appears in the bottom message line:
Fig. 24444E
2. Enter password 00530.
Fig. 23696E
The current drive bus configuration is displayed on the right

half of the screen.
3. Press softkey Drives to modify the configuration.

Fig. 23697E
4. With softkeys Delete or Delete all, you can delete one or all
components of the drive bus.
5. Components can be added to the drive bus using softkeys

Append or Insert.
Softkey Append Fig. 23699E
The necessary entries for the module being appended are

listed on the left.
The selectable components are listed beneath that.
6. Make the following entries and confirm with Enter :

• Module type 1 or 2 axis module, DMP or
Bitbus module
• Inverter code type of servo drive module
(s. machine datum 13020)
• Logical number is assigned automatically
• Active is automatically set to 1
• Number in channel is assigned automatically
• Drive type 1 VSA drive
2 linear drive

When all entries have been completed, the selected module is
displayed on the right half of the screen.
Selected module Fig. 24445E
7. Proceed in the same manner to select all other modules.

(e.g. DMP, Bitbus)
8. When you have completed the configuration, press Esc and

then softkey Finished.
Terminal block 1. Press softkey DMP.

configuration 2. Use softkey Delete to remove any existing DMP modules.
3. Press softkey Append.
Fig. 23704E
4. Make the following entries:

Module type
Type of DMP module (e.g. 2 for analog output)
DMP module
On which terminal block is the DMP located? (if several
terminal blocks, e.g. 1)

Slot
On which slot on the terminal block is the DMP module
located?
Synchronous operation
Default setting: 0.
Normally: Digital modules → 0 for asynchronous
Analog modules → 1 for synchronous
The chosen setting is displayed on the right side of the screen:
Fig. 24446E
5. Choose additional DMP modules.

or
6. Press softkey Finished if you are finished configuring the DMP
modules.
Checking the configuration 1. Press softkey Show.
Display showing the complete configuration Fig. 23708E
The current configuration is displayed.

This can take some time.
2. Check the configurations for the drive bus and for the terminal
block with its DMP modules.
3. Press softkey Cancel to terminate.

Saving the configuration 1. In the main screen, press softkey Save to store the
configuration and terminate.
The selected configuration is then processed and compared
with the actual setup of the drive bus.
Fig. 23709E
If an error occurs during verification, a red screen is displayed

and message "ATTENTION ! The current configuration is
invalid !" appears.
2. Press softkey Error to view the error detected:
Error display Fig. 24447E
In the above example, the user forgot to select the machine

type.
3. Press End to exit the error display.
4. Modify or correct the configuration (in the above example,

machine type L3030 must be activated)
5. Save the configuration again with Save.

If no error was detected, the following screen will be displayed:
Fig. 23713E
A new ’initial.ini’ file was generated.
6. Reply with N to the question "Install other data?"
Ending the configuration Press softkey NCK first load in the Load software menu to load the
selected configuration to the NCK.
If the configuration is not correct, an error message to this effect
will be issued after NCK first load.

Machine data description
10000 Machine axis designation [K2/4-1]

Machine axis designation
$MN_AXCONF_MACHAX_NAME_TAB[0]="X"
$MN_AXCONF_MACHAX_NAME_TAB[1]="Y"
$MN_AXCONF_MACHAX_NAME_TAB[2]="Z"
$MN_AXCONF_MACHAX_NAME_TAB[3]="C1"
$MN_AXCONF_MACHAX_NAME_TAB[4]="C2"
Machine axes designation

Axis number
13000 Drive activation [G2/4-2]

"1" activates and "0" deactivates the drive at the respective slot number. In case of service, a drive can
be deactivated in this manner.
$MN_DRIVE_IS_ACTIVE[0]=1 Slot 0 for SIMODRIVE active

$MN_DRIVE_IS_ACTIVE[5]=1 Slot 5 for Bitbus module active
$MN_DRIVE_IS_ACTIVE[6]=1 Slot 6 for Bitbus module active
$MN_DRIVE_IS_ACTIVE[7]=1 Slot 7 for Terminal block active
Slot on drive bus
13010 Logical driver number to [Slot number] [G2/4-2]

This machine datum defines which machine axis is located at which slot on the drive bus. In case of
service, two axes can be swapped in this manner.
$MN_DRIVE_LOGIC_NR[0]=1 X axis on slot 0 of the drive bus

$MN_DRIVE_LOGIC_NR[1]=5 C2 axis on slot 1 of the drive bus
$MN_DRIVE_LOGIC_NR[2]=2 Y axis on slot 2 of the drive bus
$MN_DRIVE_LOGIC_NR[3]=4 C1 axis on slot 3 of the drive bus
$MN_DRIVE_LOGIC_NR[4]=3 Z axis on slot 4 of the drive bus
$MN_DRIVE_LOGIC_NR[5]=6 Bitbus module on slot 5 of the drive bus
$MN_DRIVE_LOGIC_NR[6]=7 Bitbus module on slot 6 of the drive bus
$MN_DRIVE_LOGIC_NR[7]=8 Terminal block on slot 7 of the drive bus
Logical drive number

Slot on drive bus
Application If a drive fault occurs and it is not certain whether the motor or the
drive module is defective, one possibility is to swap the drive
module:
• A different slot is assigned to the logical drive.

• The encoder cables and power cables of the drive module in
question must also be swapped, otherwise the wrong motor
will be set in motion.

Example:
Swapping X and Y axes
$MN_DRIVE_LOGIC_NR[0]=2 Y axis now on slot 0 of the drive bus

$MN_DRIVE_LOGIC_NR[2]=1 X axis now on slot 2 of the drive bus
X-Motor Y-Motor
X drive modul Y drive modul
NCK NCK
X-Interpolator Y-Interpolator
Fig. 18421E

30130 Nominal value output [Nominal value range, machine axis] [G2/4-12]
0 = Simulation axis
1 = Standard SINUMERIK 840D
2,3 = FM-NC-Stepping motor, FM module
$MA_CTRLOUT_TYPE[0,AX1]=1 X axis
$MA_CTRLOUT_TYPE[0,AX2]=1 Y axis
$MA_CTRLOUT_TYPE[0,AX3]=1 Z axis
$MA_CTRLOUT_TYPE[0,AX4]=1 C1 axis
$MA_CTRLOUT_TYPE[0,AX5]=1 C2 axis
30240 Encoder type [Encoder, machine axis] [G2/4-19]

0 = Simulation axis
1 = Raw signal (Motor) encoder
2,3,4,5 = Rectangular, stepper motor, absolute encoder
$MA_ENC_TYPE[0,AX1]=1 Raw signal encoder

13020 Drive module inverter code on [Slot] [G2/4-1]
$MN_DRIVE_INVERTER_CODE[0]=H’16’ HEX, Drive module 18/ 36A (X)

$MN_DRIVE_INVERTER_CODE[1]=H’16’ HEX, Drive module 18/ 36A (C2)
$MN_DRIVE_INVERTER_CODE[2]=H’17’ HEX, Drive module 28/ 56A (Y)
$MN_DRIVE_INVERTER_CODE[3]=H’12’ HEX, Drive module 5/ 10A (C1)
$MN_DRIVE_INVERTER_CODE[4]=H’12’ HEX, Drive module 5/ 10A (Z)
13030 Module recognition of drive module on [Slot] [G2/4-4]
$MN_DRIVE_MODULE_TYPE[0]=2 Dual-axis module (X)

$MN_DRIVE_MODULE_TYPE[1]=2 Dual-axis module (C2)
$MN_DRIVE_MODULE_TYPE[2]=1 Single axis module (Y)
$MN_DRIVE_MODULE_TYPE[3]=2 Dual-axis module (C1)
$MN_DRIVE_MODULE_TYPE[4]=2 Dual-axis module (Z)
$MN_DRIVE_MODULE_TYPE[5]=10 Bitbus module 1st segment
$MN_DRIVE_MODULE_TYPE[6]=10 Bitbus module 2nd segment
$MN_DRIVE_MODULE_TYPE[7]=9 Terminal block
30200 Number of encoders [machine axis] [G2/4-20]

1 = Motor encoder only (Minimum)
2 = Motor and direct encoder
$MA_NUM_ENCS[AX1]=1 Motor encoder only


30210 Actual value assignment to drive number [Encoder number] [G2/4-18]
0 = FM-NC
1 = Drive bus SINUMERIK 840D
$MA_ENC_SEGMENT_NR[0,AX1]=1 Encoder
30220 Logical drive number for actual value [Encoder, machine axis] [G2/4-18]
With SINUMERIK 840D logical drive number
With FM-NC modules (for example.: FM-NC, FM-position)
$MA_ENC_MODULE_NR[0,AX1]=1 log.1=Slot 0=X axis

$MA_ENC_MODULE_NR[0,AX2]=2 log.2=Slot 2=Y axis
$MA_ENC_MODULE_NR[0,AX3]=3 log.3=Slot 4=Z axis
$MA_ENC_MODULE_NR[0,AX4]=4 log.4=Slot 3=C1 axis
$MA_ENC_MODULE_NR[0,AX5]=5 log.5=Slot 1=C2 axis
30230 Actual value assignment on drive module [Encoder, machine axis] [G4/4-16]
1, 2 = SINUMERIK 840D Encoder, direct measuring system
1..4 = FM-NC
$MA_ENC_INPUT_NR[0,AX1]=1 Encoder
30300 Rotary axis definition [machine axis] [R2/4-2]

0 = Linear axis
1 = This is a rotary axis
Unit: degrees, RPM, R/s²
$MA_IS_ROT_AX[AX1]=...
30310 Modulo conversion for rotary axis [machine axis] [R2/4-3]

1 = Limit switches have no effect
$MA_ROT_IS_MODULO[AX1]=...

30320 Modulo display for rotary axis [machine axis] [R2/4-1]
1 = Display in degrees
$MA_DISPLAY_IS_MODULO[AX1]=...
30450 Concurrent positioning axis [machine axis] [P2/4-1]

1 = Axis movement only from PLC and JOG mode
$MA_IS_CONCURRENT_POS_AX[AX1]=...
Axis dynamics (Speeds, servo gain,

acceleration, backlash)
32000 Maximum axis speed [machine axis] [G2/4-20]

Maximum programmable speed, rapid speed
$MA_MAX_AX_VELO[AX1]=... mm/min, RPM

32010 Conventional rapid speed [machine axis] (active only in JOG mode [H1/4-4]
JOG feedrate + rapid speed override
$MA_JOG_VELO_RAPID[AX1]=... mm/min, RPM

32020 Conventional axis speed [machine axis] (active in JOG mode only) [H1/4-5]
Feedrate during JOG
$MA_JOG_VELO[AX1]=... mm/min, RPM


32200 Servo gain factor [Regulation parameter, machine axis] [G2/4-21]
I/O unit: (m/min)/mm; equals 1mm lag at 1m/min feed
$MA_POSCTRL_GAIN[0,AX1]=... 1000/min
32300 Maximum axis acceleration [machine axis] [B2/4-2]

See also MAX_ACCEL_OVL_FACTOR
$MA_MAX_AX_ACCEL[AX1]=... m/s², R/s²

32450 Backlash [Encoder, machine axis] [K3/4-2]

Positive when the encoder is ahead of the machine, always active after referencing
$MA_BACKLASH[0,AX1]=... mm
The following machine data apply only to the TLC 1005:
31030 Ballscrew pitch

The pitch of the ballscrew is entered in the MADA for compensation purposes.
$MA_LEADSCREW-PITCH[AX1]=..... for X, Y and Z axis
31050 Drive ratio denomination

The drive ratio is entered in the MADA:
$MA_DRIVE_AX-RATIO_DENOM[AX...]=..... for B, C and A axis
31060 Drive ratio numbers

The number of motor revolutions are entered in the MADA.
$MA_DRIVE_AX_RTIO_NUMERA[AX...]=..... for B, C and A axis

Referencing
The type of reference point approach is dependent, amongst other

things, on machine datum 34050.
MADA 34050 Direction reversal on reference point cam is 0
The axis searches for the reference point cam at the cam search
speed stated in MADA 34020 and in the direction stated in MADA
34010. As soon as this is reached with interface signal
„Referencing delay“ (DB31-48, DBB12.7) Prox. switch on cam, the
axis reverses and looks for the reference point marker. This is
followed by a reference point offset as per MADA 34090,
subsequently, the actual reference point value as per MADA 34100
and interface signal „Referenced“ (DB31-48, DBB60.4), Axis has
reached referenced point, are set.
PLC NCK
BERO
DB 31-48, DBX12.7, interface signal
PLC to NC, Prox. switch on cam
P34010, Referencing direction
P34020, Ref.point cam approach speed
Reference point cam

P34040, marker search speed
P34090 pos.or neg. ref. offset

Reference point
Reference point
P34070 Reference point offset

speed
P34100 Actual reference point value P34100
Zero marker
Fig. 19796E

MADA 34050 Direction reversal on reference point cam is 1
The axis searches for the reference point cam at the cam search
speed stated in MADA 34020 and in the direction stated in MADA
34010. As soon as this is reached with interface signal
„Referencing delay“ (DB31-48, DBB12.7) Prox. switch on cam, the
axis reverses and withdraws from the cam. As soon as interface
signal „Referencing delay“ Proximity switch on reference point cam
is 0, the axis reverses again and approaches the reference cam
again. When interface signal „Referencing delay“ again reports
Proximity switch on cam, the reference point marker is searched.
This is followed by a reference point offset as per MADA 34090,
subsequently, the actual reference point value as per MADA 34100
and interface signal „Referenced“ (DB31-48, DBB60.4), Axis has
reached referenced point, are set.
PLC NCK
BERO
DB 31-48, DBX12.7, interface signal
PLC to NC, Prox. switch on cam
Zero marker
P34010, Referencing direction
P34020, Reference point cam approach speed
Reference point cam

P34020
P34020 P34040, marker search speed
P34090 pos.or neg. ref. offset

Reference point
Reference point
P34070 Reference point offset

speed
P34100 Actual reference point value P34100
Fig. 19797E

34000 Axis with referencing cam [machine axis] [R1/4-8]
1 = Axis with reference cam
0 = Axis with zero marker in total travel range
$MA_REFP_CAM_IS_ACTIVE[AX1]=...
34010 Referencing in minus direction [machine axis] [R1/4-6]

1 = Referencing in minus direction
$MA_REFP_CAM_DIR_IS_MINUS[AX1]=...
34020 Reference point approach speed [machine axis] Cam search [R1/4-12]
Cam search speed
$MA_REFP_VELO_SEARCH_CAM[AX1]=... mm/min, RPM

34030 Maximum distance to reference [machine axis] [R1/4-8]

Maximum distance to cam
$MA_REFP_MAX_CAM_DIST[AX1]=... mm, degrees

34040 Shutdown speed [Encoder, machine axis] 0 marker search [R1/4-13]

Speed for marker search
$MA_REFP_VELO_SEARCH_MARKER[0,AX1]=... mm/min, RPM


34050 Direction reversal to reference cam [machine axis] [R1/4-6]
0 = Go on cam, reverse, search marker
1 = Go on cam, reverse, reverse, search marker
$MA_REFP_SEARCH_MARKER_REVERSE[0,AX1]=...
34060 Maximum distance to 0 marker [Encoder, machine axis] [R1/4-8]

Maximum distance to where marker must be recognized
$MA_REFP_MAX_MARKER_DIST[0,AX1]=... mm, degrees

34070 Reference point approach speed [machine axis] after 0-Marker [R1/4-5]
Speed between marker and reference point
$MA_REFP_VELO_POS[AX1]=... mm/min, RPM

34090 Additive reference point distance [Encoder, machine axis] [R1/4-10]

Additive travel distance between marker and reference position
$MA_REFP_MOVE_DIST_CORR[0,AX1]=... mm, degrees

34100 Reference point value [Reference point number, machine axis] [R1/4-11]
The axis position is displayed when the axis completes the referencing cycle.
One of four reference positions is selectable by PLC
$MA_REFP_SET_POS[0,AX1]=... mm, degrees


Exact stop, axis monitoring
36000 Exact stop coarse [machine axis] [B1/4-4]

Actual position must be in exact stop window to allow block change. Programmable with G60 and
G602
$MA_STOP_LIMIT_COARSE[AX1]=... mm, degrees

36010 Exact stop fine [machine axis] [B1/4-4]

Actual position must be in exact stop window to allow block change. Programmable with G60 and
G601 (Standard)
$MA_STOP_LIMIT_FINE[AX1]=... mm, degrees

36020 Delay in Exact stop fine/coarse [machine axis]

Time within which the Exact stop window fine/coarse must be reached
$MA_POSITIONING_TIME[AX1]=... s
36030 Stop tolerance [machine axis] [A3/4-6]

Limit value for lag at end of motion block
$MA_STANDSTILL_POS_TOL[AX1]=... mm, degrees

36040 Delay time, stop monitoring [machine axis] [A3/4-7]

Time in which stop tolerance must be reached
$MA_STANDSTILL_DELAY_TIME[AX1]=... s

36060 Maximum speed with stationary axis [machine axis] [A2/4-13]
Under this speed, the NST signal "Axis/Spindle stop" is set
$MA_STANDSTILL_VELO_TOL[AX1]=... mm/min, RPM

30600 Working range Minus/Plus

The machine working range in minus and plus directions is defined in this datum
$MA_FIX_POINT_POS[0,AX1]=..... Working range Minus X axis

$MA_FIX_POINT_POS[1,AX1]=..... Working range Plus X axis
$MA_FIX_POINT_POS[0,AX2]=..... Working range Minus Y axis
$MA_FIX_POINT_POS[1,AX2]=..... Working range Plus Y axis
36100 Software limit switch, minus [machine axis] [A3/4-5]

Active if the second software limit switch was not activated by the PLC
$MA_POS_LIMIT_MINUS[AX1]=... mm, degrees

36110 Software limit switch, plus [machine axis] [A3/4-5]

Active if the second software limit switch was not activated by the PLC
$MA_POS_LIMIT_PLUS[AX1]=... mm, degrees

36200 Limit value for speed monitoring [Regulation parameters, machine axis] [A3/4-2]
MAX_AX_VELO can be exceeded by regulation processes
$MA_AX_VELO_LIMIT[0,AX1]=... mm/min, RPM


36400 Tolerance width, contour monitoring [machine axis] [A3/4-3]
Tolerance width for maximum lag error
$MA_CONTOUR_TOL[AX1]=... mm, degrees

Digital NCK periphery
10350 Number of current digital NCK input bytes [A2/4-4]

Number of digital input bytes
$MN_FASTIO_DIG_NUM_INPUTS=...
10360 Number of active digital NCK output bytes [A2/4-4]

$MN_FASTIO_DIG_NUM_OUTPUTS=...
10366 Hardware assignment of external digital NCK input bytes [A2/4-6]

Assignment of input bytes
H1000000 means Input/Outputs on NCU
$MN_HW_ASSIGN_DIG_FASTIN[0]=...HEX, see above
10368 Hardware assignment of external digital NCK output bytes [A2/4-7]

Assignment of output bytes
H1000000 means I/O on NCU
$MN_HW_ASSIGN_DIG_FASTOUT[0]=...HEX, see above
Analog NCK periphery
10300 Number of active analog NCK inputs [A2/4-1]

Number of analog inputs (max. 8) on the DMP terminal block
$MN_FASTIO_ANA_NUM_INPUTS=...
10310 Number of active analog NCK outputs [A2/4-1]

Number of analog outputs (max. 8) on the DMP terminal block
$MN_FASTIO_ANA_NUM_OUTPUTS=...

10320 Evaluation factor for analog NCK inputs [A2/4-2]
Value read in by NCK at ADU modulation
$MN_FASTIO_ANA_INPUT_WEIGHT[0]=...
$MN_FASTIO_ANA_INPUT_WEIGHT[1]=...
10330 Evaluation factor for analog NCK output [A2/4-3]

Value issued by NCK at DAU modulation
$MN_FASTIO_ANA_OUTPUT_WEIGHT[0]=...
10362 Hardware assignment of external analog NCK inputs [A2/4-5]

Assignment where the analog inputs are to be found, values in hexadecimal mode
e.g.:
§MN_HW_ASSIGN_ANA_FASTIN[0]=´H1 08 02 01´
Byte on DMP-Module
Slot on Terminal block
Logical drive number for the terminal block
Code for drive bus, analog inputs are on the
drive bus
10364 Hardware assignment of external analog NCK outputs [A2/4-5]

Assignment where the analog outputs are to be found, values in hexadecimal mode
e.g.:
§MN_HW_ASSIGN_ANA_FASTOUT[0]= ´H1 08 01 01´
Byte on DMP-Module
Slot on the terminal block
Logical drive number for the terminal
block
Code for drive bus, analog inputs are on
the drive bus
The analog values of the respective inputs and outputs can be queried at the PLC interface.
Actual value 1. Analog input DB10,DBW 194 e.g. DIAS on TC600L

Actual value 2. Analog input DB10,DBW 196 e.g. Cutting gas pressure on TC600L
Actual value 3. Analog input DB10,DBW 198
Actual value 1. Analog output DB10,DBW 210 e.g. Laser power on TC600L
Actual value 2. Analog output DB10,DBW 212

Channel assignment, system cycles
Machine parameters 10010, 10050, 10060 and 10070 may

only be checked but never modified!
10010 Channel valid in operation mode group (BAG) [Channel number] [K1/4-1]
Channel for operation modes
Indicates how many channels are active
$MN_ASSIGN_CHAN_TO_MODE_GROUP[0]=1 1st channel active

$MN_ASSIGN_CHAN_TO_MODE_GROUP[1]=0 No 2nd channel active
10050 Basic system cycle [G2/4-10]

Time units used for activating operating system time interrupts
$MN_SYSCLOCK_CYCLE_TIME=.... (Unit in seconds, e.g. 0.002)
10060 Position control cycle factor [G2/4-5]

A multiple of the basic system cycle
$MN_POS_CTRL_SYSCLOCK_TIME_RATIO=.... Position control cycle/Basic system cycle,

e.g. 1 x MADA 1050 = 0.002s
10070 Interpolation cycle factor [G2/4-5]

A multiple of the position regulation cycle
$MN_IPO_SYSCLOCK_TIME_RATIO=.... Interpolation cycle,

e.g. 3 x MADA 10050 = 0.006s

Memory areas
18050, 18060, 18070 Display free memory [S7/4-1]
$MN_INFO_FREE_MEM_DYNAMIC=.... Byte, dynamic memory

$MN_INFO_FREE_MEM_STATIC=.... Byte, static memory
$MN_INFO_FREE_MEM_DPR=.... Byte, DUAL-PORT-RAM
Definition of memory areas The size of the PLC memory is defined with the two machine data
below. For example, if you have difficulties loading the PLC
program into the PLC, check the two MADA below. The PLC
program cannot be loaded into the PLC if the memory areas are
too small.
19270 PLC memory enable

$ON_PLC_USER_MEM_SIZE=.... S7 user memory 64 kB
19280 PLC memory enable, C programs
$ON_PLC_C_USER_MEM_SIZE=.... C user memory 320 kB
Nibbling machine data
26000 Input byte, nibbling

Assignment of input Byte for nibbling
(see HW_ASSIGN_DIG_FASTIN)
$MC_PUNCHNIB_ASSIGN_FASTIN=’H1’
26002 Output byte, nibbling

Assignment of output byte for nibbling
(see HW_ASSIGN_DIG_FASTOUT)
$MC_PUNCHNIB_ASSIGN_FASTOUT=’H1’
26004 Assignment of "Punching in sheet" to input byte

Assignment of input Byte for nibbling
$MC_NIBBLE_PUNCH_OUTMASK[0]=’H2’
26006 Assignment of "In Position" to output byte

Assignment of output bit for nibbling
$MC_NIBBLE_PUNCH_INMASK[0]=’H1’

26008 Assignment of M functions for punching/nibbling
Analog to NIBBLE_ON (Nibbling) and PUNCH_ON (Punching)
$MC_NIBBLE_PUNCH_CODE[0]=’H14’ M20 Punching/Nibbling OFF

$MC_NIBBLE_PUNCH_CODE[1]=’H17’ M21 Punching/Nibbling OFF
$MC_NIBBLE_PUNCH_CODE[2]=’H16’ M22 Nibbling
$MC_NIBBLE_PUNCH_CODE[3]=’H19’ M25 Punching
$MC_NIBBLE_PUNCH_CODE[4]=’H1a’ M26 Delayed punching
$MC_NIBBLE_PUNCH_CODE[5]=’H0’
Setting datum for delayed punching

$SC_PUNCH_DWELLTIME=150
Offsets
61001/61002 Laser head offset

The offset between laser head and punching head is defined in this machine datum.
$MN_TC_CORR_LASER_HEAD_X=..... Offset X axis in mm

$MN_TC_CORR_LASER_HEAD_Y=..... Offset Y axis in mm
61003 Stop pin offset

The stop pin offset is defined in this machine datum.
$MN_TC_CORR_LOCATER_PIN_X=..... Offset in mm
5-axes transformation (TLC 1005)
24550 Vector for basis tool in 5-axes transformation
$MC_TRAFO5-BASE_TOOL_1[0]=..... X axis offset

$MC_TRAFO5-BASE_TOOL_1[1]=..... Y axis joint offset
$MC_TRAFO5-BASE_TOOL_1[2]=..... Tool length

TRUMPF machine data
Height regulation MN_TC_DIST_CONTROL

0 = Disable height regulation module
1 = Height regulation can be activated
Default: 1
MN_TC_DIST_AX_INDEX
Axis index of standoff axis
Default: 3 (Z axis)
MN_TC_DIST_ANALOG_INPUT_NR
Number of analog input at drive bus
Default: 1
MN_TC_DIST_GAIN
Standardization/Amplification factor of analog signal [m/minV]
Default: 2.25 (at 66MHz-CPU)
MN_TC_DIST_UPPER_LIMIT
Upper correction value limit in [mm], relative to activation point
Default: 160
MN_TC_DIST_LOWER_LIMIT
Lower correction value limit [mm], relative to activation point
Default: -160
MN_TC_DIST_VELO_LIMIT
Upper limit of correction speed in [mm/min], relative to activation
point
Default: 50000
Bitbus MN_TELE_MASK_BB_KNOTEN
Identification of Bitbus parties by setting individual bits
Default: 3 (Laser control, ram control)
Data transfer CNC-PLC MN_TC_DPR_IN_DATA

MN_TC_DPR_OUT_DATA
MN_TC_DPRHANDLER_PLC_TIMEOUT
MN_TC_DPRHANDLER_DEBUGINFO
MN_DIAG_DEBUGINFO
Laser technology tables MC_TC_LTT_POWERINWATT

0= Laser power is transferred to PLC as percent of rated power
1= Laser power is transferred to PLC in Watts
Default: 0

MC_TC_LTT_LASERTOOLNR
T-Address of "Laser tool". A tool used for laser kerf correction is
registered under this address.
Default: 1
Rail assignment check MN_TC_MAGAZIN_POS1

X position of first tool station [mm]
MN_TC_MAGAZIN_MAX_NUM
Number of rail positions
MN_TC_MAGAZIN_DELTA_POS
Distance between tool positions in X [mm]
MN_TC_MAGAZIN_DELTA_CHK_POS1
Distance between clamp check positions [mm]
MN_TC_MAGAZIN_DELTA_CHK_POS2
not applicable
MN_TC_MAGAZIN_BERO_NR_LEFT
Number of digital NC input for the left tool proximity switch
MN_TC_MAGAZIN_BERO_NR_RIGHT
Number of digital NC input for the right tool proximity switch

3. List of machine and setting data
3.1 Machine drive data
1000 CURRCTRL_CYCLE_TIME Reference:

/DS1/
Current control cycle Relevant: Protection level:
VSA/HSA 2/4
Unit: Standard: Minimum: Maximum: Data type: Effect:
31.25 µs 4 2 4 UNS. WORD POWER ON
5 (810D) 8 (810D)
1001 SPEEDCTRL_CYCLE_TIME Reference:
/DD21/
Speed control cycle Relevant: Protection level:
VSA/HSA 2/4
10 (810D) 32 (810D)
1002 MONITOR_CYCLE_TIME Reference:
/DB1/
Monitoring cycle Relevant: Protection level:
VSA/HSA 2/4
640 (810D)
1003 STS_CONFIG Reference:
/DS1/
Configuration STS Relevant: Protection level:
VSA/HSA 2/4
HEX 0330 0000 FFFF WORD POWER ON
1004 CTRL_CONFIG Reference:
/IAD/
Configuration structure (not 810D) Relevant: Protection level:
VSA/HSA 2/4
HEX 0000 0000 7FFF WORD POWER ON
1005 ENC_RESOL_MOTOR Reference:
/DG1/, /DM1/
Encoder resolution - motor measuring system Relevant: Protection level:
VSA/HSA 2/4
Incr/rev 2048 128 8192 UNS. WORD POWER ON
1007 ENC_RESOL_DIRECT Reference:
/DG1/
Encoder resolution direct measuring system Relevant: Protection level:
VSA/HSA 2/4
Incr/rev 0 0 65535 UNSIGNED POWER ON
Incr/mm WORD

1008 ENC_PHASE_ERROR_CORRECTION Reference:
/DG1/
Encoder phase error correction Relevant: Protection level:
VSA/HSA 2/4
degrees 0.0 -20.0 20.0 FLOAT DWORD IMMEDIATE
1011 ACTUAL_VALUE_CONFIG Reference:
/DG1/
Configuration -actual value recording Relevant: Protection level:
VSA/HSA 2/4
1012 FUNC_SWITCH Reference:
/DB1/
Function switch Relevant: Protection level:
VSA/HSA 2/4
HEX 0004 0000 FFFF WORD IMMEDIATE
1013 ENABLE_STAR_DELTA Reference:
/IAD/
Star/delta change enable (not 810D)) Relevant: Protection level:
HSA 2/4
- 0 0 1 UNS. WORD POWER ON
1021 ENC_ABS_TURNS_MOTOR Reference:
/DG1/
Multi-turn resolution absolute value encoder, Motor measuring Relevant: Protection level:
system VSA/HSA 2/4
U 4096 0 4096 UNS. WORD POWER ON
1022 ENC_ABS_RESOL_MOTOR Reference:
/DG1/
Measuring resolution of absolute motor measuring system Relevant: Protection level:
VSA/HSA 2/4
1023 ENC_ABS_DIAGNOSIS_MOTOR Reference:
/DG1/
Measuring circuit motor absolute path, diagnosis Relevant: Protection level:
VSA/HSA 2/4
- - 0000H FFFFH UNS. WORD POWER ON
1030 ACTUAL_VALUE_CONFIG_DIRECT Reference:
/DG1/
Encoder resolution motor measuring system Relevant: Protection level:
VSA/HSA 2/4

1031 ENC_ABS_TURNS_DIRECT Reference:
/DG1/
Multi-turn resolution, absolute value encoder direct measuring Relevant: Protection level:
system VSA/HSA 2/4
turns 4096 0 4096 UNS. WORD POWER ON
1032 ENC_ABS_RESOL_DIRECT Reference:
/DG1/
Measuring resolution of absolute direct measuring system Relevant: Protection level:
VSA/HSA 2/4
1033 ENC_ABS_DIAGNOSIS_DIRECT Reference:
/DG1/
Direct measuring circuit absolute path diagnostics Relevant: Protection level:
VSA/HSA 2/4
- - 0000H FFFFH UNS. WORD POWER ON
1100 PWM_FREQUENCY Reference:
/IAD/
Frequency pulse width modulation (not 810D) Relevant: Protection level:
VSA/HSA 2/4
Hz 4000/3200 2000 8000 FLOAT DWORD POWER ON
1101 CTRLOUT_DELAY Reference:
/IAD/
Current control circuit control out delay time (not 810D) Relevant: Protection level:
VSA/HSA 2/4
µs 62 0 124 SIGNED WORD POWER ON
1102 MOTOR_CODE Reference:
/DM1/
Motor code number Relevant: Protection level:
VSA/HSA 2/4
1103 MOTOR_NOMINAL_CURRENT Reference:
/DM1/
Nominal motor current Relevant: Protection level:
VSA/HSA 2/4
Unit: Standard:0.0 Minimum: Maximum: Data type: Effect:
A 0.0 500.0 FLOAT DWORD POWER ON
1104 MOTOR_MAX_CURRENT Reference:

/DM1/
Maximum motor current Relevant: Protection level:
VSA 2/4
A 0.0 0.0 500.0 FLOAT DWORD POWER ON

1105 MOTOR_MAX_CURRENT_RECUCTION Reference:
/DÜ1/
Reduction of Maximum motor current Relevant: Protection level:
VSA 2/4
% 100 0 100 SIGNED WORD IMMEDIATE
1106 INVERTER_CODE Reference:
/DM1/
Inverter code number Relevant: Protection level:
VSA/HSA 2/4
1107 INVERTER_MAX_CURRENT Reference:
/DM1/
Inverter current transistor limit Relevant: Protection level:
VSA/HSA 2/4
1108 INVERTER_MAX_THERMAL_CURRENT Reference:
/DM1/
Inverter thermal current limit Relevant: Protection level:
VSA/HSA 2/4
1109 INVERTER_MAX_S6_CURRENT Reference:
/DM1/
Inverter current limit, S6 Relevant: Protection level:
HSA 2/4
1111 INVERTER_RATED_CURRENT Reference:
/DM1/
Inverter rated current, Relevant: Protection level:
VSA/HSA 2/4
1112 NUM_POLE_PAIRS Reference:
/DM1/
Motor pole pair number Relevant: Protection level:
VSA 2/4
1113 TORQUE_CURRENT_RATIO Reference:
/DM1/
Torque ratio Relevant: Protection level:
VSA 2/4
Nm/A 0.0 0.0 5.0 FLOAT DWORD POWER ON

1114 EMF_VOLTAGE Reference:
/DM1/
Voltage constant Relevant: Protection level:
VSA 2/4
V 0.0 0.0 300.0 FLOAT DWORD POWER ON
1115 ARMATURE_RESISTANCE Reference:
/DM1/
Armature resistance Relevant: Protection level:
VSA 2/4
Ω 0.0 0.0 20.0 FLOAT DWORD POWER ON
1116 ARMATURE_INDUCTANCE Reference:
/DM1/
Armature inductance Relevant: Protection level:
VSA 2/4
mH 0.0 0.0 100.0 FLOAT DWORD POWER ON
1117 MOTOR_INERTIA Reference:
/DM1/
Motor inertia Relevant: Protection level:
VSA/HSA 2/4
kg m² 0.0 0.0 32.0 FLOAT DWORD POWER ON
1118 MOTOR_STANDSTILL_CURRENT Reference:
/DM1/
Motor standstill current Relevant: Protection level:
VSA 2/4
1119 SERIES_INDUCTANCE Reference:
/DM1/
Series choke inductance Relevant: Protection level:
HSA 2/4
mH 0.0 0.0 65.0 FLOAT DWORD IMMEDIATE
1120 CURRCTRL_GAIN Reference:
/DS1/
Current regulator P-amplification Relevant: Protection level:
VSA/HSA 2/4
V/A 10.0 0.0 10000.0 FLOAT DWORD IMMEDIATE
1121 CURRCTRL_INTEGRATOR_TIME Reference:
/DS1/
Current regulator reaction time Relevant: Protection level:
VSA/HSA 2/4
µs 2000.0 0.0 8000.0 FLOAT DWORD IMMEDIATE

1124 CURRCTRL_REF_MODEL_DELAY Reference:
/DS1/
Current circuit reference model symmetry Relevant: Protection level:
VSA/HSA 2/4
- 0.5 0.0 1.0 FLOAT DWORD IMMEDIATE
0.0 (810D)
1130 MOTOR_NOMINAL_POWER Reference:
/DM1/
Nominal motor power Relevant: Protection level:
VSA/HSA 2/4
kW 0.0 0.0 1500.0 FLOAT DWORD POWER ON
1132 MOTOR_NOMINAL_VOLTAGE Reference:
/DM1/
Nominal motor voltage Relevant: Protection level:
HSA 2/4
V 380 0.0 5000.0 FLOAT DWORD POWER ON
1134 MOTOR_NOMINAL_FREQUENCY Reference:
/DM1/
Nominal motor frequency Relevant: Protection level:
HSA 2/4
Hz 50 0.0 3000.0 FLOAT DWORD POWER ON
1135 MOTOR_NOLOAD_VOLTAGE Reference:
/DM1/
Motor no-load voltage Relevant: Protection level:
HSA 2/4
V 0.0 0.0 500.0 FLOAT DWORD POWER ON
1136 MOTOR_NOLOAD_CURRENT Reference:
/DM1/
Motor no-load current Relevant: Protection level:
HSA 2/4
1137 STATOR_COLD_RESISTANCE Reference:
/DM1/
Stator cold resistance Relevant: Protection level:
HSA 2/4
1138 ROTOR_COLD_RESISTANCE Reference:
/DM1/
Rotor cold resistance Relevant: Protection level:
HSA 2/4

1139 STATOR_LEAKAGE_REACTANCE Reference:
/DM1/
Stator leakage reactance Relevant: Protection level:
HSA 2/4
1140 ROTOR_LEAKAGE_REACTANCE Reference:
/DM1/
Rotor leakage reactance Relevant: Protection level:
HSA 2/4
1141 MAGNETIZING_REACTANCE Reference:
/DM1/
Magnetizing reactance Relevant: Protection level:
HSA 2/4
mΩ 0.0 0.0 1000.0 FLOAT DWORD POWER ON
1142 FIELD_WEAKENING_SPEED Reference:
/DD2/, /DM1/
Field weakening speed Relevant: Protection level:
HSA 2/4
1/min 0.0 0.0 50000.0 FLOAT DWORD POWER ON
1143 LH_CURVE_UPPER_SPEED Reference:
/DD2/, /DM1/
Upper speed LH curve Relevant: Protection level:
HSA 2/4
1144 LH_CURVE_GAIN Reference:
/DD2/, /DM1/
LH curve gain Relevant: Protection level:
HSA 2/4
% 100.0 100.0 500.0 FLOAT DWORD POWER ON
1145 STALL_TORQUE_REDUCTION Reference:
/DÜ1/
Stall torque reduction factor Relevant: Protection level:
HSA 2/4
% 100.0 5.0 1000.0 FLOAT DWORD IMMEDIATE
1146 MOTOR_MAX_ALLOWED_SPEED Reference:
/DM1/
Maximum motor speed Relevant: Protection level:
VSA/HSA 2/4
1/min 1500 0.0 50000.0 FLOAT DWORD POWER ON

1147 SPEED_LIMIT Reference:
/DÜ1/
Speed limit Relevant: Protection level:
VSA/HSA 2/4
1/min 7000.0/8000.0 0.0 50000.0 FLOAT DWORD IMMEDIATE
1150 FIELDCTRL_GAIN Reference:
/DS1/
Pre-amplifier field control gain Relevant: Protection level:
HSA 2/4
A/Vs 400.0 0.0 100000.0 FLOAT DWORD IMMEDIATE
1151 FIELDCTRL_INTEGRATOR_TIME Reference:
/DS1/
Field control integrator time Relevant: Protection level:
HSA 2/4
ms 10.0 0.0 500.0 FLOAT DWORD IMMEDIATE
1160 FIELDVAL_WEAKENING_SPEED Reference:
/DS1/
Weakening speed field evaluation Relevant: Protection level:
HSA 2/4
1161 FIELDVAL_FIXED_LINK_VOLTAGE Reference:
/DS1/
Fixed link voltage evaluation Relevant: Protection level:
HSA 2/4
V 600 0 700 UNS. WORD IMMEDIATE
0 (810D)
1191 TORQUE_LIMIT_ADAPT_SERVO Reference:
/IAD/
Servo torque limit adapter (not 810D) Relevant: Protection level:
VSA/HSA 2/4
1200 NUM_URRENT_FILTERS[n] Reference:
/DD2/
Number of current filters [Drive parameter block]: 0...7 Relevant: Protection level:
VSA/HSA 2/4
- 1 0 4 UNS. WORD IMMEDIATE
0 (810D)
1201 CURRENT_FILTER_CONFIG[n] Reference:
/DD2/
Current filter configuration [Drive parameter block]: 0...7 Relevant: Protection level:
VSA/HSA 2/4
HEX Low pass Low pass Band disable WORD IMMEDIATE
0 0 FFFF

1202 CURRENT_FILTER_1_FREQUENCY[n] Reference:
/DD2/
Current filter 1 frequency [Drive parameter block]: 0...7 Relevant: Protection level:
VSA/HSA 2/4
Hz 2000.0 0.0 8000.0 FLOAT DWORD IMMEDIATE
0.0 (810D) 3999.0 (810D)
1203 CURRENT_FILTER_1_DAMPING[n] Reference:
/DD2/
Current filter 1 damping [Drive parameter block]: 0...7 Relevant: Protection level:
VSA/HSA 2/4
1.0 (810D)
/DD2/
Current filter 2 frequency 2 [Drive parameter block]: 0...7 Relevant: Protection level:
VSA/HSA 2/4
1999.0 (810D)
/DD2/
VSA/HSA 2/4
/DD2/
Current filter 3 frequency [Drive parameter block]: 0...7 Relevant: Protection level:
VSA/HSA 2/4
1999.0 (810D)
/DD2/
VSA/HSA 2/4
/DD2/
Current filter 4 frequency 4 [Drive parameter block]: 0...7 Relevant: Protection level:
VSA/HSA 2/4
1999.0 (810D)

/DD2/
VSA/HSA 2/4
1210 CURRENT_FILTER_1_SUPPR_FREQ[n] Reference:
/DD2/
Current filter 1 frequency suppression [Drive parameter block]: Relevant: Protection level:
0...7 VSA/HSA 2/4
3999.0 (810D)
1211 CURRENT_FILTER_1_BANDWIDTH[n] Reference:
/DD2/
Current filter 1 band width [Drive parameter block]: 0...7 Relevant: Protection level:
VSA/HSA 2/4
400.0 (810D) 3999.0 (810D)
1212 CURRENT_FILTER_1_BW_NUM[n] Reference:
/DD2/
Current filter 1 band width counter Relevant: Protection level:
[Drive parameter block]: 0...7 VSA/HSA 2/4
3999.0 (810D)
/DD2/
0...7 VSA/HSA 2/4
1200.0 (810D) 1999.0 (810D)
/DD2/
VSA/HSA 2/4
400.0 (810D) 1999.0 (810D)
/DD2/
1999.0 (810D)

/DD2/
0...7 VSA/HSA 2/4
1200.0 (810D) 1999.0 (810D)
/DD2/
VSA/HSA 2/4
400.0 (810D) 1999.0 (810D)
/DD2/
1999.0 (810D)
/DD2/
0...7 VSA/HSA 2/4
1200.0 (810D) 1999.0 (810D)
/DD2/
VSA/HSA 2/4
400.0 (810D) 1999.0 (810D)
/DD2/
1999.0 (810D)
1230 TORQUE_LIMIT_1[n] Reference:
/DÜ1/
1st torque limit [Drive parameter block]: 0...7 Relevant: Protection level:
VSA/HSA 2/4

1231 TORQUE_LIMIT_2 Reference:
/IAD/
2nd torque limit (not 810D) Relevant: Protection level:
VSA/HSA 2/4
1232 TORQUE_LIMIT_SWITCH_SPEED Reference:
/IAD/
Torque switch speed from Md1 to Md2 (not 810D) Relevant: Protection level:
VSA/HSA 2/4
1/min 6000.0 0.0 50000.0 FLOAT DWORD IMMEDIATE
1233 TORQUE_LIMIT_GENERATOR[n] Reference:
/IAD/
Generator limit [Drive parameter block]: 0...7 Relevant: Protection level:
(not 810D) VSA/HSA 2/4
1234 TORQUE_LIMIT_SWITCH_HYST Reference:
/IAD/
Torque switch limit hysteresis MD 1232 (not 810D) Relevant: Protection level:
VSA/HSA 2/4
1235 POWER_LIMIT_1[n] Reference:
/DÜ1/
1st Power limit [Drive parameter block]: 0...7 Relevant: Protection level:
VSA/HSA 2/4
1236 POWER_LIMIT_2 Reference:
/IAD/
2nd power limit (not 810D) Relevant: Protection level:
VSA/HSA 2/4
1237 POWER_LIMIT_GENERATOR Reference:
/DÜ1/
Generator power limit Relevant: Protection level:
VSA/HSA 2/4
kW 100.0 0.3 500.0 FLOAT DWORD IMMEDIATE
1238 CURRENT_LIMIT Reference:
/DÜ1/
Current limit Relevant: Protection level:
HSA 2/4

1239 TORQUE_LIMIT_FOR_SETUP Reference:
/DÜ1/
Torque limit for set-up Relevant: Protection level:
VSA/HSA 2/4
1245 CURRENT_SMOOTH_SPEED Reference:
/IAD/
Threshold for current smoothing Relevant: Protection level:
VSA/HSA 2/4
1246 CURRENT_SMOOTH_HYSTERESIS Reference:
/IAD/
Smooth speed current hysteresis Relevant: Protection level:
1250 ACTUAL_CURRENT_FILTER_FREQ Reference:
/DB1/
Actual current filter frequency Relevant: Protection level:
VSA/HSA 2/4
3999.0 (810D)
1252 TORQUE_FILTER_FREQUENCY Reference:
/DB1/
Torque filter frequency Relevant: Protection level:
VSA/HSA 2/4
3999.0 (810D)
1254 SPACE_VECTOR_FILTER_TIME Reference:
/DÜ1/
Space vector filter time Relevant: Protection level:
VSA/HSA 2/4
1400 MOTOR_RATED_SPEED Reference:
/DM1/
Motor speed rating Relevant: Protection level:
VSA/HSA 2/4
1/min 1450 0.0 25000.0 FLOAT DWORD POWER ON
1401 MOTOR_MAX_SPEED[n] Reference:
/DD1/
Maximum motor speed [Drive parameter block]: 0...7 Relevant: Protection level:
VSA/HSA 2/4

1403 PULSE_SUPPRESSION_SPEED Reference:
/DB1/
Pulse suppression speed Relevant: Protection level:
VSA/HSA 2/4
1404 PULSE_SUPPRESSION_DELAY Reference:
/DB1/
Pulse suppression delay step Relevant: Protection level:
VSA/HSA 2/4
ms 100.0/5000.0 0.0 100000.0 FLOAT DWORD IMMEDIATE
1405 MOTOR_SPEED_LIMIT[n] Reference:
/DÜ1/
Motor speed limit [Drive parameter block]: 0...7 Relevant: Protection level:
VSA/HSA 2/4
1406 SPEEDCTRL_TYPE Reference:
/IAD/
Speed limiter type (not 810D) Relevant: Protection level:
VSA/HSA 2/4
1407 SPEEDCTRL_GAIN_1[n] Reference:
/DD2/
Speed control gain [Drive parameter block]: 0...7 Relevant: Protection level:
VSA/HSA 2/4
Nm/s-1 0.3 0.0 100000.0 FLOAT DWORD IMMEDIATE
1408 SPEEDCTRL_GAIN_2[n] Reference:
/DD2/
Speed control gain, upper speed control Relevant: Protection level:
Nm/s-1 0.3 0.0 100000.0 FLOAT DWORD IMMEDIATE
1409 SPEEDCTRL_INTEGRATOR_TIME_1[n] Reference:
/DD2/
Speed control integrator time [Drive parameter block]: 0...7 Relevant: Protection level:
VSA/HSA 2/4
1410 SPEEDCTRL_INTEGRATOR_TIME_2[n] Reference:
/DD2/
Speed control integrator time, upper speed control Relevant: Protection level:

1411 SPEEDCTRL_ADAPT_SPEED_1 Reference:
/DD2/
Speed control adaptation, lower speed Relevant: Protection level:
VSA/HSA 2/4
1412 SPEEDCTRL_ADAPT_SPEED_2 Reference:
/DD2/
Speed control adaptation, upper speed Relevant: Protection level:
VSA/HSA 2/4
1413 SPEEDCTRL_ADAPT_ENABLE Reference:
/DD2/
Speed control adaptation selection Relevant: Protection level:
VSA/HSA 2/4
1414 SPEEDCTRL_REF_MODEL_FREQ[n] Reference:
/IAD/
Speed control reference model frequency [Drive parameter block]: Relevant: Protection level:
0...7 (not 810D) VSA/HSA 2/4
1415 SPEEDCTRL_REF_MODEL_DAMPING[n] Reference:
/IAD/
Speed control reference model damping [Drive parameter block]: Relevant: Protection level:
0...7 (not 810D) VSA/HSA 2/4
1416 SPEEDCTRL_REF_MODEL_DELAY Reference:
/IAD/
Speed control reference model delay (not 810D) Relevant: Protection level:
VSA/HSA 2/4
1417 SPEED_THRESHOLD_X[n] Reference:
/DB1/
Speed threshold -nx for nist < nx signal [Drive parameter block]: Relevant: Protection level:
0...7 VSA/HSA 2/4
1418 SPEED_THRESHOLD_MIN[n] Reference:
/DB1/
Speed threshold - nmin for nist < nmin signal [Drive parameter block]: Relevant: Protection level:
0...7 VSA/HSA 2/4

1420 MOTOR_MAX_SPEED_SETUP Reference:
/IAD/, /DÜ1/
Maximum motor speed for set-up Relevant: Protection level:
VSA/HSA 2/4
1421 SPEEDCTRL_INTEGRATOR_FEEDBK[n] Reference:
/DD2/
Speed control integrator feedback [Drive parameter block]: 0...7 Relevant: Protection level:
VSA/HSA 2/4
1424 SPEED_FFW_FILTER_TIME Reference:
/IAD/
Speed FFW filter symmetry (not 810D) Relevant: Protection level:
VSA/HSA 2/4
µs 0.0 0.0 50000.0 FLOAT DWORD IMMEDIATE
1425 SPEED_FFW_DELAY Reference:
/IAD/
Speed FFW delay symmetry (not 810D) Relevant: Protection level:
VSA/HSA 2/4
1426 SPEED_DES_EQ_ACT_TOL[n] Reference:
/DB1/
Tolerance band width for nsoll = nist signal [Drive parameter block]: Relevant: Protection level:
0...7 VSA/HSA 2/4
1427 SPEED_DES_EQ_ACT_DELAY Reference:
/DB1/
Delay time nnom = nact signal Relevant: Protection level:
VSA/HSA 2/4
1428 TORQUE_TRESHOLD_X[n] Reference:
/DB1/
Torque threshold Md < Mdx signal Relevant: Protection level:
1429 TORQUE_TRESHOLD_X_DELAY Reference:
/DB1/
Torque threshold delay time Md < Mdx signal Relevant: Protection level:
VSA/HSA 2/4

1500 NUM_SPEED_FILTERS[n] Reference:
/DD2/
Number of speed filters [Drive parameter block]: 0...7 Relevant: Protection level:
VSA/HSA 2/4
1 (810D)
1501 SPEED_FILTER_TYPE[n] Reference:
/IAD/
Type of speed filter [Drive parameter block]: 0...7 Relevant: Protection level:
HEX 0000 0000 0303 WORD IMMEDIATE
1502 SPEED_FILTER_1_TIME[n] Reference:
/DD2/
Speed filter 1 time Relevant: Protection level:
Drive parameter block]: 0...7 VSA/HSA 2/4
1503 SPEED_FILTER_2_TIME[n] Reference:
/IAD/
Speed filter 2 time Relevant: Protection level:
Drive parameter block]: 0...7 (not 810D) VSA/HSA 2/4
1506 SPEED_FILTER_1_FREQUENCY[n] Reference:
/IAD/
Speed filter 1 frequency Relevant: Protection level:
1507 SPEED_FILTER_1_DAMPING[n] Reference:
/IAD/
Speed filter 1 damping Relevant: Protection level:
1508 SPEED_FILTER_2_FREQUENCY[n] Reference:
/IAD/
1509 SPEED_FILTER_2_DAMPING[n] Reference:
/IAD/
Speed filter 2 damping Relevant: Protection level:

1514 SPEED_FILTER_1_SUPPR_FREQ[n] Reference:
/IAD/
Speed filter 1 suppression frequency Relevant: Protection level:
1515 SPEED_FILTER_1_BANDWIDTH[n] Reference:
/IAD/
Speed filter 1 band width [Drive parameter block]: 0...7 Relevant: Protection level:
1516 SPEED_FILTER_1_BW_NUM[n] Reference:
/IAD/
Speed filter 1 band width counter Relevant: Protection level:
1517 SPEED_FILTER_2_SUPPR_FREQ[n] Reference:
/IAD/
1518 SPEED_FILTER_2_BANDWIDTH[n] Reference:
/IAD/
Speed filter 2 band width [Drive parameter block]: 0...7 Relevant: Protection level:
1519 SPEED_FILTER_2_BW_NUM[n] Reference:
/IAD/
Speed filter 2 band width counter Relevant: Protection level:
1520 SPEED_FILTER_1_BS_FREQ Reference:
/IAD/
Speed filter 1 band frequency suppression (not 810D) Relevant: Protection level:
VSA/HSA 2/4
1521 SPEED_FILTER_2_BS_FREQ Reference:
/IAD/
Speed filter 2 band frequency suppression (not 810D) Relevant: Protection level:
VSA/HSA 2/4

1600 ALARM_MASK_POWER_ON Reference:
/DB1/
Suppressable alarms (Power ON ) Relevant: Protection level:
VSA/HSA 2/4
1601 ALARM_MASK_RESET Reference:
/DB1/
Suppressable alarms (RESET) Relevant: Protection level:
VSA/HSA 2/4
1602 MOTOR_TEMP_WARN_LIMIT Reference:
/DM1/, /DÜ1/
Motor temperature warning limit Relevant: Protection level:
VSA/HSA 2/4
°C 120 0 200 UNS. WORD IMMEDIATE
1603 MOTOR_TEMP_ALARM_TIME Reference:
/DÜ1/
Motor temperature alarm time Relevant: Protection level:
VSA/HSA 2/4
s 240 0 600 UNS. WORD IMMEDIATE
1604 LINK_VOLTAGE_WARN_LIMIT Reference:
/DÜ1/
Link voltage warning limit Relevant: Protection level:
VSA/HSA 2/4
1605 SPEEDCTRL_LIMIT_TIME Reference:
/DÜ1/
Speed control limit time Relevant: Protection level:
VSA/HSA 2/4
1606 SPEEDCTRL_LIMIT_TRESHOLD Reference:
/DÜ1/
Speed control limit threshold Relevant: Protection level:
VSA/HSA 2/4
1607 MOTOR_TEMP_SHUTDOWN_LIMIT Reference:
/DÜ1/
Motor temperature shutdown limit Relevant: Protection level:
VSA/HSA 2/4

1608 MOTOR_FIXED_TEMPERATURE Reference:
/DÜ1/
Fixed motor temperature Relevant: Protection level:
VSA/HSA 2/4
1610 DIAGNOSIS_ACTIVATION_FLAGS Reference:
/IAD/
Diagnostic functions (not 810D) Relevant: Protection level:
VSA/HSA 2/4
HEX 0000 0000 0001 WORD POWER ON
1611 DNDT_TRESHOLD Reference:
/IAD/
DN/TN response threshold Relevant: Protection level:
VSA/HSA 2/4
% 800 0 1600 - IMMEDIATE
1612 ALARM_REACTION_POWER_ON Reference:
/DB1/
Power ON alarm reaction time Relevant: Protection level:
VSA/HSA 2/4
HEX 0DBC/FFFF 0000 FFFF WORD IMMEDIATE
0DB2/FFFF (810D)
1613 ALARM_REACTION_RESET Reference:
/DB1/
RESET Alarm reaction Relevant: Protection level:
VSA/HSA 2/4
HEX 0100/FFFF 0000 FFFF WORD IMMEDIATE
1615 SMOTH_RUN_TOL Reference:
Reserved
Truth-of-rotation monitoring Relevant: Protection level:
VSA/HSA 2/4
1620 PROG_SIGNAL_FLAGS Reference:
/IAD/
Bits for variable report functions (not 810D) Relevant: Protection level:
VSA/HSA 2/4
1621 PROG_SIGNAL_NR Reference:
/IAD/
Signal number of variable report functions (not 810D) Relevant: Protection level:
VSA/HSA 2/4

1622 PROG_SIGNAL_ADDRESS Reference:
/IAD/
Address of variable signal functions (not 810D) Relevant: Protection level:
VSA/HSA 2/4
HEX 0000 0000 FFFF UNS. WORD IMMEDIATE
1623 PROG_SIGNAL_TRESHOLD Reference:
/IAD/
Program signal threshold (not 810D) Relevant: Protection level:
VSA/HSA 2/4
HEX 000000 000000 FFFFFF UNS. WORD IMMEDIATE
1624 PROG_SIGNAL_HYSTERESIS Reference:
/IAD/
Program signal hysteresis (not 810D) Relevant: Protection level:
VSA/HSA 2/4
HEX 0000 0000 FFFF - IMMEDIATE
1625 PROG_SIGNAL_ON_DELAY Reference:
/IAD/
Program signal on delay (not 810D) Relevant: Protection level:
VSA/HSA 2/4
ms 0 0 10000 UNS. WORD IMMEDIATE
1626 PROG_SIGNAL_OFF_DELAY Reference:
/IAD/
Program signal off delay (not 810D) Relevant: Protection level:
VSA/HSA 2/4
1630 LINK_VOLTAGE_MON_TRESHOLD Reference:
/IAD/
Link voltage monitor threshold (not 810D) Relevant: Protection level:
VSA/HSA 2/4
1631 LINK_VOLTAGE_GEN_ON Reference:
/IAD/
Link voltage generation on (not 810D) Relevant: Protection level:
VSA/HSA 2/4
1632 LINK_VOLTAGE_GEN_HYST Reference:
/IAD/
Link voltage generation hysteresis (not 810D) Relevant: Protection level:
VSA/HSA 2/4

1633 LINK_VOLTAGE_GEN_OFF Reference:
/IAD/
Link voltage generation off (not 810D) Relevant: Protection level:
VSA/HSA 2/4
1634 LINK_VOLTAGE_RETRACT Reference:
/IAD/
Link voltage retract (not 810D) Relevant: Protection level:
VSA/HSA 2/4
1635 GEN_AXIS_MIN_SPEED Reference:
/IAD/
Minimum generator axis speed (not 810D) Relevant: Protection level:
VSA/HSA 2/4
1636 RETRACT_MODE Reference:
/IAD/
Emergency retract mode drive operation (not 810D) Relevant: Protection level:
VSA/HSA 2/4
1637 GEN_STOP_DELAY Reference:
/IAD/
Generator stop delay (not 810D) Relevant: Protection level:
VSA/HSA 2/4
1638 RETRACT_TIME Reference:
/IAD/
Emergency retract time (not 810D) Relevant: Protection level:
VSA/HSA 2/4
1639 RETRACT_SPEED Reference:
/IAD/
Emergency retract speed (not 810D) Relevant: Protection level:
VSA/HSA 2/4
1/min 0.0 -50000.0 50000.0 FLOAT DWORD IMMEDIATE
1650 DIAGNOSIS_CONTROL_FLAGS Reference:
/IAD/
Diagnostic control flags (not 810D) Relevant: Protection level:
VSA/HSA 2/4

1651 MINMAX_SIGNAL_NR Reference:
/IAD/
Min/max memory signal number (not 810D) Relevant: Protection level:
VSA/HSA 2/4
1652 MINMAX_ADDRESS Reference:
/IAD/
Min/max memory cell (not 810D) Relevant: Protection level:
VSA/HSA 2/4
1653 MINMAX_MIN_VALUE Reference:
/IAD/
Min/max minimum memory value (not 810D) Relevant: Protection level:
VSA/HSA 2/4
HEX 00000000 00000000 FFFFFFFF UNS. WORD IMMEDIATE
1654 MINMAX_MAX_VALUE Reference:
/IAD/
Min/max maximum memory value (not 810D) Relevant: Protection level:
VSA/HSA 2/4
1655 MONITOR_SEGMENT Reference:
/DD1/
Monitor memory segment Relevant: Protection level:
VSA/HSA 2/4
1656 MONITOR_ADDRESS Reference:
/DD1/
Monitor memory address Relevant: Protection level:
VSA/HSA 2/4
1657 MONITOR_DISPLAY Reference:
/DD1/
Monitor value display Relevant: Protection level:
VSA/HSA 2/4
1658 MONITOR_INPUT_VALUE Reference:
/DD1/
Monitor input value Relevant: Protection level:
VSA/HSA 2/4

1659 MONITOR_INPUT_STROBE Reference:
/DD1/
Monitor input strobe Relevant: Protection level:
VSA/HSA 2/4
1660 UF_MODE_FREQUENCY Reference:
/IAD/
UF mode motor frequency (not 810D) Relevant: Protection level:
VSA/HSA 2/4
Hz 0.0 -2000.0 2000.0 FLOAT DWORD IMMEDIATE
1661 UF_MODE_RATIO Reference:
/IAD/
UF mode ratio (not 810D) Relevant: Protection level:
VSA/HSA 2/4
V/Hz 0.0 2.4 100.0 FLOAT DWORD IMMEDIATE
1662 UF_MODE_DELTA_FREQUENCY Reference:
/IAD/
UF mode delta frequency (not 810D) Relevant: Protection level:
VSA/HSA 2/4
Hz/s 5.0 0.0 10000.0 FLOAT DWORD IMMEDIATE
1665 IPO_SPEEDCTRL_DELAY_FACTOR Reference:
/IAD/
IPO speed control delay factor (not 810D) Relevant: Protection level:
VSA/HSA 2/4
1700 TERMINAL_STATE Reference:
/DD1/
Terminal status, binary I/O’s Relevant: Protection level:
VSA/HSA 2/4
1701 LINK_VOLTAGE Reference:
/DD1/
Link voltage (intermediate circuit) Relevant: Protection level:
VSA/HSA 2/4
1702 MOTOR_TEMPERATURE Reference:
/DD1/
Motor temperature Relevant: Protection level:
VSA/HSA 2/4
°C 0 0 32767 SIGNED WORD IMMEDIATE

1703 LEAD_TIME_MOTOR_ENC Reference:
/DD1/
Motor encoder lead time Relevant: Protection level:
VSA/HSA 2/4
µs 0 0 32767 UNS. WORD IMMEDIATE
1704 LEAD_TIME_DIRECT_ENC Reference:
/DG1/
Direct encoder lead time Relevant: Protection level:
VSA/HSA 2/4
µs 0 0 32767 UNS. WORD IMMEDIATE
1706 DESIRED_SPEED Reference:
/DD1/
Desired speed Relevant: Protection level:
VSA/HSA 2/4
1707 ACTUAL_SPEED Reference:
/DD1/
Actual speed, direct motor measuring system conversion Relevant: Protection level:
VSA/HSA 2/4
1708 ACTUAL_CURRENT Reference:
/DD1/
Actual smoothed current Relevant: Protection level:
VSA/HSA 2/4
1709 VOLTAGE_LSB Reference:
/DD1/
Voltage display value Relevant: Protection level:
VSA/HSA 2/4
µV 0.0 0.0 32767.0 FLOAT DWORD POWER ON
1710 CURRENT_LSB Reference:
/DD1/
Current display value Relevant: Protection level:
VSA/HSA 2/4
µA 0.0 0.0 32767.0 FLOAT DWORD IMMEDIATE
1711 SPEED_LSB Reference:
/DD1/
Speed display value Relevant: Protection level:
VSA/HSA 2/4

1712 ROTOR_FLUX_LSB Reference:
/DD1/
Rotor flux display value Relevant: Protection level:
VSA/HSA 2/4
µVs 0.0 0.0 32767.0 FLOAT DWORD IMMEDIATE
1713 TORQUE_LSB Reference:
/DD1/
Torque display value Relevant: Protection level:
VSA/HSA 2/4
µNm 0.0 0.0 32767.0 FLOAT DWORD IMMEDIATE
1714 ROTOR_POS_LSB Reference:
/DD1/
Rotor position display value Relevant: Protection level:
VSA/HSA 2/4
Degree 0.0 0.0 32767.0 FLOAT DWORD IMMEDIATE
1720 CRC_DIAGNOSIS Reference:
/DD1/
CRC diagnostic parameter Relevant: Protection level:
VSA/HSA 2/4
1721 ACCEL_DIAGNOSIS Reference:
res.
Acceleration diagnosis Relevant: Protection level:
VSA/HSA 2/4
1722 LOAD Reference:
/DD1/
Load Relevant: Protection level:
VSA/HSA 2/4
% 0 0 32767 FLOAT DWORD IMMEDIATE
1723 ACTUAL_RAMP_TIME Reference:
Reserved
Actual ramp time diagnosis Relevant: Protection level:
VSA/HSA 2/4
ms 0.0 0.0 32767.0 UNS. WORD IMMEDIATE
1724 SMOOTH_RUN_DIAGNOSIS Reference:
Reserved
Smooth run diagnosis Relevant: Protection level:
VSA/HSA 2/4
- 0.0 0.0 32767.0 UNS. WORD IMMEDIATE

1725 MAX_TORQUE_FROM_NC Reference:
/DD1/
Standardization maximum torque from NC Relevant: Protection level:
VSA/HSA 2/4
Nm 0.0 -100000.0 100000.0 FLOAT DWORD IMMEDIATE
1730 OPERATING_MODE Reference:
/IAD/
Operating mode display Relevant: Protection level:
VSA/HSA 2/4
- 0.0 0.0 32767.0 UNS. WORD IMMEDIATE
1731 CL1_PO_IMAGE Reference:
/DB1/
CL1 PO image register Relevant: Protection level:
VSA/HSA 2/4
1732 CL1_RES_IMAGE Reference:
/DB1/
CL1 RES image register Relevant: Protection level:
VSA/HSA 2/4
1733 LPFC_DIAGNOSIS Reference:
/DD1/
NPFK diagnostics Relevant: Protection level:
VSA/HSA 2/4
1790 ENC_TYPE_MOTOR Reference:
/DG1/
Motor encoder type, indirect measuring system Relevant: Protection level:
VSA/HSA 2/4
- 0 0 32767 SIGNED WORD IMMEDIATE
1791 ENC_TYPE_DIRECT Reference:
/DG1/
Encoder type, direct measuring system Relevant: Protection level:
VSA/HSA 2/4
- 0 0 32767 SIGNED WORD IMMEDIATE
1797 PBL_VERSION Reference:
/DD1/
Data version Relevant: Protection level:
VSA/HSA 2/4

1798 FIRMWARE_DATE Reference:
/DD1/
Firmware date Relevant: Protection level:
VSA/HSA 2/4
1799 FIRMWARE_VERSION Reference:
/DD1/
Firmware version Relevant: Protection level:
VSA/HSA 2/4
The HSA (main spindle) drive data of the 2nd motor are listed as
follows:
The relevance of the 2nd motor’s MDs is identical to that of the first
motor. See explanation for 1st motor.
MD No. Title
2005 ENC_RESOL_MOTOR_M2
2102 MOTOR_CODE_M2
2103 MOTOR_NOMINAL_CURRENT_M2
2117 MOTOR_INERTIA_M2
2120 CURRCTRL_GAIN_M2
2121 CURRCTRL_INTEGRATOR_TIME_M2
2130 MOTOR_NOMINAL_POWER_M2
2132 MOTOR_NOMINAL_VOLTAGE_M2
2134 MOTOR_NOMINAL_FREQUENCY_M2
2135 MOTOR_NOLOAD_VOLTAGE_M2
2136 MOTOR_NOLOAD_CURRENT_M2
2137 STATOR_COLD_RESISTANCE_M2
2138 ROTOR_COLD_RESISTANCE_M2
2139 STATOR_LEAKAGE_REACTANCE_M2
2140 ROTOR_LEAKAGE_REACTANCE_M2
2141 MAGNETIZING_REACTANCE_M2
2142 FIELD_WEAKENING_SPEED_M2
2143 LH_CURVE_UPPER_SPEED_M2
2144 LH_CUREVE_GAIN_M2
2145 STALL_TORQUE_REDUCTION_M2
2146 MOTOR_MAX_ALLOWED_SPEED_M2
2147 SPEED_LIMIT_M2
2150 FIELDCTRL_GAIN_M2
2151 FIELDCTRL_INTEGR_TIME_M2
2160 FIELDVAL_WEAKENING_SPEED_M2
2190 TORQUE_LIMIT_FROM_NC_M2
2230 TORQUE_LIMIT_1_M2

2231 TORQUE_LIMIT_2_M2
2232 TORQUE_LIMIT_SWITCH_SPD_M2
2233 TORQUE_LIMIT_GENERATOR_M2
2234 TORQUE_LIMIT_SWITCH_HYST_M2
2235 POWER_LIMIT_1_M2
2236 POWER_LIMIT_2_M2
2238 CURRENT_LIMIT_M2
2239 TORQUE_LIMIT_FOR_SETUP_M2
2245 CURRENT_SMOOTCH_SPEED_M2
2246 CURRENT_SMOOTH_HYST_M2
2400 MOTOR_RATED_SPEED_M2
2401 MOTOR_MAX_SPEED_M"
2403 PULSE_SUPPRESSION_SPEED_M2
2405 MOTOR_SPEED_LIMIT_M2
2407 SPEEDCTRL_GAIN_1_M2
2408 SPEEDCTRL_GAIN_2_M2
2409 SPEEDCTRL_INTEGR_TIME_1_M2
2410 SPEEDCTRL_INTEGR_TIME_2_M2
2411 SPEEDCTRL_ADAPT_SPEED_1_M2
2412 SPEEDCTRL_ADAPT_SPEED_2_M2
2413 SPEEDCTRL_ADAPT_ENABLE_M2
2417 SPEED_TRESHOLD_X_M2
2418 SPEED_TRSHOLD_MIN_M2
2426 SPEED_DES_EQ_ACT_TOL_M2
2602 MOTOR_TEMP_WARN_LIMIT_M2
2607 MOTOR_TEMP_SHUTDOWN_LIM_M2
2608 MOTOR_FIXED_TEMPERATURE_M2
2711 SPEED_LSB_M2
2712 ROTOR_FLUX_LSB_M2
2713 TORQUE_LSB_M2
2725 MAX_TORQUE_FROM_NC_M2

3.2 General machine data
System settings
Number MD identifier Reference

Unit Name, other information Effect
HW / Function Standard value Minimum value Maximum value D-Type Prot.
10000 AXCONF_MACHAX_NAME_TAB K2
- Machine axis name [axis no.]: 0...7 POWER ON
_always X1, Y1, Z1, A1, B1,C1, *** *** STRING 2/7
U1, V1, , , ...
10010 ASSIGN_CHAN_TO_MODE_GROUP K1
- Channel valid in mode group [channel no.]: 0, 1 POWER ON
_always 1, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 1 DWORD 2/7
0, ...
10050 SYSCLOCK_CYCLE_TIME G2
s Basic system cycle POWER ON
_always DOUBLE 2/7
NCU570 0.006 0.004 0.032 DOUBLE 2/7
NCU571 0.006 0.002 0.032 DOUBLE 2/7
NCU572 0.004 0.000125 0.032 DOUBLE 2/7
NCU573 0.002 0.000125 0.032 DOUBLE 2/7
810D 0.0025 0.000625 0.04 DOUBLE 2/7
10060 POSCTRL_SYSCLOCK_TIME_RATIO G2
Factor * Factor for position control cycle POWER ON
MD10050
_always 1 1 100 DWORD 0/0
NCU570 1 1 1 DWORD 2/7
10070 IPO_SYSCLOCK_TIME_RATIO G2
Factor * Factor for interpolation cycle POWER ON
MD10050
_always 1 100 DWORD 2/7
NCU572, 573 3 1 100 DWORD 2/7
NCU571 3 1 100 DWORD 2/7
NCU570 3 1 100 DWORD 2/7
810D 4 1 100 DWORD 2/7
10072 COM_IPO_TIME_RATIO -
- Division ratio between interpolation and communications task POWER ON
Communic. task 1 1 100 DWORD 0/0

10080 SYSCLOCK_SAMPL_TIME_RATIO -
- Division factor of position control cycle for actual value acquisition POWER ON
_always DWORD 0/0
NCU572 4 1 32 DWORD 2/7
NCU573 2 1 32 DWORD 2/7
NCU571 6 1 32 DWORD 2/7
NCU570.1 1 1 1 DWORD 0/7
NCU570.2 32 1 64 DWORD 0/7
810D 2 1 32 DWORD 2/7
10082 CTRLOUT_LEAD_TIME -
% Shift of setpoint transfer time POWER ON
_always 0.0 0.0 100.0 DOUBLE 0/0
10100 PLC_CYCLIC_TIMEOUT P3
s Maximum PLC cycle time POWER ON
_always 0.050 0.0 plus DOUBLE 2/7
NCU570 0.100 0.0 plus DOUBLE 2/7
10110 PLC_CYCLE_TIME_AVERAGE B1
s Maximum PLC acknowledgement time POWER ON
10120 PLC_RUNNINGUP_TIMEOUT H2
s Monitoring time for PLC power up POWER ON
10130 TIME_LIMIT_NETTO_COM_TASK OEM
s Runtime of communication to MMC POWER ON
_always .001 0.100 DOUBLE 1/7
NCU572, 573 0.005 .001 0.100 DOUBLE 2/7
NCU571 0.012 .001 0.100 DOUBLE 2/7
NCU570 0.012 .001 0.100 DOUBLE 2/7
810D 0.005 .001 0.100 DOUBLE 2/7
10132 MMC_CMD_TIMEOUT PA, M4
s Monitoring time for MMC command in the part program POWER ON
_always 1.0 0.0 100.0 DOUBLE 2/7
10134 MM_NUM_MMC_UNITS B3
- Number of MMC communication stations possible simultaneously POWER ON
NCU572, 573 6 1 10 DWORD 2/7
NCU571 3 1 10 DWORD 2/7
NCU570 4 1 10 DWORD 2/7
810D 3 1 10 DWORD 2/7

10140 TIME_LIMIT_NETTO_DRIVE_TASK -
s Runtime limit of drive communications sub-task POWER ON
611D 0.010 .001 0.100 DOUBLE 1/7
10150 PREP_DRIVE_TASK_CYCLE_RATIO -
- Division ratio drive communication task in non-cyclic time level POWER ON
611D 2 1 50 DWORD 1/7
10160 PREP_COM_TASK_CYCLE_RATIO -
- Indexing ratio drive communications task on non-cyclic time level POWER ON
10200 INT_INCR_PER_MM G2
- Computational resolution for linear positions POWER ON
_always 1000 0 *** DOUBLE 2/7
10210 INT_INCR_PER_DEG G2
- Computational resolution for angular positions POWER ON
10220 SCALING_USER_DEF_MASK G2
HEX Activation of standardizing factors POWER ON
_always 0x200 0 0x1FFF DWORD 2/7
10230 SCALING_FACTORS_USER_DEF G2
- Standardizing factors of physical variables [index number]: 0...12 POWER ON
_always 1.0, 1.0, 1.0, 1.0, 1.0, 0.0 plus DOUBLE 2/7
1.0, 1.0, ...
10240 SCALING_SYSTEM_IS_METRIC G2
- Basic system metric POWER ON
_always 1 *** *** BOOLEAN 2/7
10250 SCALING_VALUE_INCH G2
- Conversion factor for conversion to INCH system POWER ON
10300 FASTIO_ANA_NUM_INPUTS A2
- Number of active analog NCK inputs POWER ON
_always 0 0 8 BYTE 2/7
10310 FASTIO_ANA_NUM_OUTPUTS A2
- Number of active analog NCK outputs POWER ON
10320 FASTIO_ANA_INPUT_WEIGHT A2
- Evaluation factor for analog NCK inputs (analog input]: 0...7 POWER ON
_always 10000, 10000, 10000, 1 10000000 DWORD 2/7
10000, 10000, ...
NCU570 11851, 11851, 11851, 1 10000000 DWORD 2/7
11851, 11851, ...

10330 FASTIO_ANA_OUTPUT_WEIGHT A2
- Evaluation factor for analog NCK outputs (analog output]: 0...7 POWER ON
_always 10000, 10000, 10000, 1 10000000 DWORD 2/7
10000, 10000, ...
NCU570 11852, 11852, 11852, 1 10000000 DWORD 2/7
11852, 11852, ...
10350 FASTIO_DIG_NUM_INPUTS A2
- Number of active digital NCK input bytes POWER ON
10360 FASTIO_DIG_NUM_OUTPUTS A2
- Number of active digital NCK output bytes POWER ON
10362 HW_ASSIGN_ANA_FASTIN A2
HEX Hardware assignment of external analog NCK inputs [analog input]: POWER ON
0...7
1st byte: (low byte) No. of the I/O byte on DP compact module (1...2)
2nd byte: Submodule slot on terminal block (1...8)
3rd byte: Logical drive no. (MD 13010) of terminal block (1...1I)
4th byte: Segment no. (always 1 for 840D)
_always 0x01000000, 0x01000000 0x011E0801 DWORD 2/7
0x01000000,
0x01000000, ...
NCU570 0x02000000, 0x02000000 0x02070004 DWORD 2/7
0x02000000,
0x02000000, ...
10364 HW_ASSIGN_ANA_FASTOUT A2
HEX Hardware assignment of external analog NCK outputs [analog output]: POWER ON
0...7
0x01000000,
0x01000000, ...
NCU570 0x02000000, 0x02000000 0x02070004 DWORD 2/7
0x02000000,
0x02000000, ...
810D 0x02000000, 0x02000000 0x02070004 DWORD 0/0
0x02000000,
0x02000000, ...
10366 HW_ASSIGN_DIG_FASTIN A2
HEX Hardware assignment of external digital NCK inputs [input byte]: 0...3 POWER ON
0x01000000,
0x01000000, ...
NCU570 0x02000000, 0x02000000 0x02070004 DWORD 2/7
0x02000000,
0x02000000, ...

10368 HW_ASSIGN_DIG_FASTOUT A2
HEX Hardware assignment of external digital NCK outputs [output byte): POWER ON
0...3
0x01000000,
0x01000000, ...
NCU570 0x02000000, 0x02000000 0x02070004 DWORD 2/7
0x02000000,
0x02000000, ...
10380 HW_UPDATE_RATE_FASTIO A2
- Updating rate of clocked external NCK I/O devices POWER ON
Value = 1: hardware cycle, value = 2: pos. control cycle, value = 3:

interpolation cycle
_always 2, 2, 2, 2, 3 2 3 BYTE 2/7
10382 HW_LEAD_TIME_FASTIO A2
us Lead time of synchronous external NCK I/Os [terminal block]: 0...3 POWER ON
_always 100, 100, 100, 100, 100 0.0 plus DWORD 2/7
10384 HW_CLOCKED_MODULE_MASK A2
HEX Synchronous processing of external PLC I/Os (terminal block]: 0...3 POWER ON
Bit = 0/1: I/O module operated asynchronously/synchronously

_always 0, 0, 0, 0, 0 - - BYTE 2/7
10400 CC_VDI_IN_DATA OEM
Byte Number of interface bytes to compile cycles POWER ON
Compile cycles 0 0 1024 DWORD 1/7
NC570 compile 0 0 1024 DWORD 0/0
cycles
10410 CC_VDI_OUT_DATA OEM
Byte Number of interface bytes from compile cycles POWER ON
Compile cycles 0 0 1024 DWORD 1/7
NC570 compile 0 0 1024 DWORD 0/0
cycles
10420 CC_ASSIGN_FASTOUT_MASK OEM
HEX Reservation of external outputs for CC applications POWER ON
Bits 0-15/16-31: reserved digital output bytes / analog outputs
Compile cycles 0 - - DWORD 2/7
10430 CC_HW_DEBUG_MASK OEM
HEX Hardware debug mask for compile cycles POWER ON
_always 0 - - DWORD 1/7

10450 SW_CAM_ASSIGN_TAB N3
- Assignment software cams to machine axes POWER ON
(software cams): 0...15
Fct.: SW cam 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 31 BYTE 2/7
0,0, 0, ...
10460 SW_CAM_MINUS_LEAD_TIME N3
s Lead time or delay time at minus cams 1-16 POWER ON
positive value: lead time, negative value: delay time
Fct.: SW cam 0.0, 0.0, 0.0, 0.0, 0.0, - - DOUBLE 2/7
0.0, 0.0, ...
10461 SW_CAM_PLUS_LEAD_TIME N3
s Lead time or delay time at plus cams 1-16 POWER ON
Bit 0-7: no. of 1st HW byte Bit 8-15: no. of 2nd HW byte
Bit 16-23: inversion mask 1st byte Bit 24-31: inversion mask 2nd byte
Fct.: SW cam 0.0, 0.0, 0.0, 0.0, 0.0, - - DOUBLE 2/7
0.0, 0.0, ...
10470 SW_CAM_ASSIGN_FASTOUT_1 N3
HEX Hardware assignment for output of cams 1-8 to NCK I/Os POWER ON
Bit 0-7: no. of 1st HW byte Bit 8-15: no. of 2nd HW byte
Bit 16-23: inversion mask 1st byte Bit 24-31: inversion mask 2nd byte
Fct.: SW cam 0 - - DWORD 2/7
10471 SW_CAM_ASSIGN_FASTOUT_2 N3
HEX Hardware assignment for the output of cams 9-16 to NCK I/Os POWER ON
10480 SW_CAM_TIMER_FASTOUT_MASK N3
HEX Mask for output of cam signals via timer interr. to NCU POWER ON
10530 COMPAR_ASSIGN_ANA_INPUT_1 A2
- Hardware assignment of analog inputs for comparator byte 1 POWER ON
(comparator bit): 0...7
_always 0, 0, 0, 0, 0, 0, 0, 0 - - BYTE 2/7
10531 COMPAR_ASSIGN_ANA_INPUT_2 A2
- Hardware assignment of analog inputs for comparator byte 2 POWER ON
_always 0, 0, 0, 0, 0, 0, 0, 0 - - BYTE 2/7
10540 COMPAR_TYPE_1 A2
HEX Parameterization for comparator byte 1 POWER ON
Bit 0-7: Mask of comparison type
Bit = 0/1: Comp. bit = 1 if analog value</>= SD threshold value
Bit 16-23: No. of HW byte for output of the comparator outputs
Bit 24-31: Inversion mask for the output of comparator states

10541 COMPAR_TYPE_2 A2
HEX Parameterization of comparator byte 2 POWER ON
10600 FRAME_ANGLE_INPUT_MODE K2
- Input type for rotation with FRAME(1: RPY notation, 2: Eulerian angle) POWER ON
10610 MIRROR_REF_AX K2
- Reference axis for FRAME elements POWER ON
10620 EULER_ANGLE_NAME_TAB F2
- Name of Eulerian angle (GEO axis no.): 0...2 POWER ON
_always A2, B2, C2 - - STRING 2/7
NCU570 A2, B2, C2 - - STRING 0/0
10630 NORMAL_VECTOR_NAME_TAB -
- Name of normal vectors (GEO axis no.): 0...2 POWER ON
_always A4, B4, C4, A5, B5, C5 - - STRING 2/7
NCU570 A4, B4, C4, A5, B5, C5 - - STRING 0/0
10640 DIR_VECTOR_NAME_TAB F2
- Name of direction vectors (GEO axis no.): 0...2 POWER ON
_always A3, B3, C3 - - STRING 2/7
NCU570 A3, B3, C3 - - STRING 0/0
10650 IPO_PARAM_NAME_TAB K2
- Name of interpolation parameters (GEO axis no.): 0...2 POWER ON
_always I, J, K - - STRING 2/7
10660 INTERMEDIATE_POINT_NAME_TAB K2
- Name of interm. point coordinates for G2/G3 (GEO axis no.]: 0...2 POWER ON
_always I1, J1, K1 - - STRING 2/7
10700 PREPROCESSING_LEVEL K1
- Program preprocessing level POWER ON
10710 PROG_SD_RESET_SAVE_TAB K1
- Setting data to be updated (SD number): 0...29 POWER ON
_always 0, 0, 0, 0, 0, 0, 0, 0, 0, - - DWORD 2/7
0,0, 0, ...
10712 NC_USER_CODE_CONF_NAME_TAB PA
- List of reconfigured NC codes POWER ON
_always - - - STRING 2/2
NCU572, 573 - - - STRING 2/7
10720 OPERATING_MODE_DEFAULT H2
- Initial setting of mode after Power On (mode group no.]: 0...7 POWER ON
0: AUTOMATIC mode 4: MDA mode, submode TEACH IN
1: AUTO mode 5: MDA mode, submode REF PT-F
2: MDA mode 6: JOG mode
3: MDA mode 7: JOG mode, submode REF PT-F
_always 7, 7, 7, 7, 7, 7, 7, 7 0 7 BYTE 2/7

10730 JOG_MODE_KEYS_LEVELTRIGGRD -
- Effect of Jog mode keys POWER ON
0 = Key functions
1 = Switch functions
10900 INDEX_AX_LENGTH_POS_TAB_1 T1
- Number of positions for indexing axis table 1 POWER ON
10910 INDEX_AX_POS_TAB_1 T1
mm Indexing position table 1 (position no.): 0...59 POWER ON
_always 0., 0., 0., 0., 0., 0., 0., 0., - - DOUBLE 2/7
0., ...
10920 INDEX_AX_LENGTH_POS_TAB_2 T1
- Number of positions for indexing axis table 2 POWER ON
10930 INDEX_AX_POS_TAB_2 T1
mm Indexing position table 2 (position no.): 0...59 POWER ON
_always 0., 0., 0., 0., 0., 0., 0., 0., - - DOUBLE 2/7
0., ...
11100 AUXFU_MAXNUM_GROUP_ASSIGN S5
- Number of auxiliary functions assigned to aux. fct. groups POWER ON
11110 AUXFU_GROUP_SPEC S5
HEX Auxiliary function group specification (group no.): 0...14 POWER ON
Bit 0 = 1: Output duration 1 OB1 pass
Bit 1 = 1: Output duration 1 PLC basic cycle
Bit 2: -
Bit 3 = 1: No output at the interface
Bit 4: - Default setting:
Bit 5 = 1: Output before movement Group 1 = 81 H
Bit 6 = 1: Output during movement Group 2 = 21 H
Bit 7 = 1: Output at end of block Group 3 - 15 = 41 H
_always 0x81, 0x21, 0x41, 0x41, - - BYTE 2/7
0x41,0x41, ...
11200 INIT_MD H2
HEX Standard machine data loaded on next Power On POWER ON
_always 0 - - BYTE 2/7
11210 UPLOAD_MD_CHANGES_ONLY IAD
- MD backup of changed MD only NEW CONF
11220 INI_FILE_MODE IAD
- Error response on INI file errors RESET
0: Abort read-in
1 and 2: No abort, output alarms

11230 MD_FILE_STYLE IAD
HEX Structure of MD files on "upload" RESET
Bit 0: Line checksum Bit 1: MD numbers
11300 JOG_INC_MODE_LEVELTRIGGRD H1
- INC and REF in Jog mode POWER ON
11310 HANDWH_REVERSE H1
- Threshold for direction change handwheel POWER ON
_always 2 0.0 plus BYTE 2/7
11320 HANDWH_IMP_PER_LATCH H1
- Handwheel pulses per detent position (handwheel number): 0...2 POWER ON
_always 1., 1., 1. - - DOUBLE 2/7
11330 JOG_INCR_SIZE_TAB H1
- Increment size for INC/handwheel (key index): 0...4 POWER ON
_always 1., 10., 100., 1000., 0.0 plus DOUBLE 2/7
10000.
11380 MONITOR_ADDRESS STZ
- Test MD for setting NCK code or data for Sisitec IMMEDIATE
address of memory cell to be read or written
11382 MONITOR_DISPLAY_INT STZ
- INTEGER display of the addressed cell IMMEDIATE
11384 MONITOR_DISPLAY_REAL STZ
- REAL display of the addressed cell IMMEDIATE
_always 0.0 - - DOUBLE 0/0
11386 MONITOR_INPUT_INT STZ
- INTEGER input for the addressed cell IMMEDIATE
11388 MONITOR_INPUT_REAL STZ
- REAL input for addressed cell IMMEDIATE
11390 MONITOR_INPUT_STROBE STZ
- Overwrite the addressed cell MONITOR_INT/REAL IMMEDIATE
11400 TRACE_SELECT -
- Activation of internal trace functions POWER ON
11410 SUPPRESS_ALARM_MASK -
HEX Mask for support of special alarm outputs POWER ON
Bit 0 = 1 alarm 15110 is not displayed

11430 DIG_ASSIGN_DIGITIZE_TO_CHAN FBD
- Channel definition for digitizing POWER ON
Fct.: Digitizing 0 0 10 DWORD 2/7
11460 OSCILL_MODE_MASK P5
HEX Mode mask for asynchronous oscillation POWER ON
_always 0x0 0 0xFFFF DWORD 2/7
Override switch settings

12000 OVR_AX_IS_GRAY_CODE V1
- Axis feedrate override switch Gray-coded POWER ON
12010 OVR_FACTOR_AX_SPEED V1
Factor Evaluation of axis feedrate override switch (switch position): 0...30 POWER ON
_always 0.00, 0.01, 0.02, 0.04, 0.00 2.00 DOUBLE 2/7

0.06, 0.08, ...
12020 OVR_FEED_IS_GRAY_CODE V1
- Path feedrate override switch Gray-coded POWER ON
12030 OVR_FACTOR_FEEDRATE V1
Factor Evaluation of path feedrate override switch (switch position]: POWER ON
0...30
_always 0.00, 0.01, 0.02, 0.04, 0.00 2.00 DOUBLE 2/7
0.06, 0.08, ...
12040 OVR_RAPID_IS_GRAY_CODE V1
- Rapid traverse override switch Gray-coded POWER ON
12050 OVR_FACTOR_RAPID_TRA V1
Factor Evaluation of rapid traverse override switch (switch position]: 0...30 POWER ON
_always 0.00, 0.01, 0.02, 0.04, 0.00 1.00 DOUBLE 2/7
0.06, 0.08, ...
12060 OVR_SPIND_IS_GRAY_CODE V1
- Spindle speed override switch Gray-coded POWER ON
12070 OVR_FACTOR_SPIND_SPEED V1
Factor Evaluation of spindle speed override switch (switch position): 0...30 POWER ON
_always 0.5, 0.55, 0.60, 0.65, 0.00 2.00 DOUBLE 2/7
0.70, 0.75, ...

12080 OVR_REFERENCE_IS_PROG_FEED V1
- Override reference speed POWER ON
Bit = 0/1: Sp. override affects limited speed/progr. speed
12100 OVR_FACTOR_LIMIT_BIN V1
- Limitation for binary-coded override switch POWER ON
_always 1.2 0.0 2.0 DOUBLE 2/7
Central drive data

13000 DRIVE_IS_ACTIVE G2
- Drive activation (611D) (slot number): 0...29 POWER ON
611D 0 *** *** BOOLEAN 2/7
13010 DRIVE_LOGIC_NR G2
- Logical drive number (slot number): 0...29 POWER ON
611D 1, 2, 3, 4, 5, 6, 0, 0, 0, 0 31 BYTE 2/7
0,0, 0, ...
611D, not 810D 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 31 BYTE 2/7
0,0, 0, ...
13020 DRIVE_INVERTER_CODE G2
HEX Inverter module code of drive module (slot number]: 0...29 POWER ON
611D 0xE, 0x13, 0x13, 0, 0, 0, - - DWORD 2/7
0, 0, 0, ...
611D, not 810D 0, 0, 0, 0, 0, 0, 0, 0, 0, - - DWORD 2/7
0,0, 0, ...
13030 DRIVE_MODULE_TYPE G2
- Module recognition (slot number): 0...29 POWER ON
(1: 1-axis module, 2: 2-axis module, 9: Terminal block for digital I/Os,
10: Bit-
bus interface)
611D 6, 6, 6, 6, 6, 6, 1, 1, 1, 1, 1 10 BYTE 2/7
1, ...
611D, not 810D 1, 1, 1, 1, 1, 1, 1, 1, 1, 1 10 BYTE 2/7
1,1, 1, ...
13040 DRIVE_TYPE G2
- Code for drive type (slot number): 0...29 (1:VSAvS2: HSA) POWER ON
611D 2, 1, 1, 1, 1, 1, 1, 1, 1, 1, 0 2 BYTE 2/7
1, ...
611D, not 810D 1, 1, 1, 1, 1, 1, 1, 1, 1, 0 2 BYTE 2/7
1,1, 1, ...

13100 DRIVE_DIAGNOSIS IAD, Chap. 3
- Diagnosis drive link (diagnosis parameters drive]: 0...7 POWER ON
611D 0, 0, 0, 0, 0, 0, 1, 0 - - DWORD 2/7
13200 MEAS_PROBE_LOW_ACTIVE FBD
- Polarity reversal of measuring probe POWER ON
14000 ENC_SSI_BAUD_RATE G2
- Baud rate for SSI absolute value encoder POWER ON
NCU570 0 0 4 BYTE 2/7
14010 IPUCR_DELAY_TIME -
- Computing time of position controller POWER ON
NCU570, not DOUBLE 0/0
570.1
NCU570.2, not 0.002 0.0012 0.002 DOUBLE 2/7
570.1
14020 INTCY_DELAY_TIME -
- SSI transfer time POWER ON
NCU570, not DOUBLE 0/0
570.1
NCU570.2, not 0.0002 0.0002 0.0008 DOUBLE 2/7
570.1
System-specific memory settings

18000 VDI_UPDATE_IN_ONE_IPO_CYCLE P3
- PLC interface update POWER ON
_always - - BOOLEAN 0/0
NCU572, 573 0 *** *** BOOLEAN 2/7
NCU571 1 *** *** BOOLEAN 2/7
NCU570 1 *** *** BOOLEAN 2/7
810D 0 *** *** BOOLEAN 2/7
18040 VERSION_INFO IAD
- Version and possibly data of the PCMCIA card, not FM-NC POWER ON
not NCU570 - - - STRING 2/7
18050 INFO_FREE_MEM_DYNAMIC S7
Byte Display data of free dynamic memory POWER ON
18060 INFO_FREE_MEM_STATIC S7
Byte Display data of free static memory POWER ON

18070 INFO_FREE_MEM_DPR S7
Byte Display data of free memory in DUAL PORT RAM POWER ON
not 810D 0 - - DWORD 7/0
18080 MM_TOOL_MANAGEMENT_MASK FBW
HEX Tool management memory reservation in steps (SRAM) POWER ON
Bit 0 = 1: Tool management data being loaded
Bit 1 = 1: Monitoring data being loaded
Bit 2 = 1: OEM and CC data being loaded
Bit 3 = 1: Memory for consider adjacent location
_always 0x0 0 0xFFFF DWORD 1/7
18082 MM_NUM_TOOL W1
- Number of tools the NCK can manage (SRAM) POWER ON
18084 MM_NUM_MAGAZINE FBW
- Number of magazines the NCK can manage (SRAM) POWER ON
18086 MM_NUM_MAGAZINE_LOCATION FBW
- Number of magazine locations the NCK can manage (SRAM) POWER ON
18090 MM_NUM_CC_MAGAZINE_PARAM FBW
- Number of magazine data generated and evaluated by the compile POWER ON
cycles (SRAM)
18092 MM_NUM_CC_MAGLOC_PARAM FBW
- Number of magazine location data generated and evaluated by the POWER ON
compile cycles (SRAM)
18094 MM_NUM_CC_TDA_PARAM FBW
- Number of tool-specific data per tool for OEM and compile cycle POWER ON
(SRAM)
18096 MM_NUM_CC_TOA_PARAM FBW
- Number of data per tool edge for OEM and compile cycle POWER ON
(SRAM)
18098 MM_NUM_CC_MON_PARAM FBW
- Number of monitoring data per tool edge for OEM and compile cycle POWER ON
(SRAM)
18100 MM_NUM_CUTTING_EDGES_IN_TOA S7
- Tool offsets per TOA block (SRAM) POWER ON
18118 MM_NUM_GUD_MODULES S7
- Number of GUD files in active file system (SRAM) POWER ON

18120 MM_NUM_GUD_NAMES_NCK S7
- Number of global user variables (SRAM) POWER ON
18130 MM_NUM_GUD_NAMES_CHAN S7
- Number of channel-specific user variables (SRAM) POWER ON
18140 MM_NUM_GUD_NAMES_AXIS -
- Number of axis-specific user variables (SRAM) POWER ON
18150 MM_GUD_VALUES_MEM S7
kB Memory location for user variables (SRAM) POWER ON
_always 2 0.0 plus DWORD 2/7
18160 MM_NUM_USER_MACROS S7
- Number of macros (SRAM)) POWER ON
18170 MM_NUM_MAX_FUNC_NAMES S7
- Number of additional functions (DRAM) POWER ON
18180 MM_NUM_MAX_FUNC_PARAM S7
- Number of additional functions (DRAM)) POWER ON
18190 MM_NUM_PROTECT_AREA_NCK S7
- Number of files for machine-related protection zones (SRAM) POWER ON
18210 MM_USER_MEM_DYNAMIC S7
kB Dynamic user memory for DRAM POWER ON
_always - - DWORD 2/7
NCU572, 573 2600 - - DWORD 2/7
NCU571 1600 - - DWORD 0/0
NCU570 1600 - - DWORD 0/0
810D 980 - - DWORD 2/7
18220 MM_USER_MEM_DPR -
kB User memory in DUAL POR RAM (DPR POWER ON
not 810D 0 - - DWORD 0/0
18230 MM_USER_MEM_BUFFERED S7
kB User memory in SRAM POWER ON
18240 MM_LUD_HASH_TABLE_SIZE S7
Primary Hash table size for user variables (DRAM)) POWER ON
No.
18242 MM_MAX_SIZE_OF_LUD_VALUE S7
Byte Maximum field size for LUD variables POWER ON
_always 8192 128 8192 DWORD 2/7

18250 MM_CHAN_HASH_TABLE_SIZE S7
Primary Hash table size for channel-specific data (DRAM) POWER ON
No.
18260 MM_NCK_HASH_TABLE_SIZE S7
Prim.No. Hash table size for global data (DRAM) POWER ON
_always 1201 537 1201 DWORD 0/0
18270 MM_NUM_SUBDIR_PER_DIR S7
- Number of subdirectories (SRAM) POWER ON
18280 MM_NUM_FILES_PER_DIR S7
- Number of files per directory (SRAM) POWER ON
_always 100 64 512 DWORD 1/7
18290 MM_FILE_HASH_TABLE_SIZE S7
Prim. No. Hash table size for files of one directory (SRAM) POWER ON
NCU570 19 3 67 DWORD 2/7
18300 MM_DIR_HASH_TABLE_SIZE S7
Prim. No. Hash table size for subdirectories (SRAM)) POWER ON
18310 MM_NUM_DIR_IN_FILESYSTEM S7
- Number of directories in passive file system (SRAM)) POWER ON
18320 MM_NUM_FILES_IN_FILESYSTEM S7
- Number of files in passive file system (SRAM)) POWER ON
_always 100 64 512 DWORD 2/7
18330 MM_CHAR_LENGTH_OF_BLOCK S7
Char. Maximum length of an NC block (SRAM) POWER ON
_always 256 32 512 DWORD 0/0
18342 MM_CEC_MAX_POINTS K3
- Maximum number of intermediate points for beam sag comp. (SRAM) POWER ON
[Comp.table]: 0...15
Fct.: CEC 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 2000 DWORD 2/7
0,0, 0, ...
18350 MM_USER_FILE_MEM_MINIMUM S7
kB imum part program memory (SRAM) POWER ON
18500 MM_EXTCOM_TASK_STACK_SIZE S7
kB Stack size for external communications task (DRAM POWER ON
18502 MM_COM_TASK_STACK_SIZE -
- Stack size in KB for communication POWER ON
Communic. Task 12 4 20 DWORD 0/0
18510 MM_SERVO_TASK_STACK_SIZE S7
kB Stack size of servo task (DRAM)) POWER ON

18520 MM_DRIVE_TASK_STACK_SIZE S7
kB Stack size of drive task (DRAM) POWER ON
611D 8 4 20 DWORD 0/0
18900 FPU_ERROR_MODE -
- System response to FPU calculation error POWER ON
not 810D 0x1 - - DWORD 0/0
18910 FPU_CTRLWORD_INIT -
- Basic initialization of FPU control word POWER ON
not 810D - - DWORD 0/0
NCU572, 573, not 0x37F - - DWORD 2/7
810D
NCU571, not 810D 0x3F001000 - - DWORD 2/7
NCU570, not 810D 0x3F001000 - - DWORD 2/7
18920 FPU_EXEPTION_MASK -
- Exception mask for FPU calculation errors POWER ON
not 810D - - DWORD 0/0
NCU572, 573, not 0xD - - DWORD 2/7
810D
NCU571, not 810D 0x0D000000 - - DWORD 2/7
NCU570, not 810D 0x0D000000 - - DWORD 2/7
3.3 Channel specific machine data
Basic channel machine data

20000 CHAN_NAME K1
- Channel name POWER ON
_always CHAN1 , CHAN2 , CHAN3 - - STRING 2/7
, CHAN4, ...
20050 AXCONF_GEOAX_ASSIGN_TAB K2
- Assignment geometry axis to channel axis (GEO axis no.]: 0...2 POWER ON
_always { 1, 2, 3 }, { 0, 0, 0 }, { 0, 0, 0 18 BYTE 2/7
...
20060 AXCONF_GEOAX_NAME_TAB K2
- Geometry axis name in channel (GEO axis no.): 0...2 POWER ON
_always { X, Y, Z },{ X, Y, Z },{ X, - - STRING 2/7
Y, Z }, ...

20070 AXCONF_MACHAX_USED K2
- Machine axis number valid in channel (channel axis no.): 0...7 POWER ON
_always { 1, 2, 3, 4, 0, 0, 0, 0, 0, 0, 0 31 BYTE 2/7
0, ...
20080 AXCONF_CHANAX_NAME_TAB K2
- Channel axis name in channel (channel axis no.): 0...7 POWER ON
_always { X, Y, Z, A, B, C, - - STRING 2/7
U, ...
20090 SPIND_DEF_MASTER_SPIND S1
- Initial setting of master spindle in channel POWER ON
_always 1, 1, 1, 1, 1, 1, 1, 1, 1, 1 15 BYTE 2/7
1, 1, ...
20100 DIAMETER_AX_DEF P1
max 16 Geometry axis with facing axis function POWER ON
Z.
_always - - - STRING 2/7
20110 RESET_MODE_MASK K2
HEX Definition of basic control settings after part program start RESET
Each bit = 0: The current value is maintained..
Bit 0 - 3 Reset mode
Bit 4 Current plane Bit 5 Settable ZO
Bit 6 Tool length compensation Bit 7 Transformation
Bit 8 Coupled motion Bit 9 Tangential tracking
Bit 10 Synchronous spindle
_always 0x0, 0x0, 0x0, 0x0, 0x0, 0 0xFFF DWORD 2/7
0x0, 0x0, ...
20112 START_MODE_MASK K2
HEX Definition of basic control settings after powering up and Reset RESET
Each bit = 0: The current value is maintained.
Bit 0 - 3 Reset mode
Bit 8 Coupled motion Bit 9 Tangential tracking
Bit 10 Synchronous spindle
_always 0x400, 0x400, 0x400, 0 0x7FF DWORD 2/7
0x400, 0x400, ...
20114 MODESWITCH_MASK K1
- Interruption MDA through operating mode change RESET
_always 0x0, 0x0, 0x0, 0x0, 0x0, 0 0xFFFF DWORD 2/7
0x0, 0x0, ...
20120 TOOL_RESET_VALUE K2
- Tool whose length compens. is selected during booting (Reset/end of RESET
pp).
Depends on MD 20110 and 20112..
_always 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 32000 DWORD 2/7
0, 0, ...

20122 TOOL_RESET_NAME FBW
- Definition of the tool with which length correction is selected on start- POWER ON
up/reset
_always , , ,,, , ,,,, , ,,, , - - STRING 2/7
20124 TOOL_MANAGEMENT_TOOLHOLDER FBW
- Tool holder number POWER ON
_always 0, 0, 0, 0, 0, 0, 0, 0 0 32 DWORD 2/7
20130 CUTTING_EDGE_RESET_VALUE K2
- Tool edge whose length compens. is selected during booting RESET
(Reset/end of pp).
Depends on MD 20110 and 20112.
_always 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 9 DWORD 2/7
0, 0, ...
20140 TRAFO_RESET_VALUE K2
- Transformation data record called during bootup (Reset/pp end) RESET
Depends on MD 20110 and 20112..
_always 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 4 BYTE 2/7
0, 0, ...
20150 GCODE_RESET_VALUES K1
- Initial setting of G groups (G group no.): 0...59 RESET
Selection of G groups
[0] 1 = G0, 2 = G01 (default)
[5] 1 = G17 (default), 2 = G18, 3 = G19
[7] 1 = G500 (default), 2 = G54, 3 = G 55, 4 = G56, 5 = G57
[9] 1 = G60 (default), 2 = G 64, 3 = G641
[11] 1 = G601 (default), 2 = G602, 3 = G603
[12] 1 = G70, 2 = G71 (default)
[13] 1 = G90 (default), 2 = G91
[14] 1 = G93, 2 = G94 (default), 3 = G95
[20] 1 = BRISK (default), 2 = SOFT
[22] 1 = CDOF (default), 2 = CDON
[23] 1 = FFWOF (default), 2 = FFWON
[28] 1 = DIAMOF (default), 2 = DIAMON
For more detailed information see Programming Guide
G code definition depends on MD 20110 and MD 20112..
_always {2, 0, 0, 1, 0, 1, 1, 1, 0 14 BYTE 2/7
0, ...
20160 CUBIC_SPLINE_BLOCKS K1
- Number of blocks for C spline POWER ON
_always 8, 8, 8, 8, 8, 8, 8, 8, 8, 8, 4 9 BYTE 2/7
8, ...
20170 COMPRESS_BLOCK_PATH_LIMIT K1
mm Maximum traversing distance of an NC block with compression POWER ON
Fct.: Polynom 1.0, 1.0, 1.0, 1.0, 1.0, 1.0, 0.0 plus DOUBLE 2/7
1.0, ...

20172 COMPRESS_VELO_TOL V1
mm/min Max. permissible deviation of the path feedrate during compression POWER ON
_always 1000.0, 1000.0, 1000.0, 0.0 plus DOUBLE 2/7
1000.0, ...
NCU570 1000.0, 1000.0, 1000.0, 0.0 plus DOUBLE 0/0
1000.0, ...
20200 CHFRND_MAXNUM_DUMMY_BLOCKS K1
- Empty blocks with chamfer/radii POWER ON
_always 3, 3, 3, 3, 3, 3, 3, 3,3, 3, 0 15 BYTE 2/7
3, 3, ...
NCU570 3, 3, 3, 3, 3, 3, 3, 3,3, 3, 0 10 BYTE 2/7
3, 3, ...
20210 CUTCOM_CORNER_LIMIT W1
degrees Maximum angle for compensation blocks with TRC POWER ON
_always 100., 100., 100., 100., 0.0 150. DOUBLE 2/7
100., 100., ...
20220 CUTCOM_MAX_DISC W1
Factor Maximum value for DISC POWER ON
_always 50.0, 50.0, 50.0, 50.0, 0.0 75.0 DOUBLE 2/7
50.0, 50.0, ...
20230 CUTCOM_CURVE_INSERT_LIMIT W1
- Maximum angle for calculation of intersection with TRC POWER ON
_always 10., 10., 10., 10., 10., 10., 0.0 150. DOUBLE 2/7
10., ...
20240 CUTCOM_MAXNUM_CHECK_BLOCKS W1
- Blocks for look-ahead contour calculation with TRC POWER ON
_always 3, 3, 3, 3, 3, 3, 3, 3,3, 3, 2 10 BYTE 2/7
3, 3, ...
20250 CUTCOM_MAXNUM_DUMMY_BLOCKS W1
- Number of blocks without traversing motion with TRC POWER ON
_always 3, 3, 3, 3, 3, 3, 3, 3,3, 3, 0 5 BYTE 2/7
3, 3, ...
20260 PATH_IPO_IS_ON_TCP W1
- Velocity control with spline POWER ON
20262 SPLINE_FEED_PRECISION W1
Factor Permissible rel. error of path velocity for spline POWER ON
_always 0.001, 0.001, 0.001, 0.000001 1.0 DOUBLE 0/0
0.001, 0.001, ...
20270 CUTTING_EDGE_DEFAULT W1
- Initial position of tool edge without programming POWER ON
_always 1, 1, 1, 1, 1, 1, 1, 1,1, 1, -1 9 DWORD 2/7
1, 1, ...
20310 TOOL_MANAGEMENT_MASK FBW
HEX Activation of different types of tool management POWER ON
_always 0x0, 0x0, 0x0, 0x0, 0x0, 0 0xFFFF DWORD 2/7
0x0, 0x0, ...

20320 TOOL_TIME_MONITOR_MASK FBW
HEX Activation of tool time monitoring for tool in spindle 1...5 POWER ON
_always 0x0, 0x0, 0x0, 0x0, 0x0, - - DWORD 2/7
0x0, 0x0, ...
20350 TOOL_GRIND_AUTO_TMON W1
- Activation of tool monitoring 0/1: Monitoring off/on POWER ON
_always 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 1 BYTE 2/7
0, 0, ...
20400 LOOKAH_USE_VELO_NEXT_BLOCK B1
- Lookahead to programmed following block velocity POWER ON
20430 LOOKAH_NUM_OVR_POINTS B1
- Number of override switch threshold values with lookahead POWER ON
_always 1, 0, 0, 0, 0, 0, 0, 0,0, 0, 0 2 DWORD 2/7
0, 0, ...
20440 LOOKAH_OVR_POINTS B1
Factor Prepared override velocity characteristics with lookahead (no. of POWER ON
points): 0...1
_always { 1.0, 0.2 },{ 0.2, 0.2 },{ 0.2 2.0 DOUBLE 2/7
0.2, ...
20450 LOOKAH_RELIEVE_BLOCK_CYCLE B1
Factor Relief factor for block cycle time POWER ON
_always 0.0, 0.0, 0.0, 0.0, 0.0, 0.0, 0.0 plus DOUBLE 2/7
0.0, ...
20470 CPREC_WITH_FFW K6, B1
- Progr. contour accuracy POWER ON
20500 CONST_VELO_MIN_TIME B2
s Minimum time with constant velocity POWER ON
_always 0.0, 0.0, 0.0, 0.0, 0.0, 0.0 0.1 DOUBLE 2/7
0.0, 0.0, ...
20600 MAX_PATH_JERK B2
mm/s^3 Path-related maximum jerk NEW CONF
100.0, 100.0, ...
20610 ADD_MOVE_ACCEL_RESERVE K1
- Acceleration margin for overlaid movements POWER ON
_always .2, .2, .2, .2, .2, .2, .2, 0. 0.9 DOUBLE 2/7
.2,.2, ...
20620 HANDWH_GEOAX_MAX_INCR_SIZE H1
mm, Limitation handwheel increment for geo axes POWER ON
degrees
_always 0.0, 0.0, 0.0, 0.0, 0.0, 0.0, 0.0 plus DOUBLE 2/7
0.0, ...
20622 HANDWH_GEOAX_MAX_INCR_VSIZE H1
mm/min, Path velocity overlay POWER ON
RPM
500.0,500.0, ...

20624 HANDWH_CHAN_STOP_COND H1
- Definition of the response of the handwheel to channel-specific VDI POWER ON
interface signals
Bit meanings
Bit 0: BAG Stop
Bit 1: BAG Stop Axes plus Spindle
Bit 2: NC Stop
Bit 3: NC stop axes plus spindle
Bit 4: Feedrate disable
Bit 5: Feedrate override
Bit 6: Rapid traverse override
Bit 7: Feedrate stop geometry axis
Bit = 0: Interruption / accumulation

Bit = 1: Abort travel / no accumulation
_always 0xFF, 0xFF, 0xFF, 0xFF, 0 0xFF DWORD 2/7
0xFF, 0xFF, ...
20650 THREAD_START_IS_HARD K1
- Acceleration behavior of axis when thread cutting POWER ON
20700 REFP_NC_START_LOCK R1
- NC-Start disable without reference point RESET
20750 ALLOW_G0_IN_G96 V1
- G0 logic with G96 POWER ON
20800 SPF_END_TO_VDI S5
- End of subroutine to PLC POWER ON
21000 CIRCLE_ERROR_CONST K1
mm Circle end point monitoring constant POWER ON
_always 0.01, 0.01, 0.01, 0.01, 0.0 plus DOUBLE 2/7
0.01, 0.01, ...
21010 CIRCLE_ERROR_FACTOR K1
Factor Circle end point monitoring factor POWER ON
0.001, 0.001, ...
21020 WORKAREA_WITH_TOOL_RADIUS -
- Consideration of tool radius for working area limitation RESET
21050 CONTOUR_TUNNEL_TOL F2
mm Response threshold for contour tunnel monitoring NEW CONF
Fct.: CTC 0.0, 0.0, 0.0, 0.0, 0.0, 0.0, 0.0 plus DOUBLE 2/7
0.0, ...
21060 CONTOUR_TUNNEL_REACTION F2
- Reaction when contour tunnel monitoring responds POWER ON
Fct.: CTC 1, 1, 1, 1, 1, 1, 1, 1, 1, 1, 0 2 BYTE 2/7
1, 1, ...

21070 CONTOUR_ASSIGN_FASTOUT F2
- Assignment of an analog output for the output of the contour error POWER ON
0: no output, 1: output at output 1 etc.
Fct.: CTC 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 8 BYTE 2/7
0, 0, ...
21080 CUTCOM_PARALLEL_ORI_LIMIT W1
degrees Limit angle (path tangent/tool orientation) for 3D tool radius POWER ON
compensation
_always 15., 15., 15., 15., 15., 15., 1.0 89. DOUBLE 2/7
15., ...
21082 CUTCOM_PLANE_ORI_LIMIT W5
degrees Minimum angle between surface normal and tool orientation when POWER ON
lateral angle not equal 0 (3D)
_always 5., 5., 5., 5., 5., 5., 5., 5. 1.0 89. DOUBLE 2/7
21084 CUTCOM_PLANE_PATH_LIMIT W5
degrees Minimum angle between surface normal vector and path tangent vector POWER ON
(3D face milling)
_always 15., 15., 15., 15., 15., 15., 1.0 89. DOUBLE 2/7
15., ...
21090 MAX_LEAD_ANGLE -
degrees Maximum value of permitted angle of advance for orientation progr. POWER ON
_always 80., 80., 80., 80., 80., 80., 0. 80. DOUBLE 0/0
80., ...
21092 MAX_TILT_ANGLE -
degrees Maximum value of permitted lateral angle for orientation progr. POWER ON
_always 80., 80., 80., 80., 80., 80., -80. 80. DOUBLE 0/0
80., ...
21100 ORIENTATION_IS_EULER K2
- Angle definition for orientation programming POWER ON
NCU570 1 *** *** BOOLEAN 0/0
21110 X_AXIS_IN_OLD_X_Z_PLANE F2
- Coordinate system for automatic frame definition POWER ON
NCU570 1 *** *** BOOLEAN 0/0
21200 LIFTFAST_DIST K1
mm Traversing distance on rapid retract from contour POWER ON
ASUP via fast I/O 0.1, 0.1, 0.1, 0.1, 0.1, 0.1, 0.0 plus DOUBLE 2/7
0.1, ...

21210 SETINT_ASSIGN_FASTIN S5
HEX HW assignment of ext. NCK input byte for NC progr. interrupts POWER ON
Bit 0-7: No. of HW-Byte
Bit 16-23: Mask of signals that channel is not to evaluate
ASUP via fast I/O 1, 1, 1, 1, 1, 1, 1, 1,1, 1, - - DWORD 2/7
1, 1, ...
21220 MULTFEED_ASSIGN_FASTIN S5
HEX Assignment input bytes of NCK I/O devices for "Several feedrates in a POWER ON
block"
Bit 0-7: No. of 1st byte Bit 8-15: No. of 2nd byte
Bit 16-23: Inversion mask 1st byte Bit 24-31: Invers. mask 2nd byte
Fct.: Multfeed 0, 0, 0, 0, 0, 0, 0, 0,0, 0, - - DWORD 2/7
0, 0, ...
21230 MULTFEED_STORE_MASK S5
HEX Store input signal of function of "Several feedrates in a block" POWER ON
Bit 0-1: no meaning, Bit 2-7: storage behavior, Bit 8-31: reserved
Fct.: Multfeed 0, 0, 0, 0, 0, 0, 0, 0,0, 0, - - BYTE 2/7
0, 0, ...
21300 COUPLE_AXIS_1 S3
- Synchronous spindle pair definition, mach. axis no.: following spindle[0], POWER ON
leading spindle[1]
Fct.: Synchr. {0, 0}, {0, 0}, {0, 0}, {0, 0 31 BYTE 2/7
Spindle 0},{0, ...
21310 COUPLING_MODE_1 S3
- Type of coupling in synchronous spindle operation POWER ON
0: actual value coupling 1: setpoint coupling 2: velocity
coupling
Fct.: Synchr. 1, 1, 1, 1, 1, 1, 1, 1,1, 1, 0 2 BYTE 2/7
Spindle 1, 1, ...
21320 COUPLE_BLOCK_CHANGE_CTRL_1 S3
- Block change behavior in synchronous spindle operation POWER ON
0: IMMEDIATE, 1/2: synchronism fine/coarse, 3: IPO-STOP
Fct.: Synchr. 3, 3, 3, 3, 3, 3, 3, 3,3, 3, 0 3 BYTE 2/7
Spindle 3, 3, ...
21330 COUPLE_RESET_MODE_1 S3
- Coupling abort behavior: POWER ON
Bit 0 = 0 Coupling remains active at program restart
1 Coupling is cancelled at program restart
Bit 1 = 0 Coupling remains active beyond end of program and RESET
1 Coupling is cancelled at end of program or RESET
Bit 5 = 1 Configured data are activated at program start
Bit 6 = 1 Configured data are activated at end of program or RESET
Bit 9 = 1 Coupling is activated at program start
Fct.: Synchr. 1, 1, 1, 1, 1, 1, 1, 1,1, 1, 0 0x3FF DWORD 2/7
Spindle 1, 1, ...

21340 COUPLE_IS_WRITE_PROT_1 S3
- Coupling parameters cannot be altered POWER ON
Fct.: Synchr. 0 *** *** BOOLEAN 2/7
Spindle
Machine data for Digitizing

21400 DIG_PROT_VERSION FBD

- Version number of digitizing package (SCAN link protocol) POWER ON
Fct.: Digitizing 3, 3, 3, 3, 3, 3, 3, 3, 3, 3, - - BYTE 0/0
3, 3, ...
21420 DIG_L_ORDER FBD
- Axis assignment of probe for digitizing POWER ON
0: XYZ, 1: ZXY, 2: YZX, 3: ZYX, 4: XZY, 5: YXZ
Fct.: Digitizing 0, 0, 0, 0, 0, 0, 0, 0,0, 0, 0, 0 5 BYTE 2/7
0, ...
21422 DIG_L_OFF_Z FBD
mm Initial stress in Z direction for probe calibration POWER ON
Fct.: Digitizing 1.0, 1.0, 1.0, 1.0, 1.0, 1.0, - - DOUBLE 2/7
1.0, ...
21424 DIG_L_INKR FBD
- Resolution of probe in digitizing POWER ON
(axis no..): 0...2
Fct.: Digitizing { 1.0, 1.0, 1.0 }, { 1.0, 1.0, - - DOUBLE 2/7
...
21430 DIG_L_MIN FBD
mm Minimum deflection for digitizing POWER ON
Fct.: Digitizing 0.15, 0.15, 0.15, 0.15, - - DOUBLE 2/7
0.15, 0.15, ...
21432 DIG_L_NORMAL FBD
mm Typical deflection value for digitizing POWER ON
Fct.: Digitizing 1., 1., 1., 1., 1., 1., 1., - - DOUBLE 2/7
1.,1., ...
21434 DIG_L_NOTAUS FBD
mm Deflection of probe for which emergency stop has been triggered POWER ON
2.0, ...

21436 DIG_L_NOTAUS_EXT FBD
mm Deflection of probe w. extend. deflect. range for which emergency stop POWER ON
has been triggered
3.5, ...
21440 DIG_DELTAPOS FBD
mm In position window for digitizing POWER ON
Fct.: Digitizing 0.01, 0.01, 0.01, 0.01, 0.0 plus DOUBLE 2/7
0.01, 0.01, ...
21450 DIG_V_EILGANG FBD
mm/min Typical rapid traverse velocity when digitizing POWER ON
Fct.: Digitizing 10000., 10000., 10000., 0.0 plus DOUBLE 2/7
10000., ...
21460 DIG_A_MAX FBD
mm/s^2 Maximum path acceleration when digitizing POWER ON
Fct.: Digitizing 1000., 1000., 1000., 0.0 plus DOUBLE 2/7
1000., 1000., ...
21462 DIG_A_MAX_MOVE FBD
mm/s^2 Maximum path acceleration when positioning in digitizing mode POWER ON
Fct.: Digitizing 1 0.0 plus DOUBLE 2/7
21464 DIG_A_MAX_SCAN FBD
mm/s^2 Maximum path acceleration with digitizing function POWER ON
Fct.: Digitizing 1 0.0 plus DOUBLE 2/7
21470 DIG_P_HAND FBD
1000/min Proportional factor for JOG mode POWER ON
Fct.: Digitizing 1 - - DOUBLE 2/7
21472 DIG_P_SCAN FBD
1000/min Proportional factor for probe control POWER ON
Fct.: Digitizing 1 - - DOUBLE 2/7
21474 DIG_T_SCAN FBD
s Time constant for probe control POWER ON
Fct.: Digitizing 0.15, 0.15, 0.15, 0.15, 0.0 plus DOUBLE 2/7
0.15, 0.15, ...

Machine data for Grinding

21500 TRACLG_GRINDSPI_VERT_OFFSET S8
mm Vertical position offset of grinding axis in centerless grinding POWER ON
Fct.: CLG 0., 0., 0., 0., 0., 0., 0., - - DOUBLE 2/7
0.,0., ...
21501 TRACLG_GRINDSPI_HOR_OFFSET S8
mm Horizontal position offset of grinding axis in centerless grinding POWER ON
Fct.: CLG 0., 0., 0., 0., 0., 0., 0., - - DOUBLE 2/7
0.,0., ...
21502 TRACLG_CTRLSPI_VERT_OFFSET S8
mm Vertical position offset of regulating axis in centerless grinding POWER ON
Fct.: CLG 0., 0., 0., 0., 0., 0., 0., - - DOUBLE 2/7
0.,0., ...
21504 TRACLG_SUPPORT_VERT_OFFSET S8
mm Vertical offset of work blade in centerless grinding POWER ON
Fct.: CLG 0., 0., 0., 0., 0., 0., 0., - - DOUBLE 2/7
0.,0., ...
21506 TRACLG_SUPPORT_HOR_OFFSET S8
mm Horizontal offset of work blade in centerless grinding POWER ON
Fct.: CLG 0., 0., 0., 0., 0., 0., 0., - - DOUBLE 2/7
0.,0., ...
21508 TRACLG_VERT_DIR_SUPPORTAX_1 S8
- Vertical component of work blade direction vector for Q1 POWER ON
Fct.: CLG 1., 1., 1., 1., 1., 1., 1., - - DOUBLE 2/7
1.,1., ...
21510 TRACLG_HOR_DIR_SUPPORTAX_1 S8
- Horizontal component of work blade direction vector for Q1 POWER ON
Fct.: CLG 0., 0., 0., 0., 0., 0., 0., - - DOUBLE 2/7
0.,0., ...
21512 TRACLG_VERT_DIR_SUPPORTAX_2 S8
- Vertical component of work blade direction vector for Q2 POWER ON
Fct.: CLG 0., 0., 0., 0., 0., 0., 0., - - DOUBLE 2/7
0.,0., ...
21514 TRACLG_HOR_DIR_SUPPORTAX_2 S8
- Horizontal component of work blade direction vector for Q2 POWER ON
Fct.: CLG 1., 1., 1., 1., 1., 1., 1., - - DOUBLE 2/7
1.,1., ...

21516 TRACLG_SUPPORT_LEAD_ANGLE S8
degrees Angle of lead of work blade in centerless grinding POWER ON
Fct.: CLG 0., 0., 0., 0., 0., 0., 0., -90. 90. DOUBLE 2/7
0.,0., ...
21518 TRACLG_CONTACT_UPPER_LIMIT S8
mm Upper contact limit of work blade with work in centerless grinding. POWER ON
Fct.: CLG 0., 0., 0., 0., 0., 0., 0., - - DOUBLE 2/7
0.,0., ...
21520 TRACLG_CONTACT_LOWER_LIMIT S8
mm Lower contact limit of work blade with work in centerless grinding. POWER ON
Fct.: CLG 0., 0., 0., 0., 0., 0., 0., - - DOUBLE 2/7
0.,0., ...
21522 TRACLG_GRINDSPI_NR S8
- Definition of grinding spindle for centerless grinding POWER ON
Fct.: CLG 2, 2, 2, 2, 2, 2, 2, 2,2, 2, 1 15 BYTE 2/7
2, 2, ...
21524 TRACLG_CTRLSPI_NR S8
- Definition of regulating spindle for centerless grinding POWER ON
Fct.: CLG 1, 1, 1, 1, 1, 1, 1, 1,1, 1, 1 15 BYTE 2/7
1, 1, ...
21526 TRACLG_G0_IS_SPECIAL S8
- Special logic for G0 in centerless grinding POWER ON
Fct.: CLG 1 *** *** BOOLEAN 2/7
Auxiliary channel function settings

22000 AUXFU_ASSIGN_GROUP S5
- Auxiliary function group (aux. fct. no. in channel): 0...49 POWER ON
_always { 1, 1, 1, 1, 1, 1, 1, 1, 1, 1 15 BYTE 2/7
1,1, ...
22010 AUXFU_ASSIGN_TYPE S5
- Auxiliary function type (aux. fct. no. in channel): 0...49 POWER ON
_always { , , , , , , , , , ,, , , , , , , ... - - STRING 2/7
22020 AUXFU_ASSIGN_EXTENSION S5
- Auxiliary function expansion (aux. fct. no. in channel): 0...49 POWER ON
_always { 0, 0, 0, 0, 0, 0, 0, 0, 0, 0 99 BYTE 2/7
0,0, ...

22030 AUXFU_ASSIGN_VALUE S5
- Auxiliary function value (aux. fct. no. in channel): 0...49 POWER ON
_always { 0, 0, 0, 0, 0, 0, 0, 0, 0, - - DWORD 2/7
0,0, ...
22200 AUXFU_M_SYNC_TYPE S5
- Output time of M functions POWER ON
0: Output before movement 2: Output at end of block
1: Output during movement 3: No output to the PLC
_always 0, 0, 0, 0, 0, 0, 0, 0,0, 0, 0 3 BYTE 2/7
0, 0, ...
22210 AUXFU_S_SYNC_TYPE S5
- Output time of S functions (see MD22200 for values) POWER ON
_always 0, 0, 0, 0, 0, 0, 0, 0,0, 0, 0 3 BYTE 2/7
0, 0, ...
22220 AUXFU_T_SYNC_TYPE S5
- Output time for T functions (see MD22200 for values) POWER ON
_always 0, 0, 0, 0, 0, 0, 0, 0,0, 0, 0 3 BYTE 2/7
0, 0, ...
22230 AUXFU_H_SYNC_TYPE S5
- Output time for H functions (see MD22200 for values) POWER ON
_always 0, 0, 0, 0, 0, 0, 0, 0,0, 0, 0 3 BYTE 2/7
0, 0, ...
22240 AUXFU_F_SYNC_TYPE S5
- Output time for F functions (see MD22200 for values) POWER ON
_always 3, 3, 3, 3, 3, 3, 3, 3,3, 3, 0 3 BYTE 2/7
3, 3, ...
22250 AUXFU_D_SYNC_TYPE S5
- Output time for D functions (see MD22200 for values) POWER ON
_always 0, 0, 0, 0, 0, 0, 0, 0,0, 0, 0 3 BYTE 2/7
0, 0, ...
22260 AUXFU_E_SYNC_TYPE -
- Output time of E functions POWER ON
_always 0, 0, 0, 0, 0, 0, 0, 0,0, 0, 0 3 BYTE 0/0
0, 0, ...
22300 AUXFU_AT_BLOCK_SEARCH_END S5
- Auxiliary function output after block search POWER ON
22400 S_VALUES_ACTIVE_AFTER_RESET S1
- S function effective via RESET POWER ON
22410 F_VALUES_ACTIVE_AFTER_RESET V1
- F function effective via RESET POWER ON

22510 GCODE_GROUPS_TO_PLC K1
- G codes output at NCK-PLC interface on block change/RESET POWER ON
_always {0, 0, 0, 0, 0, 0, 0, 0},{0, 0, - - BYTE 2/7
0, ...
22550 TOOL_CHANGE_MODE W1
- New tool compensation for M function POWER ON
_always 0, 0, 0, 0, 0, 0, 0, 0,0, 0, 0 1 BYTE 2/7
0, 0, ...
22560 TOOL_CHANGE_M_CODE W1
- M function for tool change POWER ON
_always 6, 6, 6, 6, 6, 6, 6, 6,6, 6, 0 99999999 DWORD 2/7
6, 6, ...
NCU570 6, 6, 6, 6, 6, 6, 6, 6,6, 6, 0 99999999 DWORD 0/0
6, 6, ...
Transformation definitions in channel

24100 TRAFO_TYPE_1 F2
- Definition of transformation 1 in channel POWER ON
_always 0, 0, 0, 0, 0, 0, 0, 0,0, 0, 0 2048 DWORD 2/7
0, 0, ...
24110 TRAFO_AXES_IN_1 F2
- Axis assignment for transformation (axis index): 0...7 POWER ON
_always { 1, 2, 3, 4, 5, 0, 0, 0 18 BYTE 2/7
0,0, ...
24120 TRAFO_GEOAX_ASSIGN_TAB_1 F2
- Assignment GEO axis to channel axis for transformation 1 POWER ON
(GEO axis no.): 0...2
_always { 0, 0, 0 }, { 0, 0, 0 }, { 0, 0, 0 18 BYTE 2/7
...
_always 0, 0, 0, 0, 0, 0, 0, 0,0, 0, 0, 0 2048 DWORD 2/7
0, ...
- Axis assignment for transformation 2 (axis index): 0...7 POWER ON
_always { 1, 2, 3, 4, 5, 0, 0, 0 18 BYTE 2/7
0,0, ...
_always { 0, 0, 0 }, { 0, 0, 0 }, { 0, 0, 0 18 BYTE 2/7

...
_always 0, 0, 0, 0, 0, 0, 0, 0,0, 0, 0, 0 2048 DWORD 2/7
0, ...
_always { 1, 2, 3, 4, 5, 0, 0, 0 18 BYTE 2/7
0,0, ...
_always { 0, 0, 0 }, { 0, 0, 0 }, { 0, 0, 0 18 BYTE 2/7
...
_always 0, 0, 0, 0, 0, 0, 0, 0,0, 0, 0, 0 2048 DWORD 2/7
0, ...
_always { 1, 2, 3, 4, 5, 0, 0, 0 18 BYTE 2/7
0,0, ...
_always { 0, 0, 0 }, { 0, 0, 0 }, { 0, 0, 0 18 BYTE 2/7
...
24500 TRAFO5_PART_OFFSET_1 F2
mm Offset vector of 5-axis transformation 1 (axis no.): 0...2 POWER ON
not 810D {0.0, 0.0 , 0.0},{0.0, 0.0 , - - DOUBLE 2/7
0.0}, ...
NCU570, not 810D {0.0, 0.0 , 0.0},{0.0, 0.0 , - - DOUBLE 0/0
0.0}, ...
All transformations {0.0, 0.0 , 0.0},{0.0, 0.0 , - - DOUBLE 2/7
0.0}, ...
NCU570, all {0.0, 0.0 , 0.0},{0.0, 0.0 , - - DOUBLE 0/0
transform. 0.0}, ...

24510 TRAFO5_ROT_AX_OFFSET_1 F2
Degrees Position offset of rotary axes 1/2 for 5-axis transformation 1 POWER ON
(axis no.): 0...1
not 810D {0.0, 0.0},{0.0, 0.0},{0.0, - - DOUBLE 2/7
0.0}, ...
NCU570, not 810D {0.0, 0.0},{0.0, 0.0},{0.0, - - DOUBLE 0/0
0.0}, ...
(axis no.): 0...1
All transformations {0.0, 0.0},{0.0, 0.0},{0.0, - - DOUBLE 2/7
0.0}, ...
NCU570, all {0.0, 0.0},{0.0, 0.0},{0.0, - - DOUBLE 0/0
24520 TRAFO5_ROT_SIGN_IS_PLUS_1 F2
- Sign of rotary axis 1/2 for 5-axis transformation 1 POWER ON
(axis no.): 0...1
not 810D {1, 1},{1, 1},{1, 1},{1, 1},{1, - - BOOLEAN 2/7
1}, ...
NCU570, not 810D {1, 1},{1, 1},{1, 1},{1, 1},{1, - - BOOLEAN 0/0
1}, ...
(axis no.): 0...1
All transformations {1, 1},{1, 1},{1, 1},{1, 1},{1, - - BOOLEAN 2/7
1}, ...
NCU570, all {1, 1},{1, 1},{1, 1},{1, 1},{1, - - BOOLEAN 0/0
transform. 1}, ...
24530 TRAFO5_NON_POLE_LIMIT_1 F2
Degrees Definition of pole range for 5-axis transformation 1 POWER ON
not 810D 2.0, 2.0, 2.0, 2.0, 2.0, 2.0, - - DOUBLE 2/7
2.0, ...
NCU570, not 810D 2.0, 2.0, 2.0, 2.0, 2.0, 2.0, - - DOUBLE 0/0
2.0, ...
All transformations 2.0, 2.0, 2.0, 2.0, 2.0, 2.0, - - DOUBLE 2/7
2.0, ...
NCU570, all 2.0, 2.0, 2.0, 2.0, 2.0, 2.0, - - DOUBLE 0/0
transform. 2.0, ...
24540 TRAFO5_POLE_LIMIT_1 F2
Degrees End angle tolerance with interpolation through pole for 5-axis POWER ON
transformation
not 810D 2.0, 2.0, 2.0, 2.0, 2.0, 2.0, - - DOUBLE 2/7
2.0, ...
NCU570, not 810D 2.0, 2.0, 2.0, 2.0, 2.0, 2.0, - - DOUBLE 0/0
2.0, ...

transformation
2.0, ...
NCU570, all 2.0, 2.0, 2.0, 2.0, 2.0, 2.0, - - DOUBLE 0/0
transform. 2.0, ...
24550 TRAFO5_BASE_TOOL_1 F2
mm Vector of base tool for activation of 5-axis transformation 1 POWER ON
(axis no.): 0...2
not 810D {0.0, 0.0 , 0.0},{0.0, 0.0 , - - DOUBLE 2/7
0.0}, ...
NCU570, not 810D {0.0, 0.0 , 0.0},{0.0, 0.0 , - - DOUBLE 0/0
0.0}, ...
(axis no.): 0...2
0.0}, ...
NCU570, all {0.0, 0.0 , 0.0},{0.0, 0.0 , - - DOUBLE 0/0
24560 TRAFO5_JOINT_OFFSET_1 F2
mm Vector of kinematic offset of 5-axis transformation 1 POWER ON
(axis no.): 0...2
not 810D {0.0, 0.0 , 0.0},{0.0, 0.0 , - - DOUBLE 2/7
0.0}, ...
NCU570, not 810D {0.0, 0.0 , 0.0},{0.0, 0.0 , - - DOUBLE 0/0
0.0}, ...
mm Vector of kinematic offset of 5-axis transformation 1 POWER ON
(axis no.): 0...2
0.0}, ...
NCU570, all {0.0, 0.0 , 0.0},{0.0, 0.0 , - - DOUBLE 0/0
24562 TRAFO5_TOOL_ROT_AX_OFFSET_1 F2
mm Offset of swivel point of 1st rotary axis for 5-axis transformation with POWER ON
swiveled linear axis, 1st trafo
Offset of rotary axis to machine zero
not 810D {0.0, 0.0 , 0.0},{0.0, 0.0 , - - DOUBLE 2/7
0.0}, ...
NCU570, not 810D {0.0, 0.0 , 0.0},{0.0, 0.0 , - - DOUBLE 0/0
0.0}, ...

24564 TRAFO5_NUTATOR_AX_ANGLE_1 F2
Degrees Angle of inclination for 2nd rotary axis of 1st rotating head POWER ON
transformation
_always 45.0, 45.0, 45.0, 45.0, 0. 89. DOUBLE 2/7
45.0, 45.0, ...
NCU570 45.0, 45.0, 45.0, 45.0, 0. 89. DOUBLE 0/0
45.0, 45.0, ...
_always {0.0, 0.0 , 0.0},{0.0, 0.0 , - - DOUBLE 2/7
0.0}, ...
NCU570 {0.0, 0.0 , 0.0},{0.0, 0.0 , - - DOUBLE 0/0
0.0}, ...
(axis no.): 0...1
not 810D {0.0, 0.0},{0.0, 0.0},{0.0, - - DOUBLE 2/7
0.0}, ...
NCU570, not 810D {0.0, 0.0},{0.0, 0.0},{0.0, - - DOUBLE 0/0
0.0}, ...
(axis no.): 0...1
All transformations {0.0, 0.0},{0.0, 0.0},{0.0, - - DOUBLE 2/7
0.0}, ...
NCU570, all {0.0, 0.0},{0.0, 0.0},{0.0, - - DOUBLE 0/0
not 810D {1, 1},{1, 1},{1, 1},{1, 1},{1, - - BOOLEAN 2/7
1}, ...
NCU570, not 810D {1, 1},{1, 1},{1, 1},{1, 1},{1, - - BOOLEAN 0/0
1}, ...
All transformations {1, 1},{1, 1},{1, 1},{1, 1},{1, - - BOOLEAN 2/7
1}, ...
NCU570, all {1, 1},{1, 1},{1, 1},{1, 1},{1, - - BOOLEAN 0/0
transform. 1}, ...

not 810D 2.0, 2.0, 2.0, 2.0, 2.0, 2.0, - - DOUBLE 2/7
2.0, ...
NCU570, not 810D 2.0, 2.0, 2.0, 2.0, 2.0, 2.0, - - DOUBLE 0/0
2.0, ...
2.0, ...
NCU570, all 2.0, 2.0, 2.0, 2.0, 2.0, 2.0, - - DOUBLE 0/0
transform. 2.0, ...
transformation
not 810D 2.0, 2.0, 2.0, 2.0, 2.0, 2.0, - - DOUBLE 2/7
2.0, ...
NCU570, not 810D 2.0, 2.0, 2.0, 2.0, 2.0, 2.0, - - DOUBLE 0/0
2.0, ...
transformation
2.0, ...
NCU570, all 2.0, 2.0, 2.0, 2.0, 2.0, 2.0, - - DOUBLE 0/0
transform. 2.0, ...
(axis no.): 0...2
not 810D {0.0, 0.0 , 0.0},{0.0, 0.0 , - - DOUBLE 2/7
0.0}, ...
NCU570, not 810D {0.0, 0.0 , 0.0},{0.0, 0.0 , - - DOUBLE 0/0
0.0}, ...
(axis no.): 0...2
0.0}, ...
NCU570, all {0.0, 0.0 , 0.0},{0.0, 0.0 , - - DOUBLE 0/0

mm Vector of kinematic offset of 5-axis transformation 2 [axis no.]: 0...2 POWER ON
not 810D {0.0, 0.0 , 0.0},{0.0, 0.0 , - - DOUBLE 2/7
0.0}, ...
NCU570, not 810D {0.0, 0.0 , 0.0},{0.0, 0.0 , - - DOUBLE 0/0
0.0}, ...
mm Vector of kinematic offset of 5-axis transformation 2 [axis no.]: 0...2 POWER ON
0.0}, ...
NCU570, all {0.0, 0.0 , 0.0},{0.0, 0.0 , - - DOUBLE 0/0
mm Offset of swivel point of 2nd 5-axis transformation with swiveled linear POWER ON
axis
not 810D {0.0, 0.0 , 0.0},{0.0, 0.0 , - - DOUBLE 2/7
0.0}, ...
NCU570, not 810D {0.0, 0.0 , 0.0},{0.0, 0.0 , - - DOUBLE 0/0
0.0}, ...
mm Offset of swivel point of 2nd 5-axis transformation with swiveled linear POWER ON
axis
0.0}, ...
NCU570, all {0.0, 0.0 , 0.0},{0.0, 0.0 , - - DOUBLE 0/0
Degrees Angle of inclination for 2nd rotary axis of 2nd rotating head POWER ON
transformation
not 810D 45.0, 45.0, 45.0, 45.0, 0. 89. DOUBLE 2/7
45.0, 45.0, ...
NCU570, not 810D 45.0, 45.0, 45.0, 45.0, 0. 89. DOUBLE 0/0
45.0, 45.0, ...
Degrees Angle of inclination for 2nd rotary axis of 2nd rotating head POWER ON
transformation
All transformations 45.0, 45.0, 45.0, 45.0, 0. 89. DOUBLE 2/7
45.0, 45.0, ...
NCU570, all 45.0, 45.0, 45.0, 45.0, 0. 89. DOUBLE 0/0
transform. 45.0, 45.0, ...
24700 TRAANG_ANGLE_1 M1
Degrees Angle between Cartesian axis and real (inclined) axis POWER ON
Fct.: Inclined axis 0.0, 0.0, 0.0, 0.0, 0.0, 0.0, - - DOUBLE 2/7
transf. 0.0, ...

24710 TRAANG_BASE_TOOL_1 M1
mm Vector of base tool for 1st TRAANG transformation [axis no.]: 0...2 POWER ON
Fct.: Inclined axis {0.0, 0.0 , 0.0},{0.0, 0.0 , - - DOUBLE 2/7
transf. 0.0}, ...
24720 TRAANG_PARALLEL_VELO_RES_1 M1
Factor Velocity reserves of parallel axis for the 1st TRAANG transf. POWER ON
Fct.: Inclined axis 0.0, 0.0, 0.0, 0.0, 0.0, 0.0, 0.0 1.0 DOUBLE 2/7
transf. 0.0, ...
24721 TRAANG_PARALLEL_ACCEL_RES_1 M1
Factor Acceleration reserve of parallel axis for the 1st TRAANG transf. POWER ON
transf. 0.0, ...
24750 TRAANG_ANGLE_2 M1
Degrees Angle between Cartesian axis and real (inclined) axis POWER ON
Fct.: Inclined axis 0.0, 0.0, 0.0, 0.0, 0.0, 0.0, - - DOUBLE 2/7
transf. 0.0, ...
24760 TRAANG_BASE_TOOL_2 M1
mm Vector of base tool for 2nd TRAANG transformation [axis no.]: 0...2 POWER ON
Fct.: Inclined axis {0.0, 0.0 , 0.0},{0.0, 0.0 , - - DOUBLE 2/7
transf. 0.0}, ...
24770 TRAANG_PARALLEL_VELO_RES_2 M1
Factor Velocity reserve of parallel axis for the 2nd TRAANG transformation POWER ON
transf. 0.0, ...
24771 TRAANG_PARALLEL_ACCEL_RES_2 M1
Factor Acceleration reserve of parallel axis for the 2nd TRAANG POWER ON
transformation
transf. 0.0, ...
24800 TRACYL_ROT_AX_OFFSET_1 M1
st
Degrees Offset of rotary axis for the 1 TRACYL transformation POWER ON
Fct.: Periph. surf. 0.0, 0.0, 0.0, 0.0, 0.0, 0.0, - - DOUBLE 2/7
transf. 0.0, ...
24810 TRACYL_ROT_SIGN_IS_PLUS_1 M1
- Sign of rotary axis for 1st TRACYL transformation POWER ON
Fct.: Periph. surf. 1 *** *** BOOLEAN 2/7
transf.
24820 TRACYL_BASE_TOOL_1 M1
mm Vector of base tool for 1st TRACYL transformation [axis no.]: 0...2 POWER ON
Fct.: Periph. surf. {0.0, 0.0 , 0.0},{0.0, 0.0 , - - DOUBLE 2/7
transf. 0.0}, ...
24850 TRACYL_ROT_AX_OFFSET_2 M1
Degrees Offset of rotary axis for the 2nd TRACYL transformation POWER ON
Fct.: Periph. surf. 0.0, 0.0, 0.0, 0.0, 0.0, 0.0, - - DOUBLE 2/7
transf. 0.0, ...

24860 TRACYL_ROT_SIGN_IS_PLUS_2 M1
- Sign of rotary axis for 2nd TRACYL transformation POWER ON
Fct.: Periph. surf. 1 *** *** BOOLEAN 2/7
transf.
24870 TRACYL_BASE_TOOL_2 M1
mm Vector of base tool for 2nd TRACYL transformation [axis no.]: 0...2 POWER ON
Fct.: Periph. surf. {0.0, 0.0 , 0.0},{0.0, 0.0 , - - DOUBLE 2/7
transf. 0.0}, ...
24900 TRANSMIT_ROT_AX_OFFSET_1 M1
Degrees Offset of rotary axis for the 1st TRANSMIT transformation POWER ON
Fct.: Transmit 0.0, 0.0, 0.0, 0.0, 0.0, 0.0, - - DOUBLE 2/7
0.0, ...
24910 TRANSMIT_ROT_SIGN_IS_PLUS_1 M1
- Sign of rotary axis for 1st TRANSMIT transformation POWER ON
Fct.: Transmit 1 *** *** BOOLEAN 2/7
24920 TRANSMIT_BASE_TOOL_1 M1
mm Vector of base tool for 1st TRANSMIT transformation [axis no.]: 0...2 POWER ON
Fct.: Transmit {0.0, 0.0 , 0.0},{0.0, 0.0 , - - DOUBLE 2/7
0.0}, ...
24950 TRANSMIT_ROT_AX_OFFSET_2 M1
Degrees Offset of rotary axis for the 2nd TRANSMIT transformation POWER ON
Fct.: Transmit 0.0, 0.0, 0.0, 0.0, 0.0, 0.0, - - DOUBLE 2/7
0.0, ...
24960 TRANSMIT_ROT_SIGN_IS_PLUS_2 M1
- Sign of rotary axis for 2nd TRANSMIT transformation POWER ON
Fct.: Transmit 1 *** *** BOOLEAN 2/7
24970 TRANSMIT_BASE_TOOL_2 M1
mm Vector of base tool for 2nd TRANSMIT transformation [axis no.]: 0...2 POWER ON
Fct.: Transmit {0.0, 0.0 , 0.0},{0.0, 0.0 , - - DOUBLE 2/7
0.0}, ...

Punching and Nibbling

26000 PUNCHNIB_ASSIGN_FASTIN N4
HEX Hardware assignment for input byte for stroke control POWER ON
Fct.: Nibbling 0, 0, 0, 0, 0, 0, 0, 0, 0, 0, - - DWORD 2/7
0, ...
26002 PUNCHNIB_ASSIGN_FASTOUT N4
HEX Hardware assignment for output byte for stroke control POWER ON
0, ...
26004 NIBBLE_PUNCH_OUTMASK N4
HEX Mask for fast output bits POWER ON
Fct.: Nibbling {1, 0, 0, 0, 0, 0, 0, 0},{0, 0, - - BYTE 2/7
0, ...
26006 NIBBLE_PUNCH_INMASK N4
HEX Mask for fast input bits POWER ON
Fct.: Nibbling {1, 0, 0, 0, 0, 0, 0, 0},{0, 0, - - BYTE 2/7
0, ...
26008 NIBBLE_PUNCH_CODE N4
HEX Definition of M functions POWER ON
Fct.: Nibbling {0,23,22, 25, 26, 0, 0, - - DWORD 2/7
0},{0, 0, 0, ...
26010 PUNCHNIB_AXIS_MASK N4
HEX Definition of punching and nibbling axes POWER ON
0, ...
26012 PUNCHNIB_ACTIVATION N4
HEX Activation of punching and nibbling functions POWER ON
0, ...
26014 PUNCH_PATH_SPLITTING N4
HEX Activation of automatic path segmentation POWER ON
0, ...
26016 PUNCH_PARTITION_TYPE N4
HEX Behavior of individual axes with automatic path segmentation POWER ON
0, ...
26018 NIBBLE_PRE_START_TIME N4
s Delay time for nibbling/punching with G603 POWER ON
Fct.: Nibbling 0., 0., 0., 0., 0., 0., 0., 0. - - DOUBLE 2/7

26020 NIBBLE_SIGNAL_CHECK N4
- Alarm on chattering punching signal POWER ON
0, ...
Channel-specific memory settings

27900 REORG_LOG_LIMIT S7
- Percentage of IPO buffer for enabling of log file POWER ON
_always 1, 1, 1, 1, 1, 1, 1, 1,1, 1, 1, - - BYTE 0/0
1, ...
28000 MM_REORG_LOG_FILE_MEM S7
kB Memory space for REORG (DRAM) POWER ON
_always 10, 1, 1, 1, 1, 1, 1, 1,1, 1, 0 500 DWORD 2/7
1, 1, ...
NCU570 10, 1, 1, 1, 1, 1, 1, 1,1, 1, 0 50 DWORD 2/7
1, 1, ...
28010 MM_NUM_REORG_LUD_MODULES S7
- Number of blocks for local user variables in REORG (DRAM) POWER ON
_always 4, 4, 4, 4, 4, 4, 4, 4,4, 4, 0 100 DWORD 2/7
4, 4, ...
28020 MM_NUM_LUD_NAMES_TOTAL S7
- Number of local user variables (DRAM) POWER ON
_always 200, 20, 20, 20, 20, 20, 0.0 plus DWORD 2/7
20, 20,20, ...
28040 MM_LUD_VALUES_MEM S7
kB Memory space for local user variables (DRAM) POWER ON
_always 25, 25, 25, 25, 25, 25, 25, 0.0 plus DWORD 2/7
25,25, ...
28050 MM_NUM_R_PARAM S7
- Number of channel-specific R parameters (SRAM) POWER ON
_always 100, 10, 10, 10, 10, 10, 0 1000 DWORD 2/7
10, 10,10, ...

28060 MM_IPO_BUFFER_SIZE S7
- Number of NC blocks in IPO buffer (DRAM) POWER ON
_always DWORD 2/7
NCU572, 573 10, 10, 10, 10, 10, 10, 10, 2 300 DWORD 2/7
10,10, ...
NCU571 10, 10, 10, 10, 10, 10, 10, 2 15 DWORD 2/7
10
NCU570 10, 10, 10, 10, 10, 10, 10, 2 30 DWORD 2/7
10
810D 10, 10, 10, 10, 10, 10, 10, 2 15 DWORD 2/7
10
28070 MM_NUM_BLOCKS_IN_PREP S7
- Number of blocks for block preparation (DRAM) POWER ON
_always DWORD 2/7
NCU572, 573 40, 40, 30, 30, 30, 30, 30, 20 50 DWORD 2/7
30,30, ...
NCU571 24, 20, 20, 20, 20, 20, 20, 20 30 DWORD 2/7
20
NCU570 40, 20, 20, 20, 20, 20, 20, 20 50 DWORD 2/7
20
810D 26, 20, 20, 20, 20, 20, 20, 20 30 DWORD 2/7
20
28080 MM_NUM_USER_FRAMES S7
- Number of settable frames (SRAM) POWER ON
_always 5, 5, 5, 5, 5, 5, 5, 5,5, 5, 5, 5 100 DWORD 2/7
5, ...
28085 MM_LINK_TOA_UNIT W1
- Assignment of a TO unit to a channel (SRAM) POWER ON
_always 1, 2, 3, 4, 5, 6, 7, 1 10 DWORD 2/7
8,9,10,11,12, ...
28090 MM_NUM_CC_BLOCK_ELEMENTS S7
- Number of block elements for compile cycles (DRAM POWER ON
Compile cycles 0, 0, 0, 0, 0, 0, 0, 0,0, 0, 0 20 DWORD 1/7
0, 0, ...
NC570 Compile 0, 0, 0, 0, 0, 0, 0, 0,0, 0, 0 20 DWORD 0/0
cycles 0, 0, ...
28100 MM_NUM_CC_BLOCK_USER_MEM S7
kB Size of block memory for compile cycles (DRAM), in KB POWER ON
Compile cycles 0, 0, 0, 0, 0, 0, 0, 0 0 256 DWORD 1/7
NCU572, 573 256, 0, 0, 0, 0, 0, 0, 0,0, 0 256 DWORD 2/7
Compile cycles 0, 0, ...
NC570 Compile 256, 0, 0, 0, 0, 0, 0, 0,0, 0 256 DWORD 0/0
cycles 0, 0, ...
28200 MM_NUM_PROTECT_AREA_CHAN S7
- Number of files for channel-specific protection zones (SRAM) POWER ON
_always 0, 0, 0, 0, 0, 0, 0, 0,0, 0, 0, 0 10 DWORD 2/7
0, ...
28210 MM_NUM_PROTECT_AREA_ACTIVE S7
- Number of simultaneously active protection zones in one channel POWER ON
_always 0, 0, 0, 0, 0, 0, 0, 0,0, 0, 0, 0 10 DWORD 2/7
0, ...

28500 MM_PREP_TASK_STACK_SIZE S7
kB Stack size of preparation task (DRAM) POWER ON
NCU572, 573 20, 20, 20, 20, 20, 20, 20, 4 40 DWORD 2/7
20,20, ...
NCU571 32, 20, 20, 20, 20, 20, 20, 4 40 DWORD 2/7
20
NCU570 20, 20, 20, 20, 20, 20, 20, 4 40 DWORD 2/7
20
810D 20, 20, 20, 20, 20, 20, 20, 4 40 DWORD 2/7
20,20, ...
28510 MM_IPO_TASK_STACK_SIZE S7
kB Stack size of IPO task (DRAM) POWER ON
NCU572, 573 12, 12, 12, 12, 12, 12, 12, 4 40 DWORD 2/7
12,12, ...
NCU571 8, 12, 12, 12, 12, 12, 12, 4 40 DWORD 2/7
12
NCU570 8, 12, 12, 12, 12, 12, 12, 4 40 DWORD 2/7
12
810D 12, 12, 12, 12, 12, 12, 12, 4 40 DWORD 2/7
12,12, ...
3.4 Axes-specific machine data
Configuration

Unit Name, other information Effect Valid from
HW/Function Standard value Minimum Maximum value D-typ Prot.
value
30100 CTRLOUT_SEGMENT_NR G2
- Setpoint assignment: Drive type (setpoint branch): 0 POWER ON
NCU570 0 0 2 BYTE 2/7
30110 CTRLOUT_MODULE_NR G2
- Setpoint assignment: Drive number/module no. (setpoint branch): 0 POWER ON
NCU570 1 1 1 BYTE 2/7
30120 CTRLOUT_NR G2
- Setpoint assignment: Setpoint output on drive submodule/module POWER ON
(setpoint branch): 0
NCU570 1 1 4 BYTE 2/7

30130 CTRLOUT_TYPE G2
- Output type of setpoint (setpoint branch): 0 POWER ON
30200 NUM_ENCS G2
- Number of encoders POWER ON
30210 ENC_SEGMENT_NR G2
- Actual value assignment: Drive type (encoder no.): 0,1 POWER ON
_always 1, 1 0 1 BYTE 0/0
NCU570 0, 0 0 2 BYTE 2/7
30220 ENC_MODULE_NR G2
- Actual value assignment: Drive number/measuring circuit number POWER ON
(encoder no.): 0, 1
_always 1, 1 1 31 BYTE 2/7
NCU570 1, 1 1 1 BYTE 2/7
30230 ENC_INPUT_NR G2
- Actual value assignment: Input to drive submodule/measuring circuit POWER ON
board (encoder no.): 0,1
NCU570 1, 1 1 4 BYTE 2/7
810D 1, 1 1 2 BYTE 2/7
30240 ENC_TYPE G2
- Type of actual value acquisition (actual position value) (encoder no.):0,1 POWER ON
0: Simulation
1: Raw signal encoder, high resolution
2: Square-wave generator, standard encoder (pulse multiplication)
3: Encoder for stepper motor
4: Absolute encoder with EnDat interface
5: Absolute encoder with SSI interface (FM-NC)
NCU570 0, 0 0 5 BYTE 2/7
30300 IS_ROT_AX R2
- Rotary axis / spindle POWER ON
30310 ROT_IS_MODULO R2
- Modulo conversion for rotary axis / spindle POWER ON
30320 DISPLAY_IS_MODULO R2
- Modulo 360 degrees display for rotary axes and spindle POWER ON
30350 SIMU_AX_VDI_OUTPUT G2
- Output of axis signals with simulation axes POWER ON

30400 IS_CC_AX OEM
- Axis programmable by C cycles POWER ON
NCU570 0 *** *** BOOLEAN 0/0
30450 IS_CONCURRENT_POS_AX P2
- Concurrent positioning axis POWER ON
30500 INDEX_AX_ASSIGN_POS_TAB T1
- Axis is indexing axis POWER ON
30550 AXCONF_ASSIGN_MASTER_CHAN K1
- Initial setting of channel for change of axis POWER ON
NCU570 0 0 10 BYTE 0/0
30552 AUTO_GET_TYPE S1, K5
- Automatic GET for get axis POWER ON
30600 FIX_POINT_POS K1
mm, Fixed-value positions of axis with G75 (position no.): 0,1 POWER ON
degrees
_always 0.0, 0.0 - - DOUBLE 2/7
Encoder matching

31000 ENC_IS_LINEAR G2
- Direct measuring system (linear scale) (encoder no.): 0,1 POWER ON
31010 ENC_GRID_POINT_DIST G2
mm Division period for linear scales (encoder no.): 0,1 POWER ON
_always 0.01, 0.01 0.0 plus DOUBLE 2/7
31020 ENC_RESOL G2
- Encoder markings per revolution (encoder no.): 0,1 POWER ON
_always 2048, 2048 0.0 plus DWORD 2/7
31030 LEADSCREW_PITCH G2
mm Pitch of leadscrew POWER ON
31040 ENC_IS_DIRECT G2
- Encoder mounted directly on the machine (encoder no:): 0,1 POWER ON

31050 DRIVE_AX_RATIO_DENOM G2
- Denominator load gearbox (control parameter no.): 0...5 POWER ON
_always 1, 1, 1, 1, 1, 1 1 2147000000 DWORD 2/7
31060 DRIVE_AX_RATIO_NUMERA G2
- Numerator load gearbox (control parameter set no.): 0...5 POWER ON
_always 1, 1, 1, 1, 1, 1 1 2147000000 DWORD 2/7
31070 DRIVE_ENC_RATIO_DENOM G2
- Denominator measuring gearbox (encoder no.): 0,1 POWER ON
_always 1, 1 1 2147000000 DWORD 2/7
31080 DRIVE_ENC_RATIO_NUMERA G2
- Numerator measuring gearbox (encoder no.): 0,1 POWER ON
_always 1, 1 1 2147000000 DWORD 2/7
31090 JOG_INCR_WEIGHT H1
mm, Evaluation of an increment with INC/handwheel RESET
degrees
31100 BERO_CYCLE S6
- Steps for rotation monitoring POWER ON
NCU570 2000, 2000 10 10000000 DWORD 2/7
31110 BERO_EDGE_TOL S6
- Step tolerance for monitoring rotation POWER ON
NCU570 50, 50 10 10000000 DWORD 2/7
31120 BERO_EDGE S6
- BERO evaluation edge POWER ON
NCU570 1 *** *** BOOLEAN 0/0
31130 VCO25_WEIGHT S6
- VCO characteristic correction 62.5 kHz NEW CONF
NCU570 1.0 -1.10 1.10 DOUBLE 2/7
- VCO characteristic correction 125 KHz NEW CONF
NCU570 1.0 -1.10 1.10 DOUBLE 2/7
- VCO characteristic correction 185.5 KHz NEW CONF
NCU570 1.0 -1.10 1.10 DOUBLE 2/7
- VCO characteristic correction 250 KHz NEW CONF
NCU570 1.0 -1.10 1.10 DOUBLE 2/7
31200 SCALING_FACTOR_G70_G71 G2
- Factor for converting values while G70/G71 is active POWER ON
31300 START_STOP_FREQUENCY S6
- Max. frequency deviation with stepper motors NEW CONF
NCU570 2002.0 0.1 4000.0 DOUBLE 0/0

31310 FREQUENCY1 S6
- 1st frequency deviation limit NEW CONF
NCU570 2001.0 0.1 4000.0 DOUBLE 0/0
31320 FREQUENCY2 S6
- 2nd frequency deviation limit NEW CONF
NCU570 2000.0 0.1 4000.0 DOUBLE 0/0
31330 FREQ_REDUCTION_POINT1 S6
- Frequency at which stroke limitation 1 is active NEW CONF
NCU570 10.0 0.1 4000.0 DOUBLE 0/0
31340 FREQ_REDUCTION_POINT2 S6
- Frequency at which stroke limitation 2 is active NEW CONF
NCU570 50.0 0.1 4000.0 DOUBLE 0/0
31350 FREQ_STEP_LIMIT S6
- Stepping rate at maximum velocity NEW CONF
NCU570 250.0 0.1 4000.0 DOUBLE 2/7
Closed-loop control

32000 MAX_AX_VELO G2
mm/min, Maximum axis velocity NEW CONF
rpm
_always 10000. 0.0 plus DOUBLE 2/7
32010 JOG_VELO_RAPID H1
mm/min, Conventional rapid traverse RESET
rpm
32020 JOG_VELO H1
mm/min, Conventional axis speed RESET
rpm
32040 JOG_REV_VELO_RAPID H1
mm/rpm Rotational feedrate in JOG with rapid traverse overlay RESET
32050 JOG_REV_VELO H1
mm/rpm Rotational feedrate in JOG RESET
32060 POS_AX_VELO P2
mm/min, Initial setting for positioning axis speed RESET
rpm

32070 CORR_VELO H1, K2, W4
% Axis velocity for handwheel override, ext. ZO, cont. dressing, distance RESET
control
Height regulation
32080 HANDWH_MAX_INCR_SIZE H1
mm, Limitation of selected increment RESET
degrees
32082 HANDWH_MAX_INCR_VELO_SIZE H1
mm/min, Limitation of selected increment for velocity overlay RESET
RPM
32084 HANDWH_STOP_COND H1
- Control of VDI signals with respect to handwheel RESET
_always 0x3F 0 0x3F DWORD 2/7
32090 HANDWH_VELO_OVERLAY_FACTOR H1
- Ratio of JOG speed to handwheel speed (DRF) RESET
32100 AX_MOTION_DIR G2
- Traversing direction (not control direction) POWER ON
_always 1 -1 1 DWORD 2/7
32110 ENC_FEEDBACK_POL G2
- Sign actual value (control direction) (encoder no.): 0,1 POWER ON
_always 1, 1 -1 1 DWORD 2/7
32200 POSCTRL_GAIN G2
1000/min Servo gain factor (control parameter set no.): 0...5 NEW CONF
_always 1 0.0 plus DOUBLE 2/7
32250 RATED_OUTVAL G2
% Rated output voltage (setpoint branch): 0 NEW CONF
32260 RATED_VELO G2
RPM Rated motor speed (setpoint branch): 0 NEW CONF
NCU572, 573 300 0.0 plus DOUBLE 0/0
NCU571 300 0.0 plus DOUBLE 0/0
32300 MAX_AX_ACCEL B2
mm/s^2, Axis acceleration NEW CONF
Rev/s^2
32310 MAX_ACCEL_OVL_FACTOR B1
Factor Overload factor for axial velocity steps RESET

32400 AX_JERK_ENABLE B2
- Axial jerk limitation NEW CONF
32410 AX_JERK_TIME B2
s Time constant for axial jerk filter NEW CONF
32420 JOG_AND_POS_JERK_ENABLE B2
- Default setting of axis jerk limitation RESET
32430 JOG_AND_POS_MAX_JERK B2
mm/s^3, Axial jerk RESET
degr./s^3
32432 PATH_TRANS_JERK_LIM B1
mm/s^3, Max. axial jerk of a Geo axis at block limit RESET
degr./s^3
32450 BACKLASH K3
mm, Backlash (encoder no.): 0...1 NEW CONF
degrees
_always 0.0, 0.0 - - DOUBLE 2/7
32460 TORQUE_OFFSET K3
% Additional torque for electronic weight compensation NEW CONF
_always 0.0 -100.0 100.0 DOUBLE 2/7
NCU570 0.0 -100.0 100.0 DOUBLE 0/0
810D 0.0 -100.0 100.0 DOUBLE 0/0
32490 FRICT_COMP_MODE K3
- Type of friction compensation (setpoint branch): 0 POWER ON
0: No comp, 1: Compens. with const. injected value
2: Comp. with characteristic learned via neural network (option)
810D 1 0 1 BYTE 2/7
32500 FRICT_COMP_ENABLE K3
- Friction compensation active NEW CONF
32510 FRICT_COMP_ADAPT_ENABLE K3
- Adaptation friction compensation active (setpoint branch): 0 NEW CONF
32520 FRICT_COMP_CONST_MAX K3
mm/min, Maximum friction compensation value (setpoint branch): 0 NEW CONF
RPM
32530 FRICT_COMP_CONST_MIN K3
mm/min, Minimum friction compensation value (setpoint branch): 0 NEW CONF
RPM

32540 FRICT_COMP_TIME K3
s Friction compensation time constant (setpoint branch): 0 NEW CONF
32550 FRICT_COMP_ACCEL1 K3
mm/s^2, Adaptation acceleration value 1 (setpoint branch): 0 NEW CONF
Rev/s^2
Rev/s^2
Rev/s^2
32580 FRICT_COMP_INC_FACTOR K3
% Weighting factor of friction compensation value with short traversing NEW CONF
movements
_always 0.0 0 100.0 DOUBLE 2/7
32610 VELO_FFW_WEIGHT K3
Factor Feed forward factor for speed feed forward control NEW CONF
32620 FFW_MODE K3
- Feed forward control type POWER ON
0: No feed forward control 1: Speed feed forward control
2: Speed and torque feed forward control
810D 1 0 1 BYTE 2/7
32630 FFW_ACTIVATION_MODE K3
- Activate feed forward control from program POWER ON
_always 1 - - BYTE 2/7
32650 AX_INERTIA K3
kgm^2 Moment of inertia for torque feed forward control NEW CONF
32700 ENC_COMP_ENABLE K3
- Interpolatory compensation (encoder no.): 0,1 POWER ON
32710 CEC_ENABLE K3
- Enable sag compensation NEW CONF
Fct.: CEC 0 *** *** BOOLEAN 2/7
32720 CEC_MAX_SUM K3
mm, Maximum compensation value for sag compensation NEW CONF
degrees
Fct.: CEC 1.0 0 10.0 DOUBLE 2/7

32730 CEC_MAX_VELO K3
% Maximum change value with sag compensation with ref. to MD32000 NEW CONF
Fct.: CEC 10.0 0 100.0 DOUBLE 2/7
32750 TEMP_COMP_TYPE K3
HEX Temperature compensation type POWER ON
0: No compensation
Bit 0 = 1: Position-independent compensation active
Bit 1 = 1: Position-dependent compensation active
32760 COMP_ADD_VELO_FACTOR K3
Factor Excessive velocity due to compensation POWER ON
_always 0.01 0. 0.10 DOUBLE 2/7
32800 EQUIV_CURRCTRL_TIME K3
s Equivalent time constant current control loop for feed forward control NEW CONF
(control parameter set no.): 0...5
0.0005, ...
32810 EQUIV_SPEEDCTRL_TIME K3
s Equivalent time constant speed control loop for feed forward control NEW CONF
(control parameter set no.): 0...E
_always 0.0 plus DOUBLE 2/7
NCU572, 573 0.004, 0.004, 0.004, 0.0 plus DOUBLE 2/7
0.004, 0.004, ...
NCU571 0.004, 0.004, 0.004, 0.0 plus DOUBLE 2/7
0.004, 0.004, ...
NCU570 0.004, 0.004, 0.004, 0.0 plus DOUBLE 2/7
0.004, 0.004, ...
810D 0.0025, 0.0025, 0.0025, 0.0 plus DOUBLE 2/7
0.0025, ...
32900 DYN_MATCH_ENABLE G2
- Dynamic matching NEW CONF
32910 DYN_MATCH_TIME G2
s Time constant of dynamic response adaptation NEW CONF
(control parameter set no.): 0...5
_always 0.0, 0.0, 0.0, 0.0, 0.0, 0.0 0.0 plus DOUBLE 2/7
32920 AC_FILTER_TIME S5
s Smoothing factor time constant for adaptive control POWER ON
32950 POSCTRL_DAMPING G2
Factor Damping of position control loop NEW CONF
33000 FIPO_TYPE G2
- Fine interpolator type (1: differential FIPO, 2: cubic FIPO) POWER ON

33050 LUBRICATION_DIST A2
mm, Traversing distance for lubrication from PLC NEW CONF
degrees
33100 COMPRESS_POS_TOL K1
mm, Maximum deviation during compression POWER ON
degrees
Fct.: Polynom 0.1 0.0 plus DOUBLE 2/7
Fct.: NCU570 0.1 0.0 plus DOUBLE 0/0
Polynom
Referencing

34000 REFP_CAM_IS_ACTIVE R1
- Axis with reference point cam RESET
34010 REFP_CAM_DIR_IS_MINUS R1
- Approach reference point in minus direction RESET
34020 REFP_VELO_SEARCH_CAM R1
mm/min, Reference point approach speed RESET
rpm
34030 REFP_MAX_CAM_DIST R1
mm, Maximum distance to reference cam RESET
degrees
34040 REFP_VELO_SEARCH_MARKER R1
mm/min, Shutdown speed (encoder no.): 0,1 RESET
rpm
34050 REFP_SEARCH_MARKER_REVERSE R1
- Direction reversal to reference cams (encoder no.): 0,1 RESET
34060 REFP_MAX_MARKER_DIST R1
mm, Maximum distance to reference mark. Max. distance to 2 reference RESET
degrees marks
for distance-coded measuring systems. (encoder no.): 0,1

34070 REFP_VELO_POS R1
mm/min, Reference point positioning velocity RESET
RPM
34080 REFP_MOVE_DIST R1
mm, Reference point distance/target point for distance-coded system RESET
degrees
_always -2.0, -2.0 - - DOUBLE 2/7
34090 REFP_MOVE_DIST_CORR R1
mm, Reference point offset/absolute offset distance-coded POWER ON
degrees (encoder no.): 0,1
_always 0.0, 0.0 - - DOUBLE 2/7
34092 REFP_CAM_SHIFT R1
mm, Electr. cam offset of incremental measuring systems with equidistant RESET
degrees zero marks
34100 REFP_SET_POS R1
mm, Reference point value/irrelevant for distance-coded system RESET
degrees
_always 0., 0., 0., 0. - - DOUBLE 2/7
34102 REFP_SYNC_ENCS R1
- Calibration of measuring system RESET
34110 REFP_CYCLE_NR R1
- Sequence of axes in channel-specific referencing RESET
-1: No obligatory reference point for NC Start
0: No channel-specific reference-point approach
1-15: Sequence in channel-specific reference point approach
34200 ENC_REFP_MODE R1
- Type of position measuring system (encoder no.): 0,1 POWER ON
0: No ref. point appr.; if absolute encoder exists: REFP_SET_POS
accepted
1: Zero pulse (on encoder track)
2: Proximity switch
3: Distance-coded reference marks
4: Proximity switch with two edges
5. Proximity switch cam
6. Measuring system calibration to referenced encoder
NCU570 1, 1 0 5 BYTE 2/7
34210 ENC_REFP_STATE R1
- Status absolute encoder [encoder no.]: 0,1 RESET
0: Encoder not adjusted
1: Encoder enabled
2; Encoder is adjusted

34220 ENC_ABS_TURNS_MODULO R2
- Range limit rotary axis with absolute encoder POWER ON
_always 1, 1 1 4096 DWORD 2/7
34300 ENC_REFP_MARKER_DIST R1
mm, Reference mark distance for distance-coded scales (encoder no.): 0,1 POWER ON
degrees
_always 10.0, 10.0 - - DOUBLE 2/7
34310 ENC_MARKER_INC R1
mm, Differential distance between reference marks for distance-coded RESET
degrees scales
(encoder no.): 0,1
34320 ENC_INVERS R1
- Linear measurement system in opposite sense (encoder no.): 0,1 RESET
34330 REFP_STOP_AT_ABS_MARKER R1
- Distance coded linear measurement system without target point RESET
[encoder no.]: 0.1
34400 ENC_SSI_STATUS G2
- Synchronization data for SSI absolute value encoder POWER ON
NCU570 0x00, 0x00 - - BYTE 2/7
34410 ENC_SSI_MESSAGE_LENGTH G2
- Message length for SSI absolute value encoder POWER ON
NCU570 0, 0 0 3 BYTE 2/7
34420 ENC_SSI_MESSAGE_FORMAT G2
- Steps per encoder revolution POWER ON
NCU570 0, 0 0 13 BYTE 2/7
Spindles

35000 SPIND_ASSIGN_TO_MACHAX S1
- Assignment of spindle to machine axis POWER ON
35010 GEAR_STEP_CHANGE_ENABLE S1
- Gear change possible. Spindle has several gear steps POWER ON

35020 SPIND_DEFAULT_MODE S1
- Spindle initial setting RESET
0/1: speed mode without/with pos. control., 2: pos. mode, 3: axis
mode
35030 SPIND_DEFAULT_ACT_MASK S1
HEX Time at which basic spindle setting is effective RESET
0: Power on, 1: Progr. start. 2: Reset (M2/M30)
_always 0x00 0 0x03 BYTE 2/7
35040 SPIND_ACTIVE_AFTER_RESET S1
- Own spindle reset POWER ON
35100 SPIND_VELO_LIMIT S1
rpm Maximum spindle speed POWER ON
35110 GEAR_STEP_MAX_VELO S1
rpm Maximum speed for gear change (gear step no.): 0..5 NEW CONF
35120 GEAR_STEP_MIN_VELO S1
rpm Minimum speed for gear change (gear step no.): 0..5 NEW CONF
35130 GEAR_STEP_MAX_VELO_LIMIT S1
rpm Maximum speed of gear step (gear step no.): 0...5 NEW CONF
35140 GEAR_STEP_MIN_VELO_LIMIT S1
rpm Minimum speed of gear step (gear step no.): 0...5 NEW CONF
35150 SPIND_DES_VELO_TOL S1
Factor Spindle speed tolerance RESET
35160 SPIND_EXTERN_VELO_LIMIT S1
rpm Spindle speed limitation from PLC NEW CONF
35200 GEAR_STEP_SPEEDCTRL_ACCEL S1
rpm/s^2 Acceleration in speed control mode [gear step no.]: 0...5 NEW CONF
35210 GEAR_STEP_POSCTRL_ACCEL S1
rpm/s^2 Acceleration in position control mode (gear step no.): 1...5 NEW CONF
35220 ACCEL_REDUCTION_SPEED_POINT S1
Factor Speed for reduced acceleration RESET

35230 ACCEL_REDUCTION_FACTOR S1
Factor Reduced acceleration RESET
_always 0.0 0.0 0.95 DOUBLE 2/7
35240 ACCEL_TYPE_DRIVE B2
- Type of acceleration RESET
Fct.: Stepper 0 *** *** BOOLEAN 2/7
motor
35242 ACCEL_REDUCTION_TYPE B2
- Type of acceleration reduction RESET
Fct.: Stepper 1 0 2 BYTE 2/7
motor
35300 SPIND_POSCTRL_VELO S1
rpm Position control switch-on speed NEW CONF
35350 SPIND_POSITIONING_DIR S1
- Direction of rotation when positioning RESET
35400 SPIND_OSCILL_DES_VELO S1
rpm Oscillation speed NEW CONF
35410 SPIND_OSCILL_ACCEL S1
rpm/s^2 Acceleration during oscillation NEW CONF
35430 SPIND_OSCILL_START_DIR S1
- Starting direction during oscillation RESET
0-2: As last direction of rotation (zero-speed M3)
3: M3 direction
4: M4 direction
35440 SPIND_OSCILL_TIME_CW S1
s Oscillation time for M3 direction NEW CONF
35450 SPIND_OSCILL_TIME_CCW S1
s Oscillation time for M4 direction NEW CONF
35500 SPIND_ON_SPEED_AT_IPO_START S1
- Feedrate enable for spindle in the set range RESET
35510 SPIND_STOPPED_AT_IPO_START S1
- Feedrate enable for spindle stopped RESET

Monitoring functions

36000 STOP_LIMIT_COARSE B1
mm, Exact stop coarse NEW CONF
degrees
36010 STOP_LIMIT_FINE B1
mm, Exact stop fine NEW CONF
degrees
36020 POSITIONING_TIME B1
s Delayed exact stop, fine NEW CONF
36030 STANDSTILL_POS_TOL A3
mm, Zero-speed tolerance NEW CONF
degrees
36040 STANDSTILL_DELAY_TIME A3
s Delay zero-speed monitoring NEW CONF
36050 CLAMP_POS_TOL A3
mm, Clamping tolerance NEW CONF
degrees
36060 STANDSTILL_VELO_TOL A2
mm/min, Maximum velocity/speed "axis/spindle stopped" NEW CONF
RPM
36100 POS_LIMIT_MINUS A3
mm, 1st software limit switch minus RESET
degrees
_always -100000000 - - DOUBLE 2/7
36110 POS_LIMIT_PLUS A3
mm, 1st software limit switch plus RESET
degrees
_always 100000000 - - DOUBLE 2/7
36120 POS_LIMIT_MINUS2 A3
mm, 2nd software limit switch minus RESET
degrees
_always -100000000 - - DOUBLE 2/7

36130 POS_LIMIT_PLUS2 A3
mm, 2nd software limit switch plus RESET
degrees
_always 100000000 - - DOUBLE 2/7
36200 AX_VELO_LIMIT A3
mm/min, Threshold value for velocity monitoring NEW CONF
RPM (control parameter set no.): 0...55
_always 11500., 11500., 11500., 0.0 plus DOUBLE 2/7
11500., ...
36210 CTRLOUT_LIMIT G2
% Maximum speed setpoint (set point branch): 0 NEW CONF
_always 110.0 0 200 DOUBLE 2/7
NCU570 100.0 0 100 DOUBLE 2/7
36220 CTRLOUT_LIMIT_TIME A3
s Delay for speed setpoint [setpoint branch]: 0 NEW CONF
36300 ENC_FREQ_LIMIT A3
Hz Encoder limit frequency (encoder no.): 0,1 POWER ON
36302 ENC_FREQ_LIMIT_LOW A3
% Encoder limit frequency at which encoder is switched on again. NEW CONF
(Hysteresis)
_always 99.9, 99.9 0 100 DOUBLE 2/7
36310 ENC_ZERO_MONITORING A3
- Zero mark monitoring (encoder no.): 0,1 NEW CONF
0: Zero mark monitoring off, encoder HW monitoring on
1-99, >100: Number of recognized zero mark errors during monitoring
100: Zero mark monitoring off, encoder HW monitoring off
_always 0, 0 0.0 plus DWORD 2/7
36400 CONTOUR_TOL A3
mm, Tolerance band for contour monitoring NEW CONF
degrees
36500 ENC_CHANGE_TOL G2
mm, Maximum tolerance for position actual value switchover NEW CONF
degrees
36600 BRAKE_MODE_CHOICE A3
- Deceleration response on hardware limit switch; POWER ON
0: Deceleration ramp

36610 AX_EMERGENCY_STOP_TIME A3
s Duration of the deceleration ramp for error states NEW CONF
36620 SERVO_DISABLE_DELAY_TIME A2
s Cutout delay servo enable NEW CONF
36690 AXIS_DIAGNOSIS -
- Internal data for test purposes POWER ON
36700 DRIFT_ENABLE K3
- Automatic drift compensation NEW CONF
NCU572, 573 0 *** *** BOOLEAN 0/0
NCU571 0 *** *** BOOLEAN 0/0
810D 0 *** *** BOOLEAN 0/0
36710 DRIFT_LIMIT K3
% Drift limit value for automatic drift compensation NEW CONF
36720 DRIFT_VALUE K3
% Drift basic value NEW CONF
_always 0.0 DOUBLE 0/0
NCU570 0.0 -5.0 5.0 DOUBLE 2/7
36730 DRIVE_SIGNAL_TRACKING S5
- Acquisition of additional drive actual values POWER ON
36750 AA_OFF_MODE S5
- Effect of value assignment for axial overlay in synchronous actions POWER ON
37000 FIXED_STOP_MODE F1
- Mode travel to fixed stop POWER ON
37010 FIXED_STOP_TORQUE_DEF F1
% Default fixed stop clamping torque POWER ON
_always 5.0 0.0 100.0 DOUBLE 2/7
37020 FIXED_STOP_WINDOW_DEF F1
mm, Default fixed-stop monitoring window POWER ON
degrees

37030 FIXED_STOP_THRESHOLD F1
mm, Threshold for fixed stop detection NEW CONF
degrees
37040 FIXED_STOP_BY_SENSOR F1
- Fixed stop detection by sensor POWER ON
37050 FIXED_STOP_ALARM_MASK F1
- Enable of the fixed stop alarms POWER ON
37060 FIXED_STOP_ACKN_MASK F1
- PLC acknowledgements observed for travel to fixed stop POWER ON
0. Do not wait, 1: wait, 3: Analog drives
37070 FIXED_STOP_ANA_TORQUE F1
% Torque limit for startup of the fixed stop for analog drives POWER ON
_always 5.0 0.0 100.0 DOUBLE 2/7
37100 GANTRY_AXIS_TYPE G1
- Gantry axes definition POWER ON
Fct.: Gantry Axes 0 0 33 BYTE 2/7
37110 GANTRY_POS_TOL_WARNING G1
mm, Gantry warning limit RESET
degrees
Fct.: Gantry Axes 0.0 - - DOUBLE 2/7
37120 GANTRY_POS_TOL_ERROR G1
mm, Gantry shutdown limit POWER ON
degrees
37130 GANTRY_POS_TOL_REF G1
mm, Gantry shutdown limit during referencing POWER ON
degrees
37140 GANTRY_BREAK_UP G1
- Invalidate gantry axis grouping RESET
Fct.: Gantry Axes 0 *** *** BOOLEAN 2/7
37200 COUPLE_POS_TOL_COARSE S3
mm, Threshold value for "synchronism coarse" NEW CONF
degrees
Fct.: Synchr. 1.0 0.0 plus DOUBLE 2/7
Spindle

37210 COUPLE_POS_TOL_FINE S3
mm, Threshold value for "synchronism fine" NEW CONF
degrees
Spindle
37220 COUPLE_VELO_TOL_COARSE S3
mm/min, Velocity tolerance "coarse" between leading and following spindles NEW CONF
RPM
Fct.: Synchr. 1 0.0 plus DOUBLE 2/7
Spindle
37230 COUPLE_VELO_TOL_FINE S3
mm/min, Velocity tolerance "coarse" between master and slave spindles NEW CONF
RPM
Spindle
37300 DIG_P_MIN FBD
mm Lower working area limit (software limit) when digitizing POWER ON
Fct.: Digitalize -100000000 - - DOUBLE 2/7
37310 DIG_P_MAX FBD
mm Upper working area limit (software limit) when digitizing POWER ON
Fct.: Digitalize 100000000 - - DOUBLE 2/7
37320 DIG_V_MAX FBD
mm/min Maximum axis velocity during digitization POWER ON
Fct.: Digitalize 10000. 0.0 plus DOUBLE 2/7
37400 EPS_TLIFT_TANG_STEP T3
mm, Angle of tangent for corner recognition RESET
degrees
37402 TANG_OFFSET T3
mm, Default angle for tangential correction RESET
degrees

Axes-specific memory settings

38000 MM_ENC_COMP_MAX_POINTS K3
- Number of intermediate points for interpolatory compensation (SRAM) POWER ON
_always 0, 0 0 5000 DWORD 2/7
38010 MM_QEC_MAX_POINTS K3
- No. values for quadrant error compensation with new. network (SRAM) POWER ON
Fct.: QEC 0 0 1040 DWORD 2/7
3.5 Setting data
General setting data

41010 JOG_VAR_INCR_SIZE H1
- Size of the variable increment for JOG POWER ON
_always 0. - - DOUBLE 7/7
41050 JOG_CONT_MODE_LEVELTRIGGRD H1
- JOG continuous: (1) JOG/ (0) Continuous operation POWER ON
41100 JOG_REV_IS_ACTIVE H1
- JOG mode: (1) rotational feedrate / (0) feedrate POWER ON
41110 JOG_SET_VELO H1
mm/min Axis speed for JOG POWER ON
41120 JOG_REV_SET_VELO H1
mm/rev Rotation feedrate of axes for JOG mode POWER ON
41130 JOG_ROT_AX_SET_VELO H1
RPM Axis velocity for rotary axes for JOG mode POWER ON
41200 JOG_SPIND_SET_VELO H1
RPM Speed for spindle JOG mode POWER ON

41300 CEC_TABLE_ENABLE K3
- Preassignment for compensation table POWER ON
(compensation table): 0...15
Fct.: CEC 0 *** *** BOOLEAN 7/7
41310 CEC_TABLE_WEIGHT K3
Factor Factor preassignment for compensation tables POWER ON
(compensation table). 0...15
Fct.: CEC 1.0, 1.0, 1.0, 1.0, 1.0, - - DOUBLE 7/7
1.0, 1.0, ...
41500 SW_CAM_MINUS_POS_TAB_1 N3
- Switching points with falling flank of cams 1-8 NEW CONF
Fct.: SW cams 0.0, 0.0, 0.0, 0.0, 0.0, - - DOUBLE 7/7
0.0, 0.0, ...
41501 SW_CAM_PLUS_POS_TAB_1 N3
- Switching point with rising flank of cams 1-8 NEW CONF
0.0, 0.0, ...
41502 SW_CAM_MINUS_POS_TAB_2 N3
- Switching points with falling flank of cams 9-16 NEW CONF
0.0, 0.0, ...
41503 SW_CAM_PLUS_POS_TAB_2 N3
- Switching points with rising flank of cams 9-16 NEW CONF
0.0, 0.0, ...
41520 SW_CAM_MINUS_TIME_TAB_1 N3
s Lead times for the "-" switching points of cams 1-8 NEW CONF
positive value: lead time negative value: delay time
0.0, 0.0, ...
41521 SW_CAM_PLUS_TIME_TAB_1 N3
s Lead time for the "+" switching points of cams 1-8 NEW CONF
0.0, 0.0, ...

41522 SW_CAM_MINUS_TIME_TAB_2 N3
s Lead times for the "-" switching points of cams 9-16 NEW CONF
0.0, 0.0, ...
41523 SW_CAM_PLUS_TIME_TAB_2 N3
s Lead times for the "+" switching points of cams 9-16 NEW CONF
Fct.: SW cam 0.0, 0.0, 0.0, 0.0, 0.0, - - DOUBLE 7/7
0.0, 0.0, ...
41600 COMPAR_THRESHOLD_1 A2
mV Threshold value of the 1st comparator POWER ON
(comparator bit): 0...
_always 0.0, 0.0, 0.0, 0.0, 0.0, 0.0, - - DOUBLE 7/7
0.0, ...
41601 COMPAR_THRESHOLD_2 A2
mV Threshold value of the 2nd comparator POWER ON
_always 0.0, 0.0, 0.0, 0.0, 0.0, 0.0, - - DOUBLE 7/7
0.0, ...
Channel-specific setting data

42000 THREAD_START_ANGLE K1
degrees Starting angle for thread POWER ON
_always 0., 0., 0., 0., 0., 0., 0., 0.0 plus DOUBLE 7/7
0.,0., ...
42100 DRY_RUN_FEED V1
mm/min Test run feedrate POWER ON
5000.0, ...
42300 COUPLE_RATIO_1 S3
- Speed ratio for synchronous spindle mode, numerator(0), POWER ON
denominator(1)
_always {1.0, 1.0}, {1.0, 1.0}, {1.0, -100000000 100000000 DOUBLE 2/7
1.0}, ...
42400 PUNCH_DWELLTIME N4
S Dwell time for punching and nibbling POWER ON
Fct.: Nibbling 1.0, 0.0, 0.0, 0.0, 0.0, 0.0, 0.0 plus DOUBLE 2/7
0.0, ...

42450 CONTPREC K6, B1
Mm Contour precision POWER ON
_always 0.1, 0.1, 0.1, 0.1, 0.1, 0.1, 0.000001 999999. DOUBLE 7/7
0.1, ...
42460 MINFEED B1, K6
mm/min Minimum path feedrate for CPRECON POWER ON
_always 1., 1., 1., 1., 1., 1., 1., 1. 0.000001 999999. DOUBLE 7/7
42500 SD_MAX_PATH_ACCEL B2
mm/s^2, Max. path acceleration POWER ON
Rev/s^2
_always 10000., 10000., 10000., 1.0e-3 *** DOUBLE 7/7
10000., ...
42502 IS_SD_MAX_PATH_ACCEL B2
- Evaluate SD SC_SD_MAX_PATH_ACCEL POWER ON
42510 SD_MAX_PATH_JERK B2
mm/s^3 Max. path-related jerk as SD POWER ON
_always 100000., 100000., 0.0 plus DOUBLE 7/7
100000., 100000., ...
42512 IS_SD_MAX_PATH_JERK B2
- Evaluate SD SD_MAX_PATH_JERK POWER ON
42600 JOG_FEED_PER_REV_SOURCE V1
- Control rotational feedrate in JOG POWER ON
_always 0, 0, 0, 0, 0, 0, 0, 0 -1 31 DWORD 7/7
Axes-specific setting data

43210 SPIND_MIN_VELO_G25 S1
RPM Progr. spindle speed limitation G25 POWER ON
43220 SPIND_MAX_VELO_G26 S1
RPM Progr. spindle speed limitation G26 POWER ON
43230 SPIND_MAX_VELO_LIMS S1
RPM Spindle speed limitation with G96 POWER ON

43300 ASSIGN_FEED_PER_REV_SOURCE V1, P2, S1
- Rotation feedrate for positioning axes/spindles POWER ON
43400 WORKAREA_PLUS_ENABLE A3
- Working area limitation in positive direction active POWER ON
43410 WORKAREA_MINUS_ENABLE A3
- Working area limitation in the negative direction active POWER ON
43420 WORKAREA_LIMIT_PLUS A3
mm, Working area limitation plus POWER ON
degrees
_always 100000000 - - DOUBLE 7/7
43430 WORKAREA_LIMIT_MINUS A3
mm, Working area limitation minus POWER ON
degrees
_always -100000000 - - DOUBLE 7/7
43500 FIXED_STOP_SWITCH F1
- Selection of travel to fixed stop POWER ON
43510 FIXED_STOP_TORQUE F1
% Fixed stop clamping torque POWER ON
_always 5.0 0.0 100.0 DOUBLE 7/7
43520 FIXED_STOP_WINDOW F1
mm, Fixed stop monitoring window POWER ON
degrees
43700 OSCILL_REVERSE_POS1 P5
mm, Oscillation reversal point 1 POWER ON
degrees
43710 OSCILL_REVERSE_POS2 P5
mm, Oscillation reversal point 2 POWER ON
degrees
43720 OSCILL_DWELL_TIME1 P5
s Hold time at oscillation reversal point 1 POWER ON
43730 OSCILL_DWELL_TIME2 P5
s Hold time at oscillation reversal point 2 POWER ON

43740 OSCILL_VELO P5
mm/min, Feedrate of oscillation axis POWER ON
RPM
43750 OSCILL_NUM_SPARK_CYCLES P5
- Number of sparking out strokes POWER ON
43760 OSCILL_END_POS P5
mm, End position of oscillating axis POWER ON
degrees
43770 OSCILL_CTRL_MASK P5
- Oscillation run control mask POWER ON
43780 OSCILL_IS_ACTIVE P5
- Switch on oscillation movement POWER ON
43900 TEMP_COMP_ABS_VALUE K3
mm, Position-dependent temperature compensation value POWER ON
degrees
43910 TEMP_COMP_SLOPE K3
- Gradient angle for position-dependent temperature compensation POWER ON
43920 TEMP_COMP_REF_POSITION K3
mm, Reference position for position-dependent temperature compensation POWER ON
degrees

Chapter 6
Setup / Update
H274E6.DOC Setup / Update 6-1

1. Loading software for NCK and PLC
To load NCK or PLC software, please switch to the following menu:
1. Select "Operation (1) – Maintenance/Start-Up (5) - Load

software (3)“
2. Press ENTER
Fig. 18395E
Softkeys:
Pressing softkey copy NCK from disk causes machine files

copy NCK INITIAL.INI and *.bot-files, amongst others, to be copied from
from disk
floppy disk to directory C:\840D\MD on the hard disk during a
software change. The MASCHINE.INI file remains unchanged in
the process, so that machine-specific data are preserved.
With softkey NCK first load, machine files INITIAL.INI,
NCK MASCHINE.INI and the *.bot-files, amongst others, are loaded
first load
from directory C:\840D\MD on the hard disk to the SRAM of the
NCK.
With softkey NCK save, machine files INITIAL.INI and *.bot-files

NCK are loaded from the SRAM of the NCK into directory C:\840D\UPD
save
on the MMC hard disk. No separate MASCHINE.INI file can be
generated here. The current machine data (e.g. reference point
offset) are entered in file INITIAL.INI.
Pressing softkey NCK load causes the machine data files
NCK INITIAL.INI and the *.bot-files to be loaded to the SRAM of the
load
NCK from directory C:\840D\UPD on the MMC hard disk.

Softkey copy PLC from disk causes the PLC software to be copied
copy PLC from floppy disk to directory C:\535\PLC during a software change.
from disk
Softkey PLC load causes the PLC software to be copied from

PLC directory C:\535\PLC on the MMC hard disk to the SRAM of the
load
PLC.
Softkey Software-Update is used to start a software update for the
Software- ToPs programming system.
Update
Softkey functions: Schematic diagram
New NC software New PLC software

Disk drive - INITIAL.INI - OB...PLC, FB...PLC, DB...PLC
(standard values only) - fb30.plc
- *.bot-files
(machine drive data)
copy NCK copy PLC

from disk from disk
\840D\MD \535\PLC \840D\UPD

- INITIAL.INI - OB...PLC, FB...PLC, DB...PLC - INITIAL.INI
MMC (standard values only) - AB00.1VX (standard values and specific
hard disk - MASCHINE.INI values)
(specific values) - *.bot-files
- *.bot-files (machine drive data)
(machine drive data)
NCK PLC NCK

first load load load
NCK
save
Scrub NC
NCU NC/PLC memory
(rotary switch S3)
Scrub PLC
(rotary switch S4)
Fig. 18396E
6-4 Setup / Update H274E6.DOC

Softkey applications
Softkey Function Application Note
copy NCK from disk Diskette → Hard disk • Primary Setup

• Software update
copy PLC from disk Diskette → Hard disk • Primary Setup
• Software update
Scrub NCK and PLC Delete and re-initialize the • Setup • Before using this
NC memory function, write down the
• NCU exchange
Standard SIEMENS machine machine data and
data are loaded. • Replacing the NC- compare them with the
PCMCIA card MASCHINE.INI.
• Software update • Unload the tool from the
punching head.
• Undefined control
behavior
NCK first load C:\840D\MD\ • Setup • Before using this
function, write down the
MASCHINE.INI • NCU exchange
machine data and
INITIAL.INI • Replacing the NC- compare them with the
*.bot-files PCMCIA card MASCHINE.INI.
→ NC memory • Software update
PLC load C:\535\PLC • Setup • Unload the tool from the

punching head
OBs, FBs and fb30.plc • NCU exchange
→ PLC memory • Replacing the NC-
PCMCIA card
• Software update
• Undefined error in
operation
NCK save NC memory contents • NCU exchange Not with software update!
→ C:\840D\UPD\INITIAL.INI • Replacing the NC-
*.bot-files PCMCIA card
NCK load C:\840D\UPD\INITIAL.INI • NCU exchange Not with software update!

*.bot-files • Replacing the NC-
→ NC memory PCMCIA card

2. Subsequent NC Start-Up
Preconditions As a precondition for setting up a machine with the SINUMERIK

840D controller, the entire mechanical and electrical installation
must first be fully completed. The entire machine complex must be
ready to be powered up, the axes and spindles can be driven.
Signs of a corrupt NCU • The NCK memory is empty:

memory - GUD data is missing
• PLC memory area is empty:
- All LEDs of the MSTT blinking
• PLC memory area corrupt:
- LED PS is blinking and PF illuminated.
- All LEDs on the right side of the NCU are blinking.
Procedure The steps below must be taken following a system crash if it

becomes necessary to rebuild the system:
1. Scrub the NCK and PLC

2. Download the machine data from the MMC hard disk into the
NCK
3. Download PLC program from the MMC hard disk into the PLC
4. Activate the PLC configuration data
2.1 Scrubbing the NCK
Before scrubbing the NCK, assure yourself that the active

tool has been removed from the punching head.
The normal position of the NCK rotary setup switch S3 is "0"
1. MAIN SWITCH OFF

2. Set switch S3 to position "1"
3. MAIN SWITCH ON
→ The NCK is scrubbed,
after the control has re-booted, the NCU digital display will
show “6” and the green LED will light up
4. Set switch S3 back to position "0"
Error messages displayed while the operation environment

is booting up can be acknowledged!

2.2 Scrubbing the PLC
Before scrubbing the PLC, assure yourself that the active

tool has been removed from the punching head.
The normal position of the PLC setup switch S4 (rotary
switch) is "0"
Note When scrubbing the PLC, it is the sequence of actions that matters
most. The status of the LEDs is of minor consequence.
1. Set the S4 switch to position “2”:

• Operation STOP
• The PS LED lights up
• The green PR LED goes OFF
2. Set switch S4 to position "3"
• The PS LED extinguishes
3. Wait till the PS LED lights up again
4. Press the RESET button (S1):
• the control reboots
• the 7-segement display at the NCU shows “6”
• the red PS LED blinks
• the red PF LED lights up
5. Set switch S4 briefly to position “2” and (within 3 seconds) set
the S4 back to position “3:
• the red PS LED blinks 6 times and then lights up
permanently
→ the PLC is scrubbed, all lamps on the machine control

panel blink
6. Set the S4 switch back to position "0":

• the green PR LED blinks 6 times and then lights up
permanently
2.3 Loading machine data
To load the machine data, including the drive data (*.bot files) from
the MMC hard disk to the NCK, proceed as follows:
1. Start the TRUMPF operation environment

2. Select "Operation (1) – Maintenance/Start-Up (5) – Load
software (3) "
3. Press softkey NCK first load
4. Enter password "Min530":
5. Answer "Yes" to the prompt "Really save the data?"
The download has been successfully completed when the

corresponding message is displayed.

2.4 Loading PLC programs
Proceed as follows to transfer PLC programs from the MMC hard

disk to the PLC:
1. If necessary, start the TRUMPF operation environment

2. If necessary, select "Operation (1) – Maintenance/Start-Up (5)
– Load software (3)"
3. Press ENTER
4. Press softkey Load PLC
5. If necessary, enter password "Min530"
→ The PLC programs will be transferred to the PLC
When the "ECHO READY WITH DOWNLOAD OF PLC"

appears, the PLC program load has been successfully
completed.
The REFERENCE MACHINE pushbutton is illuminated

because no configuration data are active yet.
2.5 Activating PLC configuration data

2. Select "Operation (1) – Maintenance/Start-Up (5) – Machine
components (4) "
A prompt box appears: " Send data to PLC?"
3. Answer with "Yes"
An automatic Pin Reset now takes place (all LEDs blink)
4. Configure the available machine components (basic machine
and any automation components that may be installed):
• Mark the desired machine components with the Cursor
keys
5. Press softkey Configurations
6. Enter password "Minuten"530
7. Press ENTER
8. Check the configuration data
9. Press softkey Save values
The configuration data are transmitted to the respective units.
10. Turn the MAIN SWITCH OFF, then ON again.

3. Data Backup
The software tool GHOST is used for backing up the data on the
hard disk.
The data is backed up before and after every software exchange.
The data backup is stored in a special box in the machine’s switch
cabinet.
Currently, ZIP disks are used to store the backup data but CD-
ROMs can be used as well.
The GHOST tool is found in directory c:\tcommc\system.
Version Currently, version 5.1c of the GHOST tool is in use.
3.1 Data backup using the GHOST tool
Requirements • Windows is not active

• The MMC was started under DOS via password "SYSTEM“
• The ZIP drive was started with "c:\iomega\guest.exe“. Drive
name: "e:"
• 2 – 3 ZIP disks (ID number: 143275) are ready.
Procedure 1. Start the GHOST tool with command

"c:\tcommc\system\ghost.exe“.
2. Choose OK to confirm the initial message "About NORTON...".
3. Start the backup with "Local - Disk - To Image“:
Fig. 23716

4. Choose the hard disk you wish to back up and press ENTER:
Fig. 23717
5. Open selection box „Local drive“ and choose "e: Local drive“:
Fig. 23719
6. In "File Name“, enter the name of the backup file (Image file)
(overwrite the existing file, if any).
Make sure the extension is "GHO“ !

7. Confirm message "Not enough space - use compression?"
with "Fast" (two-fold compression).
Fig. 23721
8. Confirm message "There may not be enough space – Enable

Spanning?“ with "Yes“.
Fig. 24448
Data backup running The data backup starts when message "Proceed with Disk dump?"
is confirmed:
Starting data backup Fig. 24450

If a ZIP disk is full, the message below is displayed:
Fig. 23725
9. Insert the next ZIP disk in the ZIP drive and press OK.
This may have to be repeated several times depending on the
amount of data being saved.
Data backup completed When backup ends, you will be prompted with the message below
to place the first ZIP disk in the drive again:
Fig. 23726
10. Insert the first disk and confirm with OK .
When data backup has been completed, message "Dump

completed successfully" is displayed.
Confirmation of this message automatically returns you to the initial

screen.
11. Choose function QUIT and confirm message "Really quit?"

with YES.

Fig. 23728

3.2 Restoring data with the
GHOST Tool
Requirements • WINDOWS is not active.

• The MMC was started under DOS via password "SYSTEM“ (if
necessary, with the GHOST-BOOT disk).
• The ZIP drive has been started. Drive name "e:".
Procedure 1. Start the GHOST tool with command

"c:\tcommc\system\ghost.exe“.
2. Choose OK to confirm the initial message "About NORTON...".
3. Start data restoration with "Local – Disk - From Image“
Fig. 23730
4. Open selection box „Local drive“ and choose "e: Local drive“:
Fig. 23732
5. Choose the required image file (*.GHO) and press ENTER .

6. Select the destination drive and confirm with Enter.
Fig. 23734
7. Check the hard disk settings and again choose „OK“ to

confirm.
Fig. 23735
8. To start restoring the data, choose Yes to confirm message

"Proceed with disk load? Destination drive will be overwritten.".
Fig. 24449

Data being restored 9. When message „Insert next media and press enter to continue“
appears, place the next ZIP disk in the ZIP drive and confirm
with „OK“.
Fig. 23749
When the data has been restored, message "Clone Completed

Successfully" is displayed.
Fig. 23750
10. Confirm the "Reset Computer" message.
The MMC is rebooted.

4. Software selection sheet
SOFTWARE SELECTION
TC600L Version 06.01 Standard & Automation
Order description Material numbers
PLC software TC600L V 06.00.01 cpl. Mat. No.: 939589
Drwg. No.: 9570-500-601
4 * empty disks, 3.5” Mat.No: 094760
Software PLC TC600L V06.00.01
NCK-Software V 04.05.01 cpl. Mat. No.: 939590

Drwg. No.: 9570-100-51
PC-Card (Jeida/Flash) empty 8MB (PCMCIA 2.0) Mat.No: 147459
Software NCK V 04.05.01 (Build14) PC-Card
3 * empty disks, 3.5” Mat.No: 094760
Software NCK V 04.05.01 Diskette
MMC software V 05.07.18 BUILD 128 cpl. Mat. No.: 939591????

Drwg. No.: 9570-200-206???
1* empty ZIP disk,100MB ID.NO. 143275
Software MMC V 05.07.18 (Build 128)
Languages:
Danish (*) Dutch (*) English French
German Italian Spanish Swedish (*)
(*) = with English error texts

Software H&L 23.02.99 cpl. ( on EPROM) Mat. No.: 935813
Drwg. No.: 9570-610-20
Blank Eprom AM27C256 Mat.No: 096553
Software H&L 23.02.99 Mat.No: 149791
LASER software cpl. Mat. No.: 222588
Drwg. No.:9558-U25
With DIAS 3: Software (minimum V 1.34)
With DIAS 1: No changes
DIAS software cpl. Mat. No.: 258904
Drwg. No.: 9450-621-100
DIAS 3: Software (minimum V 2.3)
DIAS 1: No changes
HARDWARE RETROFIT KIT (from V05.XX to V06.01) Mat No: 934972
Drwg. No.: 9310-731
HARDWARE RETROFIT KIT (from V06.00 to V06.01) (no retrofit kit needed)
TRUMALIFT SHEETMASTER Mat. No.: 257952
Drwg. No.: 68341-550-10
see Sheetmaster-SW selection sheet (minimum V03.00)
Modification description: ID.NO. 257953 DRWG. NO. 68341-550-20
MODIFICATION DESCR. software V 06.01 GERMAN Mat. No: 939592
Drwg. No.: 9310-621-34
MODIFICATION DESCR. software V 06.01 ENGLISH Mat- No: 939593
Drwg. No.: 9310-621-35
DOCUMENTATION TC600L schematics Mat No: 928185
Drwg. No.: 9310-5-206
Index 01
PROGRAMMING SYSTEM
TOPS 250 from Vx.xx
Mat. No: 131970

5. Software update
5.1 MMC
Checking the software Depending on the MMC version currently installed on the control,
version at the operation the software may or may not have to be updated. The MMC
environment version can be verified at the operation environment:
1. Diagnostics (2)
2. Service (4)
3. Versions display (1)
4. MMC Version (1)
Fig. 18391E
The current MMC version is displayed in line TCOMMC. In Fig.

18391: V5.02.05.
Prerequisites for software To carry out the update, you will need the software selection sheet
updates (see 4. Software selection sheet), Function Description "Update
to MMC-Version ..." and the Modification description from Dept.
530.
Data backup A data backup of the MMC operation environment takes place
automatically during the software update. All initialization files are
saved in directory C:\UPDATE. MMCV05xxyy. The databases in
use prior to the software update are saved to directory
C:\TCOMMC\UPDATE\OLD.
Procedure The procedure described in the above mentioned Function

Description from Dept. 530 must be strictly observed.

1. Switch the machine OFF, then ON again.
2. Change to the "Confidential selection menu" when booting up
3. Activate the DOS SHELL
4. Connect the ZIP drive to the parallel port
5. Change to directory C:\IOMEGA or A:\IOMEGA (of the boot
disk provided)
6. Enter GUEST.EXE.
The respective driver is started.
An "E:" drive is created automatically
7. Enter E:\UPDATE
The software update is started
The MMC must be rebooted when the software update is
finished. After powering up, the program group SCRIPTS FOR
DATABASE if automatically opened, and the database update
program started.
Fig. 18392E
8. Choose "DB-Update - ...start"

The database is updated
Fig.18393E
9. When message "DB-Update ready" appears, quit the program

with "Exit"

10. Check the MMC-Software version:
• „Diagnostics (2) – Service (4) – Version display (1) – MMC-
Version“
• The current MMC version is displayed in line
TCOMMC.EXE.
11. Check the MMC applications:
• Operation (1)
• Maintenance/Start-Up (5)
• MMC Applications (5)
• Enter password "Minuten"530
• Press ENTER

5.2 NC/PLC
Viewing the software- Whether or not a software update needs to be performed depends
version at the operation on the NC software version currently installed. You can check the
environment NC software version at the operation environment:
1. Diagnostics (2)
2. Service (4)
3. Version display (1)
4. NCK/PLC Version (2)
Fig. 18397E
NCK version:
The current version of the NCK software is shown in the 3rd line
from the top in the "NCK" block. In Fig. 18397: V04.03.03.
The version display is updated by pressing softkey NCK.
PLC version:
The current version of the PLC software is shown in line "PLC
Version" in block "PLC and others". In Fig. 18397: V02.05.00.
The version display is updated by pressing softkey PLC.
Version of the ram control software:

The current version of the ram control software is shown in line
"H+L" in block "PLC and others".
The version display is updated by pressing softkey PLC.

Components to be The following components may also have to be replaced during a
exchanged software exchange:
• NCU-Box
• NCK-PCMCIA software card
• Load NCK and PLC diskettes under ”Load software”
Please refer to Function Description "Update to Version XYZ" from

Dept. 530 for the exact components that need to be replaced.
Data backup Where necessary, the machine data must be saved before
proceeding to exchange software.
1. Start the TRUMPF operating environment

2. "Operation (1) – Maintenance/Start-Up (5) – Machine data (1)“
3. Press ENTER
4. Write down the relevant machine data
Changing the PCMCIA card
1. Scrub the NCK / PLC

2. Turn the Main Switch OFF
3. Unplug the NCU equipment bus (ribbon cable)
4. Exchange the PCMCIA card:
The PCMCIA card is plugged into the NCU module behind the
ribbon cable.
5. Re-plug the ribbon cable.
Assure that the interfaces are fully seated!!!
Loading NCK software
Proceed as follows to copy the machine data, including drive data

(*.bot-files) from diskette to the NC memory:

3. "Operation (1) – Maintenance/Start-Up (5) – Load software (3)“
4. Place installation diskette 1 "CNC" in the floppy disk drive
5. Press softkey copy NCK from disk
Attention:
If an error box appears, press ALT+TAB to change to DOS-
Box „Inst_NCK“. Otherwise, you will not be able to terminate
the installation.
The new version will be unzipped and copied to the MMC hard
disk.

6. Wait until the installation is finished (message appears)!
The data is copied to the NCK.
8. Enter password „Minuten“530
9. Press ENTER
The loading process has been successfully completed when

the "ECHO READY WITH DOWNLOAD OF NC" message
appears.
New software versions On the newer software versions, the procedure for NCK disk
installation is different:

3. Choose "1 Operation – 5 Maintenance/Start-Up – 3 Load
software“
4. Place installation diskette 1 "CNC" in the floppy disk drive.
5. Press softkey copy NCK from disk.
During the installation routine, various machine specifications

are requested and a tool for drive configuration is run a well.
On standard machines, this configuration tool serves only to
verify the configuration.
The routine can also be started manually in directory
c:\840d.ins with the syntax „INST_NCK HD“.
Fig. 23765E
6. Select the language.
7. Press Y to confirm the machine type determined.
8. Decide whether the old NCK version should be saved to

directory c:\840d.bak.
A mask with the selection for the desired installation is

displayed:

Fig. 23766E
9. Press the corresponding number to make your selection.

In the case of an update, (1) Complete installation must
be selected here.
10. Press N in reply to the query Will "Kanji" language be used at

the machine? (In Japan, press Y
The machine configuration for the drives and terminal block is

checked.
Under normal circumstances, the service engineer does not
have to make any changes to the configuration for a standard
machine. If the displayed configuration is incorrect or if the
configuration has to be set, for example, on a TCL1005, the
configuration can be modified or set manually.
Please refer to Chapter 5 Configuration and Machine
Data, section 2.4 Individual machine data groups,
Manual configuration.
Fig. 23687E
11. Press softkey Save.
The selected configuration is processed.
The configuration is then displayed in detail and can be

checked again.
If it contained an error, this would be displayed on a red
screen.

Fig. 23708E
12. Press softkey Save. A new ’initial.ini’ file is generated.
The mask below is displayed:
Fig. 23713E
13. Reply with No to the prompt "Install other data?".

The data is transmitted to the NCK.
15. Enter the password, if necessary.
16. Answer "Yes" to the prompt "Really save the data?" The data
is loaded to the SRAM of the NCU.
A message indicates the loading has been completed.

Entering machine data After that, the machine data noted down earlier must be compared
or input again.

2. Choose "1 Operation – 5 Maintenance/Start-Up – 3 Load
software“
3. Press the ENTER key
4. If necessary, enter the machine data noted down earlier.
Loading PLC software
Proceed as follows to copy the PLC programs from diskette to the

NC memory:

2. "Operation (1) - Maintenance/Start-Up (5) – Load software (3)“
3. Place installation diskette 1 "PLC" in the floppy disk drive
4. Press softkey copy PLC from disk
Attention:
If an error box appears, press ALT+TAB to change to DOS-
Box „Inst_NCK“. Otherwise, installation will not completed
properly.
The new version is unzipped and copied to directory

C:\535\PLC of the MMC.
5. Wait until finished (message appears)!

6. Press softkey PLC load
The data is copied to the NCK.
7. Enter password „Minuten“530
8. Press ENTER
The loading process has been successfully completed when

the "ECHO READY WITH DOWNLOAD OF NC" message
appears.
10. Wait until all boot-up procedures have been completed.
The „Reference Machine“ softkey is illuminated as no

configurations exist yet!!!
11. Close the operating environment and open the SCRIPTS FOR
DATABASE program group. Start UPDATE PLC.

Fig. 18393
12. When message "DB-Update ready" appears, reboot the

operating environment.
Activating PLC configuration data
1. If necessary, start the TRUMPF operation environment

2. "Operation (1) – Maintenance/Start-Up (5) – Machine
components (4)“
3. Answer "Yes" to the prompt "Transfer data to PLC?"
A Pin Reset now automatically takes place (all LEDs blink).
4. Configure the available machine components (basic machine
and any automation components that may be installed)
• Use the cursor to select the desired machine components
5. press softkey Applications
6. Enter password "Min530",
7. Check the configuration data
8. Press softkey Save values
The configuration data is transferred to the respective units.

Checking regulator settings at the TASC200
(Lasermatic 1.5 only)
After installing the software, check the regulator settings at the

TASC200 (only for TC 600L with Lasermatic 1.5):
1. Select "Manual mode" at the TASC200 user interface
Fig. 18398
2. Press softkey Start-Up
Fig. 18399
3. Press softkey Height Regulation

Fig. 18400
4. Press softkey Regulator
Fig. 18415
5. Check the regulator settings

6. Primary installation of MMC
Prerequisites • Function Description "Update to MMC-Version V05.xx.xx and

higher" from Dept. 530
• TORX key
• ZIP drive
• Special 3½ inch primary installation disk
• ZIP primary installation disk for MMC software version
• ZIP disk for data backup
• Where necessary, new power supply unit, Id. No.: 143315
• MMC 103, Id. No..: 143316
Procedure The procedure described in the above mentioned Function

Description from Dept. 530 must be strictly observed.
1. Connect the ZIP drive to MMC

2. Save the data to the ZIP disk:
• Databases (use only command XCOPY/V to copy)
• Part programs (C:\DH\TOPSMANU.DIR)
• Machine data (C:\840D\MD\MASCHINE.INI)
• Network start file (C:\WFW_NET.BAT)
• Where applicable: Novell network files:
C:\NETWORK.BAT
C:\NWCLIENT\NET.CFG
C:\NWCLIENT\STARTNET.BAT
• Remote diagnostics initialization (C:\WINAW\AW.INI)
3. In the Program Manager, select "Control Panel – Network"
4. Write down the network setting
5. In the Program Manager, select "File Manager"
6. Write down the enabled drives and network connections
7. Shut down the control and switch it OFF
8. Replace the MMC and power supply unit
9. Power up the control again
10. While the BIOS is being processed, press key combination
CTRL + ALT + ESC to switch to BIOS
11. In the BIOS, set the date and time and boot sequence "a,c"
12. Reboot the control in order to check whether the MMC 103 is
running.
The SIEMENS user interface is started
13. Switch the control OFF.
14. Insert the special 3½ inch primary installation disk in the floppy
drive
15. Insert the ZIP primary installation disk in the ZIP drive
16. Turn the control ON
• MMC boots from the special 3½ installation disk
• The ZIP drive is installed
17. Reply with "Yes" when asked whether the hard disk should be
re-formatted
• The hard disk is formatted
• The new software is loaded from the primary installation
ZIP disk

• In the case of newer BOF (operation environment)
software versions, the PLC and NCK files are also copied
to the hard disk (directories C:\535 and C:\840D)
18. Place the ZIP data backup disk in the ZIP drive
19. Copy the backups back to the hard disk:
• Create a directory called C:\TCOMMC\DBUPDATE\OLD
• Copy the database files into this directory (use only the
XCOPY/V command for copying)
20. Load the new graphic driver (see Function Description "Update
to MMC-Version V05.xx.xx and higher)
21. Switch the control OFF, then ON again
22. Press the SHIFT key to prevent the operation environment
form booting up
23. Select program group "Scripts for Database"
24. Select "DB-Update - ...start"
Database update starts
25. Turn the control OFF
26. Where necessary, exchange the NCK-PCMCIA software card
27. Scrub the NCK and PLC
28. Turn the control ON
29. Boot the operation environment
30. Check the MMC software version
31. If necessary, load the NCK and PLC disks with menu "Load
software"
32. Make the NCK first load, followed by
33. PLC load
34. In menu "Machine components", activate the configuration
data in the PLC
35. Check the MMC configurations
36. Check the NCK and PLC-Version
37. Install the network

Chapter 7
SIMODRIVE 611D Drives
H274E7.DOC SIMODRIVE 611D Drives 7-1

1. Power Supply (NE)
The input/recovery module (I/R module) and the module for

unregulated energy input (UE module) serve to supply the
intermediate DC power circuit. In addition, the I/R, UE and the
Surveillance module (SU module) also provide the operation power
supply for the connected modules.
I/R module: The energy stored to the intermediate power circuit

during axes motor braking is returned to the power supply network.
UE module: The axes motor energy resulting during the braking of

the motors is converted to heat by integrated brake resistors and
dissipated. Additional pulse resistors (PW-Modules) can be
integrated if required
The I/R, UE module is the first module on the left side of the drive
control rack. The surveillance (SU) module is located to the left of
the module it is assigned to.
Filters are available to fulfill EMC regulation (Electromagnetic

Compatibility) requirements.
1.1 V3 Technology
Since around 1998 SIEMENS has been supplying the so-called V3

technology for all drives.
In this technology, when an I/R module is in use, the recovered

power is no longer returned in the form of a rectangular signal, but
as a sinus signal.

1 Switch S1 4 X141: Power supply signals 7 LED displays
2 X111: Ready signals 5 X161: Mains contactor signals 8 X181: Electronic power supply
3 X121: Enable and I2t sum signals 6 X171/X172 terminal blocks
9 Power supply module
Modules and switch cabinet Fig. 18422
7-4 SIMODRIVE 611D Drives H274E7.DOC

Power supply to the electronics
Function From the 400V three-phase system, an auxiliary voltage of about

540V (P500) is obtained through rectification. This input is
connected to the mains connection, as a standard.
This voltage of 540V is stepped down to a lower value of 150V by

a regulator with pulse width modulation. This voltage is then
tapped via a push-pull inverter to supply a multi-winding
transformer with a frequency of 17 kHz.
Voltages Multiple voltage levels, isolated from each other, therefore result at
the secondary side of the transformer.
• The general electronic voltage ±15V and ±24V for regulator

operation.
• A voltage of +24V for enabling all modules (terminal 63, 64, 65,
663...). Terminal 19 is the ground here.
The Enables are therefore connected voltageless by the

master control.
If the Enables are supplied from non-isolated electronics,

terminal 19 is connected to the ground of the external enable
voltage in order to prevent sporadic interference.
• A voltage for supplying the power circuitry control.

1.2 Switch S1 settings on the power
supply module (NE)
The following setups are possible at the NE module top left:
Parameter Value range Setting

component
Intermediate 600 V ... 625 V Switch S1.1
circuit voltage
Error signals Switch-over Operation ready / Error Switch S1.2
Relay terminal does not report if OP-
ready or error
Energy recovery I/R module active/inactive Switch S1.3
UE-Module 5/10 kW pulse resistor
enabled/disabled
Mains input Regulated/unregulated (only with I/R- Switch S1.5
module)
Signal functions I²t- Pre-warning and excessive motor Terminal
via temperature from NE and drive module
relays/breakers
Internal network contactor ON
Start-up inhibit
Displays Operation enable, Intermediate circuit LED
charged,
± 15 V-Error, 5 V-Error, line error,
excessive intermediate circuit voltage
ON: S1 OFF:
UZK = 625V 1 UZK = 600V
Error signal 2 Ready signal
Energy recovery OFF 3 Energy recovery ON
- 4 -
DIP switches Fig. 18387E

1.3 LEDs on I/R module
1 2
3 4
5 6
Fig. 14202
1 LED red ± 15 V power supply interrupted

2 LED red 5 V power supply interrupted
3 LED green Unit not ready for operation
(no external Enable signals)
4 LED yellow Unit ready (intermediate circuit charged)
5 LED red Line fault 30 ms < 360 V
6 LED red Intermediate circuit voltage
1.4 Overview of Enable signals
Enable terminals
Terminal Function Module

63 I/R module pulse enable I/R module
64 Drive enable I/R module
48 Contactor energizing I/R module
NS1 – NS2 Line preload contactor I/R module
663 Regulator pulse enable Regulator module
Interface signals
Interface signal Function

DB31-37.DBX21.7 Pulse enable
DB31-37.DBX2.1 Regulator enable
DB31-37.DBX1.3 No Feed Hold
DB21.DBX 6.0 No Feed Hold all axes
NCK Diagnose Nominal axis value
DB 31-37, one data module per axis

1.4 Terminals on the NE module
Terminal No. Designation Function Type1 Typ. voltage / Max. cross-section

limit values
U1 Line connection I 3AC 400 V
V1
W1
PE1 Ground I 0V
Grounding bar2 I/O -300 V Busbar
P600 Intermediate circuit I/O +300 V Busbar
M600 Intermediate circuit I/O -300 V Busbar
P600 Intermediate circuit I +300 V 16 mm²
M600 Intermediate circuit I -300 V 16 mm²
X131 Electronic M I/O 0V 16 mm²
X151 Device bus I/O Diverse Ribbon cable
M500 X181 Intermediate circuit power I 600V 1.5 mm²
supply3
P500 X181 Intermediate circuit power I 600 V 1.5 mm²
supply3
1U1 X181 Output L13 O 400 V 1.5 mm²
2U1 X181 Input L13 I 400 V 1.5 mm²
1V1 X181 Output L23 O 400 V 1.5 mm²
2V1 X181 Input L23 I 400 V 1.5 mm²
1W1 X181 Output L33 O 400 V 1.5 mm²
2W1 X181 Input L33 I 400 V 1.5 mm²
7 X141 P24 O +20.4...28.8V/50 mA 1.5 mm²
45 X141 P15 O +15 V/10 mA 1.5 mm²
44 X141 N15 O -15 V/10 mA 1.5 mm²
10 X141 N24 O -20.4...28.8 V/50 mA 1.5 mm²
15 X141 M O 0V 1.5 mm²
R X141 Reset I Term.15/RE = 10 kΩ 1.5 mm²
5.3 X121 Relay contact NC 1DC 50 V/0.5 A/ 1.5 mm²
5.2 X121 →Sum signals NO → 12 VA max 1.5 mm²
5.1 X121 I²t/Motor temperature I 1DC 5 V/ 3 mA min 1.5 mm²
63 X121 Pulse enable4 I +13 V...30 V/RE = 1.5 1.5 mm²
kΩ
9 X121 Enable voltage4 O +24 V 1.5 mm²
64 X121 Drive enable4 I +13 V...30 V/RE = 1.5 1.5 mm²
kΩ
19 X121 External reference ground O 0V 1.5 mm²
(enable voltage)
74 X111 Relay contact NC 1.5 mm²
73.2 X111 Signal I →1AC 250 V/DC 50 1.5 mm²
73.1 X111 Ready for operation I V/2 A max 1.5 mm²
72 X111 NO 1 DC 5 V/3 mA min 1.5 mm²
9 X161 Enable voltage4 O +24 V 1.5 mm²

112 X161 Setup mode/Normal mode4 I +21 V...33 V/RE = 1.5 1.5 mm²
kΩ
48 X161 Contactor energizing4 I +13 V...30 V/RE = 1.5 1.5 mm²
kΩ
1
I = Input, O = Output, NC = normally closed contact, NO = Normally open contact (signal NO = High/NC = Low)
2
The grounding bar serves to ground the intermediate circuit M-rail across 100 kΩ and should be attached to prevent the
intermediate circuit from “floating”.at power OFF .
3
X181: all contact screws must be tightened!
4
Reference ground terminal 19 (not connected to general reference ground terminal 15)

111 X161 Line breaker I
213 X161 n.c. → +30 V/1 A 1.5 mm²
113 X161 Line breaker NO
AS1 X172 Signal contact, start-up inhibit I 1AC 250 V/DC 50 V/2 1.5 mm²
A max
AS2 NC 1DC 5 V/10 mA min
NS1 X171 Enable voltage4 O +24 V 1.5 mm²
NS2 Coil contact, line preload I Only voltage over 1.5 mm²
contactor terminal NS1
15 X221 M O 0V 1.5 mm²
50 X221 Energizing contact, rapid I 0V 1.5 mm²
discharge

Circuit diagram excerpt, valid for all machines Fig. 14217E

Terminal connectors: Explanation
Terminal
U1 Line voltage 3 x 400 V
V1
W1
X121 5.2 Contact pre-warning, voltage limit and motor temperature
X121 63 Pulse enable, permanent 24 V circuit
X121 64 Drive enable, K1 "no E-STOP" and K" "MACHINE ON"
X111 72 Contact for Drive ready,
73.1 series circuit with X161 111/113
X161 48 Drive ON input
X161 111 Contact Line breaker ON
113 on breaker K7 "I/R module operation ready"
series circuit with X111 72/73.
X172 NS1 Line breaker enable by K1 "no E-STOP
NS2
X181 1U1, 2U1 Line connections U1, V1 and W1 are looped to the line connections for electronic
1V1, 2V1 power supply 2U1, 2V1 and 2W1
1W1, 2W1
Axis specific Regulator Enable terminal 65:

Axis specific function as terminal 64 (see terminal 64)
Axis specific Pulse Enable terminal 663
Start terminal 48:

This terminal has the highest priority. A defined power ON or
OFF sequence is initiated by terminal 48. If terminal 48 is
used, terminals 63 and 64 can be bridged with terminal 9.
With terminal 48 enabled, the internal pre-loading process is

initiated. When the intermediate circuit is charged the pre-
load breaker opens and the main breaker is energized.
Following this, the enable signal is issued. If terminal 48 is
disabled, the internal enable signal is suppressed. The
intermediate circuit is galvanically isolated from the line by
opening the internal line breaker.
If terminal 48 is disabled during a charging cycle, the cycle is

first of all completed. The disable is only activated after the
charging cycle has finished.
Pulse enable terminal 63:

This terminal has the highest priority for pulse
enable/disable. All axis power circuits are enabled across
terminal 63. Enable and disable is without delay and
simultaneous for all modules. Removing the signal causes
the motors to coast down unbraked.
Drive enable, terminal 64:

The drive modules are enabled across terminal 64. Enable
and disable is without delay and simultaneous for all

modules. When the signal is removed, all axes RPM nominal
signals are set to 0. All drive module regulators and pulses
are axis specifically disabled after the individual timer stages
expire (approx. 200ms). In the case of main spindle and
asynchronous motor modules, pulses are disabled if the set
RPM limit is undershot.

1.6 Technical data: Network input module
Designation Pn/PS6/Pmax Pn/PS6/Pmax Input current [A] Max. cross- Pulse resistor
Network input Network at 3 AC 400 V section1 energy for
[kW] recovery. If UE DC 600 V [mm²] single brake
with PW, via Pn/PS6/Pmax cycle
Loss [W] internal pulse
Pvtotal/Pvext/ Pvint resistor [kW] Output current
[A]
Surveillance module - - 16/10 -
70/0/70 - -
Pulse resistor module2 - 0.3/-/254 - 6/4 internal: Emax =
310/300/10 (DC 450 V) - 7.5 kWs
extern: Emax =
180 kWs
UE module 5/10 kW2 5/6:5/10 0.2/-/104 12.5/16.5/25 6/4 internal: Emax =
270/200/70 (DC 450 V) 9.3/12/18.6 13.5 kWs
(DC 540 V) -
UE module 10/25 kW 10/13/25 0.3/-/254 24/32/60 16/10 internal: Emax =
450/-/- (DC 450 V) 18.5/24/46.5 7.5 kWs
(DC 540 V) -
I/R module 16/21 kW 16/21/35 16/21/35 27/35.5/59 16/10 -
320/-/- 26.5/35/58 -
I/R module 36/47 kW 36/47/70 36/47/70 60.5/79/117.5 50 -
585 60/78/116 -
I/R module 55/71 kW 55/71/91 55/71/91 92.5/119/153 95 or -
745/-/- 91/118/151 2 x 35 -
I/R module 55/71 kW 55/71/91 55/71/91 92.5/119/153 95 or -
Line connection -/630/115 91/118/151 2 x 35 -
PvSchl/Pvint
I/R module 80/104 kW 80/104/131 80/104/131 134/175/220 95 or -
Line cooling or radial blower3 1280/1090/190 133/173/218 2 x 35 -
I/R module 120/156 kW3 120/156/175 120/156/175 202/262/294 150 or -
Line cooling or radial blower3 1950/1660/290 200/260/291 2 x 50 -
Power definitions Pn , P s6 , P max Indicates the entire allowable I/R module

voltage range.
Pn Produced constant power of the power
supply module
P s6 Produced power for max. 4 min at S6 load
variation.
P max Output peak power.
1
The 1st statement is valid for wire end ferrules, the 2nd without wire end ferrules.
2
When the internal pulse resistor is disabled, only Pvint occurrence is valid for internal and external power
4
Motor braking energy is converted to heat in the built-in pulse resistor. A heat sink may become necessary
3
If no line cooling is used, only Pvtotal is relevant.

For load variation see following diagrams.
Pv total Total power loss by module

Pv Schl Loss with cooling lines;
Pv ext Power loss through external heat dissipation
Pv int Internal power loss
This power loss remains in the switch cabinet.
Connected voltage and 3AC 360 to 440 V/45 to 65 Hz at DC 600 V:

frequency
3AC 373 to 457 V/45 to 65 Hz at DC 625 V:
Valid for all power supply modules to P n ≤ 55 kW
Note:
For I/R module 80/104 kW and 120/156 kW internal, external and

line cooling:
For power connection U1, V1, W1:

3AC 360 to 440 V/45 to 65 Hz at DC 600 V:
3AC 373 to 457 V/45 to 65 Hz at DC 625 V
For coil connection L1, L2:

2AC 360 V to 457 V/45 to 53 Hz:
2AC 400 to 510 V/57 to 65 Hz
Cooling All I/R modules are separately cooled.
All UE modules, the surveillance module and the pulse resistor

modules are self cooled.
Ground-fault proof Switch cabinet wiring and motor cable connections are to be
thoroughly checked for grounding consistency prior to powering-
up.
• When a power loss occurs at the I/R module 80/104 kW or

120/150 kW, or control fuses F1, F2 are tripped, the
input/recovery pulses are disabled and the internal line breaker
de-energizes. This is indicated by the line error LED, operation
ready relay and breaker contacts. In this case the unit must be
shut OFF/ON or terminal 48 disabled and re-enabled after ≥ 1
s.
• When I/R module 80/104 kW or 120/150 kW is used, the

KL9/48 bridge must be removed and a switch installed. If the
unit is turned OFF/ON, a switch is not required.

Service News: "New I/R module"
Date: 23.03.98
Source: Memo by 533st, 16.01.98
To contact: 533st
Register No. 4.3.1
Machines TC L 3030, TC L 4030, TC L 6030, TC L 2530, TC 600L, TLC 1005
New All driver modules of type Simodrive 611 has been modified by the
manufacturer Siemens.
Measure The new I/R module 16 KW has a sliding switch. This switch
enables you to switch from block current to sinusoidal current and
vice-versa. Siemens sets the I/R module to simple sinusoidal
current at the factory. When replacing an old I/R module (Id. No.
138 435) with a new one, turn sliding switch to block current on the
new I/R module. Instructions on the procedure are enclosed with
the new I/R module. The new I/R module is expected to be
available from the end of April 1998.
Replacement part New I/R module 16 KW: ID No. 145 016

2. Servo drive modules
Fig. 18423 shows the control and drive module rack in the switch
cabinet. The three modules on the right are servo drive modules,
to their left is the NCU and the all the way on the left is the power
supply module.
1 X432 5 Pulse enable relay terminals 8 X151: Device bus

2 X431 6 Drive control diagnosis LED 9 Intermediate circuit
3 Motor feedback 7 X141: drive bus 10 Motor terminals
4 Direct position ROD
(not used by TCO)
Modules in the switch cabinet Fig. 18423

A SIMODRIVE 611D servo drive module always consists of power
and control modules. As the digital regulation function is
independent of the required servo power, a combination of single
and dual axes servo modules is sufficient. On the other hand,
different power modules are required to satisfy different power
requirements.

2.1 Power module
The power module units comprise the entire motor power control
and also carry the regulation PCB. The various modules are rated
according to power stages. In addition, there are single and dual
axis power modules.
The currents stated for the power modules (LT modules) reflect the
respective transistor currents. Output currents can be limited by the
inserted regulation PCB. When inserting a regulation PCB in the
power module, make sure that the mounting screws are tightened
as shown to assure correct electrical connection.
M3 / 0,8 Nm
M4 / 1,8 Nm
M3 / 0,8 Nm M5 / 3,0 Nm
1 Power module 3 Order No. 4 Regulation PCB

2 Nameplate / Order No.
Power module internal cooling Fig. 14212

Power module: Technical data
Power Cooling5 Max. line Spindle X11 AMM- X11 [%] Feed drive Feed drive X11
module cross- drive- [%] Analog analog In/Imax digital In/Imax [%]
currents section2 Analog/ In/Is6/Imax [A] [A]
[mm²] Digital [A]
In/Is6/Imax
[A]
Max. width Loss [W] X21 Loss [W] X21 [kHz] Loss [W] Loss [W] X21
[mm] [kHz] [kHz]
Weight [kg] Pvtotal Pvtotal Pvtotal Pvtotal
Power mod. S - - - - 4/8 3/6 55
Int. 8 A 50 6/4 - - - - 35 35 4
6.5
Power mod. S - - - - 7.5/15 5/10 55
Int. 15 A 50 6/4 - - - - 45 50 4
6.5
Power mod. S - - 8/10/16 55 12.5/25 9/18 55
Int. 25 A 50 6/4 - - 74 3.2 90 90 4
6.5
Power mod. F 24/32/32 40 24/32/32 40 25/50 18/36 40
Int. 50 A 50 6/4 260 3.2 260 3.2 180 190 4
7.5
Power mod. S - - - - 2 x 4/8 2 x 3/6 55
Int. 2 x 8 A 50 6/4 - - - - 70 70 4
7
Power mod. S - - - - 2 x 7.5/15 2 x 5/10 55
Int. 2 x 15 A 50 6/4 - - - - 104 100 4
7
Power mod. F - - - - 2 x 12.5/25 2 x 9/18 55
Int. 2 x 25 A 50 6/4 - - - - 174 180 4
7
Power mod. F - - - - 2 x 25/50 2 x 18/36 40
Int. 2 x 50 A 100 6/4 - - - - 364 380 4
13.5
Power mod. F 30/40/51 55 30/40/51 55 40/80 28/56 50
Int. 80 A 100 16/10 320 3.2 320 3.2 300 300 4
9.5
Power mod. F 45/60/76 55 45/60/76 55 - -
Int. 108 A 150 50 460 3.2 460 3.2 - -
13
5
F = Seperately cooled, S = Self cooled
2
The 1st statement is valid for wire end ferrules, the 2nd without wire end ferrules.
1
X1 = Current reduction factor, current reduction from cycle frequecy X2 of power transistors.

Power mod. F 60/80/ 50 60/80/ 50 80/160 56/112 55
Int. 160 A 102 102
150 50 685 3.2 685 3.2 655 645 4
13
Power mod. F 85/110/ 55 85/110/ 55 100/200 70/140 55
Int. 200 A 127 127
300 95 or 2 x 850 3.2 850 3.2 740 730 4
35
26
Power mod. F 85/110/ 55 85/110/ 55 100/200 70/140 55
Int. 200 A 127 127
Line 300 95 or 2 x 750/100 3.2 750/100 3.2 -/650/904 -/640/904 4
connection 35
26
Power mod. F 120/150/ 120/150/ - - -
Int. 300 A3 193 193
Line connect- 300 95 or 2 x 1290/ 3.2 1290/ 3.2 - - -
ion or radial 35 1100/ 1100/
blower 1904 1904
26
Power mod. F 200/250/ 200/250/ - - -
Int. 400 A3 257 257
Line connect- 300 150 or 2 2170/ 3.2 2170/ 3.2 - - -
ion or x 50 1845/ 1845/
3254 3254
radial blower 28
Power mod. F - - - - 4/8 3/6 55
Ext. 8 A 50 6/4 - - - - 21/14 21/14 4
6.5
Power mod. F - - - - 7.5/15 5/10 55
Ext. 15 A 50 6/4 - - - - 27/18 31/19 4
6.5
Power mod. F - - 8/10/16 55 12.5/25 9/18 55
Ext. 25 A 50 6/4 - - 45/29 3.2 55/35 55/35 4
6.5
Power mod. F 24/32/32 40 24/32/32 40 25/50 18/36 40
Ext. 50 A 50 6/4 171/89 3.2 171/89 3.2 118/62 125/65 4
7.5
Power mod. F - - - - 2 x 4/8 2 x 3/6 55
Ext. 2 x 8 A 50 6/4 - - - - 43/27 43/27 4
7
4
Pvtotalamt/PvSchlauch/Pvintern
3
When no line cooling is used only Pvtotal is relevant.
3
When no line cooling is used only Pvtotal is relevant.

Power Cooling5 Max. Spindle X11 AMM- X11 [%] Feed drive Feed drive X11
module connecti drive [%] Analog analog In/Imax digital In/Imax [%]
currents on Analog/ In/Is6/Imax [A] [A]
cross- Digital [A]
section2 In/Is6/Imax
[mm²] [A]
Max. width Loss X21 Loss X21 [kHz] Loss Loss [W] X21
[mm] [W] [kHz] [W] [W] [kHz]
Weight [kg] Pvtotal Pvtotal Pvtotal Pvtotal
Power mod. F - - - - 2 x 7.5/15 2 x 5/10 55
Ext. 2x15 A 50 6/4 - - - - 64/40 62/38 4
7
Power mod. F - - - - 2 x 12.5/25 2 x 9/18 55
Ext. 2x25 A 50 6/4 - - - - 107/67 111/69 4
7
Power mod. F - - - - 2 x 25/50 2 x 18/36 40
Ext. 2x50 A 100 6/4 - - - - 240/124 250/130 4
13.5
Power mod. F 30/40/51 55 30/40/51 55 40/80 28/56 50
Ext. 80 A 100 16/10² 288/32 3.2 288/32 3.2 270/30 270/30 4
9.5
Power mod. F 45/60/76 55 45/60/76 55 - -
Ext. 120 A 150 50 441/19 3.2 441/19 3.2 - -
13
Power mod. F 60/80/ 50 60/80/ 50 80/160 56/112 55
Ext. 160 A 102 102
150 50 655/30 3.2 655/30 3.2 625/30 620/25 4
13
Power mod. F 85/110/ 55 85/110/ 55 100/200 70/140 55
Ext. 200 A 127 127
300 95 or 2 x 750/100 3.2 750/100 3.2 650/90 640/90 4
35
26
Power mod. F 120/150/ 120/150/ - - -
Ext. 300 A 193 193
300 95 or 2 x 1100/ 3.2 1100/ 3.2 - - -
35 190 190
26
Power mod. F 200/250/ 200/250/ - - -
Ext. 400 A 257 257
Line connec- 300 150 or 2 1845/ 3.2 1845/ 3.2 - - -
tion or x 50 325 325
radial
blower 28
5
F = Separately cooled, S = Self cooled
2
The 1st statement is valid for wire end ferrules, the 2nd without wire end ferrules
1
X1 = Current reduction factor , current reduction from cycle frequecy X2 of power transistors.

Definition of currents Feed drive Analog: Block type current
Amplitude values of the block type current are indicated.
BSA Digital: Sinus-shaped current,

The effective values are stated
1 In Continuous current
2 Imax Peak current
Definition of powers Pv total Total power loss by module

Pv Schl Loss with cooling lines;
Pv ext Power loss through external heat dissipation
Pv int Internal power loss
This power loss remains in the switch cabinet
Current reduction depen- X1 = Current reduction factor, current reduction from cycle
dent on cycle frequency frequency X2 of power transistors (see Technical data).
Current reduction depen- All mentioned load currents are valid for an installation altitude. up
dent on installation altitude to 1000 meters. Currents must be reduced according to the
following diagram if the installation altitude exceeds 1000 meters.

Load cycle definition: Drive modules
Rated load cycle: Feed drive
Peak current load cycle with pre-load
Peak current load cycle without pre-load
Interface overview
Terminal Designation Function Type1 Typical voltage/limit values Max. cross-section

No.
U2 Motor connection O 3AC 600 V
V2
W2
PE1 Ground I 0V Screw
PE2 Ground I 0V Screw
X151/X351 Device bus I/O Miscellaneous 34-pin ribbon cable
P600 Intermediate circuit I/O +300 V Bus bar
M600 Intermediate circuit I/O -300 V Bus bar
1
O = Output, I = Input, NC = normally closed contact

2.2 Regulation PCBs
Digital regulation PCBs for operating the motors 1FT6/1FK6 and

1PH are available as single and dual axes modules. Drive software
(Bot-files) is loaded via the drive bus to the regulation PCB
modules during the SINUMERIK 840D boot-up phase.
Single axis drive regulation
Digital single axis regulation performance can be loaded with the

feed drive regulation software or the main spindle drive regulation
software. The projected operation environment is the same in both
cases. The module is available in three variations:
• Basic version with interface possibility for absolute ROD with
EnDat–Interface
• additionally for direct positioning ROD with sine type current
signals
• additionally for direct positioning ROD with sine type voltage
signals and interface possibility for absolute value ROD with
EnDat– Interface
Dual-axis drive regulation
Digital dual-axis regulation can be loaded with the feed drive

regulation software. Main spindle drive software cannot be loaded.
The module is available in two versions which are differentiated by
TCO as to regulation performance and processing of direct
regulation ROD systems:
Dual-axis drive regulation 6SN1118-0DH1-0AA0
• Basic version with interface possibility for absolute ROD with

EnDat–Interface
• additionally with processing of 2 direct positioning RODs with
sine type current signals
• additionally with processing of 2 direct positioning RODs with
sine type voltage signals and interface possibility for absolute
value ROD with EnDat– Interface

A B
11
1
10
2
4
5
6
7
8
A Single axis version

B Dual-axis version
1 Motor ROD 5 Digital / Analog Unit (DAU) 9 Device bus

2 Direct ROD (not used at the Test signal outputs 10 Direct ROD for axis 2 (not used
present time) 6 Diagnostics LED at the present time)
3 X431 Enable signals 7 Drive bus input 11 Motor ROD for axis 2
4 External proximity switch connec- 8 Drive bus output
tion (currently not used)
Drive regulation Fig. 14216

Interface overview
Terminal Designation Function Type1 Typical Max. cross-

No. voltage/limit section
values
9 X431 Enable voltage O +24 V 1.5 mm²
663 X431 Pulse enable: the "Start-up inhibit" relay is I +21 V...30 V 1.5 mm²
energized with terminal 663. Control pulses are
disabled and the motor stopped. Start-up inhibit
relay (return signal terminal 663)
AS1 X431 Start-up inhibit relay (return signal terminal 663) I max. 250VAC/1A 1.5 mm²
AS2 X431 NC 30 VDC/2A 1.5 mm²
B1 X432 External zero mark (Prox. switch) Axis 1 I +13 V...30 V 1.5 mm²
19 X432 Negative enable voltage O 0V 1.5 mm²
B2 X432 External zero mark (Prox. switch) Axis 2 I +13 V...30 V 1.5 mm²
9 X432 Positive enable voltage O +24 V 1.5 mm²
X411 Motor ROD, axis 1
X412 Motor ROD, axis 2
X421 Direct position, axis 1
X422 Direct position, axis 2
X151 Device bus
X141 Drive bus
X341
1
I = Input; O = Output; NC = Normally closed contact; NO = Normally open contact (with signal NO = High/NC=Low)



3. Three-phase servo motor
Maintenance free, three-phase SIMODRIVE motors of the 1FT6

series are used.
The motors are fitted with an internal brake.
A Heidenhain motor feedback system for rotor, RPM and position

sensing is integrated in the motor.
2 3
6 5 4
1 Motor coils 3 Motor feedback connection 5 Rare earth magnets

2 Motor connector 4 Motor feedback 6 Brake
Three-phase SIMODRIVE servo motor 1FT608 Fig. 14215
Motor zero marker The rotor and motor housing each have a marker. If both markers
are in line, one above the other, this indicates that the motor is
located on the zero marker.
The two markers must be in line over each other when installing
the motor.

3.1 Position sensing
The motors, as a standard, are fitted with sine/cosine type RODs

for position sensing, rotor position and RPM. An external ROD is
not required.
Signal sequence in clockwise rotation
The sine/cosine ROD delivers 2048 sinus pulses per rotation (per
A & B track). The sine/cosine signals are digitized and the rotor
position, the RPM evaluation and positioning signals are produced
in the regulation module. The negative sine/cosine curves are
inverted and reduced to 8 Bit per 45°. Result: a total resolution of 8
x 8 = 64 bits sine and therefore 2048 sine waves per rotor
revolution which in turn translates into 131,072 pulses per
revolution (8 x 8 bits x 2048 sine waves).
Amplitude: 1 Vss ± 30%

Voltage supply: 5V±5%
Max. processable ROD frequency (RPM): 350 kHz
The ROD signals cannot be measured with an oscilloscope. A

special measuring kit from Heidenhain is needed to read these
signals.

4. Diagnostic aids
Integrated diagnostic aids Test programs have been integrated in the Siemens operating
environment, serving the customer or service engineer as a
diagnostic aid. The following information can be viewed at the
Siemens operating environment, under "Diagnostics":
• Service displays show the most important information

regarding the axes and spindle drives, such as
• Nominal position value
• Actual position value
• Lag
• Nominal speed
• Actual speed
• Contour deviation
• Drive status
• Actual current
• Motor temperature
• Alarms and messages displayed in plain text
External diagnostic tools The 611D Setup Tool is a supplementary tool provided for drive
optimization and for evaluating the mechanics. The Setup Tool
runs on an external PC connected to the controller by means of an
MPI interface.
4.1 Service mask: Axis/Spindle
For the purpose of setting up and diagnosing the
• Axes and
• Spindles
information on each axis/spindle can be viewed in the following

mask under "Diagnostics" in the Siemens operating environment.
Application This information allows you to
• Check the nominal values

(e.g. nominal position value, nominal speed value,
programmed nominal spindle RPM)
• Check the actual values
• Optimize the position control loop
(e.g. lag, system deviation, Kv gain factor
• Check the entire axis control loop
(e.g. by comparing the nominal and actual positions, the
nominal and actual RPMs)

• Verify hardware errors
(e.g. encoder check: if the axis is moved mechanically, this
must be reflected by a change in the actual position value)
Axis/Spindle Service
Description
Lag Difference between nominal and actual position, ROD 1/2. Unit:
mm, inch or degrees
System deviation Difference between nominal position value at the position controller
input and the actual position. Unit: mm, inch or degrees
Contour deviation This display shows the actual contour deviation (lag variations due
to corrections by the speed controller occasioned by load
variations). The contour deviation is computed from the difference
between an actual position pre-calculated on the basis of the
nominal position and the actual value measured by ROD 1/2. Unit:
mm, inch or degrees
Kv gain factor (calculated) The Kv gain factor shown here is calculated by the NC according
to the equation below:
Kv gain factor = Nominal speed value / Lag
Unit (default setting): [m/min]/[mm]
Nominal speed value = Nominal value currently being output to the

axis/spindle.
Status display for referencing (axis).

Status display "Referenced" Status 0: Machine axis with ROD 1 or 2 not referenced
Status 1: The machine axis reached the reference point
(incremental measuring system) or target point (linear
measuring system with distance-coded reference
markers) during the referencing cycle.
The display corresponds to interface signal “Referenced/

Synchronized 1 or 2” (DB 31–48, DBX 60.4 and 60.5).
Active encoder This indicates whether encoder 1 or 2 is active.
Actual position encoder Actual axis position determined via encoder. The position is
displayed in the machine coordinate system (no zero point offset
and tool corrections factored in). Unit: mm, inch or degrees
Nominal position value Nominal position output to the position controller by the
interpolator. Unit: mm, inch or degrees
Absolute compensation Shows the absolute compensation value for the encoder. The
value encoder compensation value comprises the sum of backlash and leadscrew
error compensations for the current axis position. Unit: mm, inch or
degrees
Actual speed value The NC processes and displays the pulses received from the
encoder. Unit: % 100% means maximum speed (equivalent to 10V
for analog interface; maximum speed on the 611D, specified by
611D–MD: MOTOR_MAX_SPEED (max. motor speed)).
Nominal speed value The nominal speed value (= nominal speed value from position
controller and pre-control) output to the drive. Unit: % 100% means
maximum nominal speed (10V for analog interface, maximum
speed on 611D).
Prog. nominal spindle RPM RPM programmed by the user.

Unit: RPM e.g.: Input: S1000; Display: 1000 RPM
Display applies only to spindles.
Actual nominal spindle RPM Currently effective nominal RPM, taking into consideration any
correction values and speed limitations that may be effective
(specified through setting or machine data). Unit: RPM
Display applies only to spindles
Override Correction factor for the feedrate or spindle override switch is

displayed. Unit: %
Actual gear step This shows the actual gear step.

This display is given only if a spindle is assigned to the axis. The
display corresponds to the NST “Actual gear step” (DB 31–48,
DBX 16.0 to 16.2).
Not used by TRUMPF at the present time.

Regulation parameter sets Indicates which of the 6 parameter sets of the position control is
currently active. Parameter sets are changed, for example, when
the gear step changes.
Not used by TRUMPF at the present time.
Regulation mode Indicates the current regulation status:

0: Position control
1: Speed control
2: Stop
3: Parking
4: Tracking
5: Braking
Checking the position The Service-Axis mask facilitates verification of the position control
control setting setting. To do so, enter 1 (equivalent to gain Kv = 1) in MD:
POSCTRL_GAIN [n] (Kv gain factor) . The change becomes
effective immediately.
Since the gain factor is defined as follows
Kv gain = Speed / Lag
Unit (default setting): [m/min]/[mm]
at a feedrate of 1 m/min the lag must be 1 mm (where Kv gain = 1

and uniform travel).
If the actual and desired gain factors do not match: following is a

list of possible causes and/or optimization possibilities.
• MD: RATED_VELO (rated motor speed), MD: RATED_

OUTVAL (rated output voltage) needs to be optimized (applies
only to FM–NC)
• Speed or torque pre-control is active. The gain factor shown is
higher than the one set with MD: POSCTRL_GAIN [n].
• Filter for jolt limitation or dynamic correction is activated. The
gain factor shown is lower than the one set with MD:
POSCTRL_GAIN [n].
Alarm diagnostics The information also serves as a diagnostic tool if alarms are
issued, for example :
• 25040 “Stop monitoring”

→ Lag > MD: STANDSTILL_POS_TOL (stop tolerance)
• 25050 “Contour monitoring”
→ Contour tolerance > MD: CONTOUR_TOL (tolerance
range for contour monitoring)
• 25060 “Nominal speed limit”
→ Nominal speed limit > MD: CTRLOUT_LIMIT (Maximum
nominal speed)

• 25080 “Position monitoring”
→ Lag > MD: STOP_LIMIT_FINE (Exact stop, fine)
• 25100 “ Encoder change not possible
→ Difference between Actual position ROD 1 and 2 > MD:
ENC_CHANGE_TOL (Max. tolerance in actual value
sensing)
• 26000 “Clamp monitoring”
→ Lag: CLAMP_POS_TOL (Clamping tolerance in interface
signal “Clamping active”)
Diagnosing faults in The information also allows you to look for possible reasons for
operating states faults in operating states such as
• No axes travel although a motion command has been issued:

→ Check whether Control Enable is effective. In Regulation
mode, the position control or RPM control (in the case of
spindle control) must be active
• Occurrence of feedrate variations.
→ Identify via lag or actual speed value.
• Positioning errors.
→ Compare nominal position value with actual position
encoder and abs. compensation value encoder.
• The PLC does not detect the cams during the referencing cycle
→ Check status display “referenced"
• The display shows the wrong reference point value.
→ Referencing may have taken place with the wrong
encoder.
• Spindle positioning was incorrect.
→ The wrong encoder may have been selected or
synchronization with the wrong zero marker.

4.2 Service mask: Drives (for digital drives
only)
For the purpose of setting up and diagnosing the
• Feed drives (FD) and

• Main spindle drives (MSD)
information on each axis/spindle can be viewed in the following

mask under "Diagnostics" in the Siemens operating environment.
Application This data allows you to
• Verify the status of Enable and Control signals

(e.g. Pulse enable, drive enable, motor selection, nominal
parameter set)
• Verify the status of feed drive and main spindle drive modes
(e.g. Setup mode, parking axis)
• Display temperature warnings
• Check the current displays for nominal/actual values
(e.g. Actual position value encoder 1/2, nominal speed, actual
speed)
• Check the drive status (drive ready)
• Display the current ramp-up stage
• Display a sum error message (ZK1 message)
• Display drive status messages
(e.g. torque threshold undershot, minimum speed undershot,
actual speed = nominal speed)
Service: Drives

Description
Following is a description of individual status displays, warnings,

messages etc.
Display corresponds to the status of terminal 64/63 of the 611D

Drive enable (terminal 64/63) input/recovery module
Status 1: Central drive enable

Status 0: Central drive disable
Display corresponds to drive MD: TERMINAL_STATE (binary input

states).
Pulse enable (terminal Display corresponds to the status of terminal 63/48 of the 611D
63/48) input/recovery module.
Status 1: Central pulse enable

Status 0: Central pulse suppression

states).
Pulse enable (terminal 663) Display corresponds to the status of terminal 663 (relay: Safe
operation stop) on the drive module.
Status 1: module-specific pulse enable

Status 0: module-specific pulse disable

states).
Pulse enable PLC Indicates if pulse enable for the drive has been issued by the PLC.
Status 1: The PLC has disabled the pulses for the drive module.
Status 0: The PLC has issued pulse enable for this drive.
Display corresponds to NST “Pulse enable” (DB 31–48, DBX 21.7).
Speed controller enable NC Indicates if the NC has issued speed controller enable for the drive.
Status 1: Speed controller enable = OFF

Status 0: Speed controller enable = ON
Speed ramp rapid stop Status display for speed ramp rapid stop.
Status 1: Speed ramp rapid stop is not active for the drive.
Status 0: Speed ramp rapid stop is active. In this case, the drive
is stopped without a speed ramp, with nominal speed
0 without pulse suppression.
Display corresponds to NST “Speed ramp rapid stop” (DB 31–48,

DBX 92.1).

Intermediate circuit Display contains a drive warning.
status (ON/OFF)
Status 0: Intermediate circuit voltage = ON
Status 1: Intermed. circuit voltage lower than warning threshold
The warning threshold corresponds to drive MD: LINK_VOLTAGE_

WARN_LIMIT (Intermediate circuit undervoltage warning
threshold).
Pulse enable Reports whether pulse enable has been issued for a drive.
Status 0: No pulse enable for the drive module. No axis/spindle

travel possible.
Status 1: Pulse enable issued for the drive module. The
axis/spindle can be positioned.
Display corresponds to NST “Pulse enable” (DB 31–48, DBX 93.7).
Drive ready Indicates the current status of the selected drive.
Status 0: The drive is not ready

Status 1: The drive is ready.
Display corresponds to NST “DRIVE–ready” (DB 31–48, DBX

93.5).
Ramp-up phase Displays the current ramp up phase of the selected drive.
Significance:
XYZ
internal coding
0 = Software loaded in drive modul

1 = Drive module has been initialized
2,3 = Drive machine data are being initialized
4 = Synchronization
5 = Cyclical operation
Fig. 18388E
CRC error Displays communication errors between NC and drive as detected

by the hardware.
If the display is other than 0, contact your SIEMENS

representative!
ZK1 message Indicates whether any status class 1 messages are present:
Status 0: No status class 1 message present.

Status 1: One or more status class 1 messages present
Messages of status class 1 are alarms with the following

properties:

• They lead to internal responses
(e.g. generated braking, immediate pulse suppression)
• They are self holding.
Nominal speed The nominal speed displayed here represents the unfiltered
nominal sum value. It is made up of the position control output
share and the speed pre-control branch. Unit: RPM
Display corresponds to drive MD: DESIRED_SPEED (nominal

speed).
Actual speed The actual speed displayed here represents the unfiltered actual
speed. Unit: RPM
Display corresponds to drive MD: ACTUAL_SPEED (actual

speed).
Actual smoothed current Displays the actual smoothed current. The torque-producing actual
current value is smoothed by a PT1 (first-order time-delay) element
with a constant time value (via parameter). Unit: % 100 % equal
the maximum current of the power unit.
Display corresponds to drive MD: ACTUAL_CURRENT (actual

smoothed current).
Motor temperature Displays the motor temperature measured by the thermal detector.
Unit: degrees Celsius
Display corresponds to drive MD: MOTOR_TEMPERATURE

(motor temperature).
Nominal speed smoothing Status display for nominal speed smoothing.
Status 0: No smoothing active for the nominal speed.

Status 1: Nominal speed smoothing is active, as requested by
the PLC with “Nominal speed smoothing” (DB 31– 48,
DBX 20.3), since nominal speed filter 1 is configured
as a low-pass filter.
Display corresponds to NST “Nominal speed smoothing active”

(DB 31–48, DBX 92.3).
2nd torque limit Display the active torque limit.
Status 0: Torque limit 1 is active.

Status 1: Torque limit 2 is active.
Display corresponds to NST “Torque limit 2 active” (DB 31–48,

DBX 92.2).
Integrator disable Indicates whether the speed control integrator is active.
Status 0: The integrator of the speed controller is enabled. The

speed control functions as a PI-controller.

Status 1: The integrator of the speed controller has been
deactivated for the drive module, as requested by the
PLC with NST “Integrator disable n–regulator” (DB
31–48, DBX 21.6). The speed control has therefore
been switched from PI to P-control.
Display corresponds to NST “Integrator n–regulator disabled” (DB

31–48, DBX 93.6).
Setup mode 611D operating mode display
Status 0: Normal mode active for drive.

Status 1: Setup mode active for drive
Display corresponds to NST “Setup mode active” (DB 31–48, DBX

92.0).
Axis parked 611D operating mode display
Status 0: Axis/Spindle in normal mode

Status 1: Axis/Spindle parking, i.e. all encoder-specific
monitoring and processing is OFF. In this condition,
the encoder can be detached without triggering an
alarm.
Nominal parameter set Indicates which of the 8 drive parameter sets of the 611D is to be
(drive) activated by the PLC.
Display corresponds to NST “Parameter set selection: A,B,C” (DB

31–48, DBX 21.0 to 21.2).
Actual parameter set (drive) Indicates which of the 8 drive parameter sets of the 611D is
currently active.
Display corresponds to NST “Active parameter set A,B,C” (DB 31–

48, DBX 93.0 to 93.2).
Motor selection (star/delta) Indicates which motor data set is to be activated by the PLC. At the
present time, the motor data set is used for star/delta switchover
on main spindle drives (MSD)
Assignment is as follows:
Motor Application Code

Motor 1 MSD: star operation 0 0
Motor 2 MSD: delta operation 0 1
Motor 3 reserved 1 0
Display applies only to MSD ( main spindle drives)

Display corresponds to NST “Motor selection A,B” (DB 31–48, DBX
21.3 to 21.4).

Actual motor (star/delta) Indicates which motor data set is currently active. At the present
time, the motor data set is used for star/delta switchover on main
spindle drives (MSD).
Assignment is as follows:
Motor Application Code

Motor 1 MSD: star operation 0 0
Motor 2 MSD: delta operation 0 1
Display applies only to MSD ( main spindle drives)

Display corresponds to NST “Active motor A,B” (DB 31–48, DBX
93.3 to 93.4).
Actual position value The actual axis position, measured by encoder 1/2. The position is
encoder 1/2 displayed in the machine coordinate system (no zero point offsets
and tool corrections are factored in). Unit: mm, inch or degrees
Heat sink temperature Drive warning signal.

warning
Status 0: Heat sink temperature monitoring has not responded.
Status 1: Heat sink temperature monitoring has responded.
Display corresponds to NST “Heat sink temperature warning” (DB

31–48, DBX 94.1).
Motor temperature warning Drive warning signal.
Status 0: Motor temperature under warning threshold

Status 1: Motor temperature has exceeded the prescribed
warning threshold
The warning threshold corresponds to drive MD: MOTOR_TEMP_

WARN_LIMIT (maximum motor temperature).
Display corresponds to NST “Motor temperature warning” (DB 31–

48, DBX 94.0).
Speed ramp cycle Drive status display.

completed
Status 0: Speed ramp cycle not yet terminated after a new
nominal speed specification.
Status 1: After a new nominal speed specification, the actual
speed is within the speed tolerance width.
The speed tolerance width corresponds to drive MD: SPEED_

DES_EQ_ACT_TOL (tolerance width for ‘nnom. –nactual ’ signal).
Display corresponds to NST “ Speed ramp cycle completed” (DB

31–48, DBX 94.2)

Torque threshold undershot Drive status display.
Status 0: In stationary condition (i.e. speed ramp cycle

terminated), the nominal torque is greater than the
torque threshold.
Status 1: In stationary condition, the nominal torque has
undershot the torque threshold.
The torque threshold corresponds to drive MD: TORQUE_

THRESHOLD_X.
Display corresponds to NST “M d < M dx ” (DB 31–48, DBX 94.3).
Minimum speed undershot Drive status display.
Status 0: The actual speed is higher than the minimum speed.

Status 1: The actual speed is lower than the minimum speed.
The minimum speed corresponds to drive MD: SPEED_

THRESHOLD_MIN (n min for ‘nactual < nmin ’ signal).
Display corresponds to NST “nactual < nmin ” (DB 31–48, DBX

94.4).
Speed threshold undershot Drive status display
Status 0: The actual speed is higher than the speed threshold.

Status 1: The actual speed is lower than the speed threshold.
The speed threshold corresponds to drive MD: SPEED_

THRESHOLD_X (nx for ‘nactual < nx ’ signal).
Display corresponds to NST “nactual < nx ” (DB 31–48, DBX

94.5).
Actual speed = Nominal Drive status display.

speed
speed value is outside the speed tolerance width.
speed is within the speed tolerance width.
The speed tolerance width corresponds to drive MD: SPEED_

DES_EQ_ACT_TOL (tolerance width for ‘nnom. – nactual ’ signal).
Display corresponds to NST “nactual = nnom. ” (DB 31–48, DBX

94.6).

Variable message 1 Status display for the variable report function of the 611D. In this
variable report function, a random storage cell is monitored for
overshooting of a programmable threshold. This threshold can be
assigned a tolerance width which is processed when the threshold
is queried for over- or undershooting. The signal can be associated
to a signal on or off delay time
Status 0: Threshold undershot

Status 1: Threshold overshot
The variable report function is set with the following 611D machine
data parameters:
PROG_SIGNAL_FLAGS (Variable report function bits)

PROG_SIGNAL_NR (Variable report function signal
number)
PROG_SIGNAL_ADDRESS (Variable function signal address)
PROG_SIGNAL_THRESHOLD (Variable signal threshold)
PROG_SIGNAL_HYSTERESIS (Variable signal hysteresis)
PROG_SIGNAL_ON_DELAY (Variable signal on delay)
PROG_SIGNAL_OFF_DELAY (Variable signal off delay)
Utilization For working with the service displays
Alarm diagnostics The information also serves as a diagnostic aid if alarms are
issued, for example:
• 300300 “ Error ramping up”

→ Check the Ramp-up phase to determine which ramp-up
phase the drive has reached.
• 25201 “Drive fault”
→ Message ZK1 is set.
→ Check nominal parameter set, motor selection,
intermediate circuit status. Check sequential alarms
300500 to 300515
• 25040 “Stop monitoring”,
25050 “Contour monitoring”,
25060 “Nominal speed limit”
25080 “Position monitoring”
→ Drive enable may be missing (e. g. Pulse enable, drive
enable, pulse enable PLC not present); this results in
display Enable pulse = OFF.
• 300614 “ Motor temperature overshot”
→ Check the current motor temperature.

4.3 Interface signals
DB number Bit, Byte Name Reference

Axis/spindle specific Signals from PLC to axis/spindle
31-48 16.0 to 16.2 Actual gear step S1

31-48 21.0 to 21.2 Parameter set selection A, B, C A2
31-48 21.3 to 21.4 Motor selection A, B A2
31-48 21.7 Pulse enable A2
Signals from axis/spindle to PLC
31-48 60.4 Referenced/synchronized 1 R1
31-48 60.5 Referenced/synchronized 2 R1
31-48 92.0 Setup mode active A2
31-48 92.1 Speed ramp rapid stop A2
31-48 92.2 Torque limit 2 active A2
31-48 92.3 Nominal speed smoothing active A2
31-48 93.0 to 93.2 Active parameter set A, B, C A2
31-48 93.3 to 93.4 Active motor A, B A2
31-48 93.5 DRIVE ready A2
31-48 93.6 Integrator n-controller disabled A2
31-48 93.7 Pulses enabled A2
31-48 94.0 Motor temperature pre-warning A2
31-48 94.1 Heat sink temperature pre-warning A2
31-48 94.2 Speed ramp cycle completed A2
31-48 94.3 Md < Mdx A2
A231-48 A294.4 nactual < nmin A2
A231-48 A294.5 nactual < nx A2
31-48 94.6 nactual = nnom. A2
31-48 16.0 to 16.2 Actual gear step S1
31-48 21.0 to 21.2 Parameter set selection A, B, C A2
31-48 21.3 to 21.4 Motor selection A, B A2
31-48 21.7 Pulse enable A2

4.4 Machine data
Number Designation Name Reference

Axis-specific ($MA_...)
36050 CLAMP_POS_TOL Clamping tolerance for interface signal A3

"Clamping active"
36400 CONTOUR_TOL Contour monitoring tolerance width A3
36210 CTRLOUT_LIMIT Maximum nominal speed G2
36500 ENC_CHANGE_TOL Max. tolerance for actual position sensing G2
36300 ENC_FREQ_LIMIT[n] Encoder frequency limit A3
32200 POSCTRL_GAIN[n] Servo gain (Kv) factor G2
32250 RATED_OUTVAL Rated output voltage G2
32260 RATED_VELO Rated motor speed G2
36030 STANDSTILL_POS_TOL Stop tolerance A3
36010 STOP_LIMIT_FINE Exact stop, fine B1
Machine drive data ($MD_...)
1708 ACTUAL_CURRENT Actual current, smoothed /IAD/
1707 ACTUAL_SPEED Actual speed /IAD/
1706 DESIRED_SPEED Nominal speed /IAD/
1604 LINK_VOLTAGE_WARN_LIMIT Intermed. circuit voltage threshold warning /IAD/
1401 MOTOR_MAX_SPEED Speed for max. effective motor speed /IAD/
1702 MOTOR_TEMPERATURE Motor temperature /IAD/
1602 MOTOR_TEMP_WARN_LIMIT Maximum motor temperature /IAD/
1620 PROG_SIGNAL_FLAGS Variable report function signal bits /IAD/
1621 PROG_SIGNAL_NR Variable function signal number /IAD/
1622 PROG_SIGNAL_ADDRESS Variable function signal address /IAD/
1623 PROG_SIGNAL_TRESHOLD Variable function signal threshold /IAD/
1624 PROG_SIGNAL_HYSTERESIS Variable function signal hysteresis /IAD/
1625 PROG_SIGNAL_ON_DELAY Variable function signal ON delay /IAD/
1626 PROG_SIGNAL_OFF_DELAY Variable function signal OFF delay /IAD/
1426 SPEED_DES_EQ_ACT_TOL Tolerance width for ’nnom. - nactual’ signal /IAD/
1418 SPEED_TRESHOLD_MIN nmin for ’nactual < nmin’ signal /IAD/
1417 SPEED_TRESHOLD_X nx for ’nactual < nx’ signal /IAD/
1700 TERMINAL_STATE Status of binary inputs /IAD/
1428 TORQUE_TRESHOLD_X Torque threshold /IAD/

5. Setup Tool
This program serves as a tool for
• assessing the most important variables for position, speed and

current control,
• archiving drive and regulation data and
• for analyzing given mechanical properties
5.1 Instructions for use
Application The setup software IBN–Tool is used for drive configuration and
parameter assignment on the SINUMERIK 810D and SINUMERIK
840D.
This tool allows the drive configuration to be input for primary setup
and to assign drive parameters with standard data that are
dependent on the motor/power supply unit combination. Moreover,
drive and regulation data can also be stored on the PG or PC.
Additional optimization and diagnostic aids are also offered.
Measuring function The measuring function makes it possible to evaluate important

variables RPM, positioning measuring system and torque
regulation values in time and frequency ranges at the screen,
without external measuring devices
Analog output All important regulation signals: position, RPM and torque
regulation values can be output to the drive module’s DAU–
configuration test pin array. These signals can be fed to an
oscilloscope or signal recording device for test and evaluation
purposes.
FFT analysis (Fourier- In addition to the normal procedure of optimizing the machine data
Analysis) of the regulation circuit with regard to transient response (timed
processes), the FFT is also offered. This (Fourier analysis) tool is
used to evaluate regulation circuit and mechanical characteristics
when
• unstable current, RPM or positioning signal fluctuations are

suspected
• only slow RPM circuit response can be realized
Saving measuring results Measuring diagrams can be archived by using file functions. This
record can be used in establishing a machine history and is
obviously very useful for remote diagnosis

Starting the program
Program start The IBN (Set-up) tool is started on a PG/PC with the
REG_CMD.EXE file or a self made icon in the user group. If
communication with the NCK cannot be established, a “No
communication with NCK” message will be issued. If
communication is interrupted by NCK reset, for example, the IBN
tool will attempt to reestablish communication automatically.
Quitting the program
Quitting the program The IBN tool is closed in the following manner:
• Press F10
• Press the Exit softkey to close the program
5.2 Measuring function
Explanation A number of measuring functions make it possible to graphically

display time or frequency responses of drives and regulation
processes on the screen. For this, timed measuring signals are
imposed on drive signals.
Measuring/Signal The adaptation of test nominal values to the respective application

parameters is done by measuring/ signal parameters. The unit increments of
these measuring/signal parameters depend on the respective
measuring function or mode of operation. The following table
indicates the signal parameter application for unit increment
selection:
Variable Unit
Torque Statement in percent, relative to the peak torque of the
power unit being used. The torque for the power unit is
derived from: MD 1108 x MD 1113
Speed Metric system:
Statement in mm/min or RPM for translatory or rotational
movement
Inch system:
Statement in inch/min. or RPM for translatory or rotational
movement
Distance Metric system:
Statement in mm or degrees for translatory or rotational
movement
Inch system:
Statement in inches or degrees for translatory or rotational
movement
Time Statement in ms
Frequency Statement in Hz

Supplementary information All parameters are pre-assigned a value of 0.
Functions which cause a travel motion are selected from the

softkey menu. The actual start is triggered by pressing the NC-
START pushbutton (non-designated pushbutton beneath the
RESET button), on the machine panel. If the function mask is
closed before the start is initiated, the start command will be
cancelled.
When the travel has been started, the main menu can be closed
without affecting the command.
During operation with the IBN tool, the machine is in a “Correction”

condition. In this state, neither the software limit switches nor
working range limits are monitored. The set-up engineer must
therefore assure that the axes to be used are pre-positioned. The
pre-positioning of the axes is to assure that the IBN travel range is
always within the larger machine working range and does not lead
to a mechanical crash. Only such axes motions that are stated with
IBN specifications are monitored
The user must ensure that:
• the E-STOP switch is within his reach.

• no obstacles obstruct the travel range.
Travel is normally aborted by pressing the
• NC–STOP button
• RESET button
• Softkey STOP in the respective menu.
or by taking away the

• Regulator enable
• Drive enable
• Motion enable signal
• Feed or spindle enable
or with position 0% of the feedrate override switch or

position 50% of the spindle override switch.
NCK or drive alarms (e.g. ”Function aborted by NC”) also

cause the current motion to be aborted.
The JOG mode must be active when working with measuring

functions. This assures that no parts program is able to drive any
of the axes or spindle.

5.3 NST signals: Travel request and
motion enable drive test
Explanation Axes with mechanical brakes may require the brakes to be

activated in certain conditions. The Enable with PLC option which
appears in the travel function window serves this purpose..
The drive test - travel request and the drive test - motion enable
acknowledgment signal can be combined in the PLC–user
program.
This safety mechanism can be deactivated with the Enable without

PLC option
Supplementary information The travel range monitoring system can be deactivated for axes
with an endless travel range
5.4 Measuring functions abort
• EMERGENCY STOP
• NC–Stop
• Reset (BAG, channel)
• Feedrate Override = 0
• Spindle Override = 50
• Disabling the regulator enable signal
• Closing the JOG mode
• Pressing the Feed keys
• Activating the handwheel
• Disabling the feed enable signals
• Alarms which lead to feed stop
• Hardware limit switch reached
• Travel range exceeded
• Parking function activated (in closed loop control mode).

5.5 Frequency response reading
Torque regulation circuit reading
Function Reading of the torque regulation circuit is only necessary for

diagnosis in error situations or if standard data was not used for
the applied motor / power combination, resulting in unsatisfactory
RPM frequency response.
Frequency response reading of suspended axes without

external weight/balance compensation requires additional
safety measures to be taken by the operator (securing the
axis).
Procedure 1. Set the travel range monitor and enable logic in the Start mask
2. Set the required parameters in the measuring parameter mask
3. Display the test results on the screen with the Display softkey.
Display diagram: Current regulation circuit
Measuring parameters Amplitude

This parameter defines the test signal amplitude (Unit: statement of
peak torque in %). Settings between 1 to 5 % are suitable
Range
Analyzed frequency range
• 8.0 kHz on the 840D (Sampling rate 16.0 kHz).

Averaging
The exactness and reading duration is increased with this value.
Normally a value of 20 is sufficient.
Settling time
Recording of measuring data begins time offset to the application
of the nominal test value and offset to the stated settling time by 10
ms.
Additional information Measuring parameters and results (diagrams) can be loaded or

saved with the File functions softkey
RPM regulation circuit reading
Function The transfer characteristic to the motor encoder is always

analyzed. Depending on the measurement set-up selections, the
following parameter lists are offered:
Procedure The travel range monitoring system and enable logic

(external/internal) is activated in the main menu.
1. Set the travel range monitor and the enable logic in the main
menu. Four different measurements can be selected:
• Reference frequency response
• Interference frequency response
• Nominal value check
• Disturbance step change
2. Set the required parameters in the measuring parameter menu
3. Display the reading results on the screen with the Display
softkey
Display diagram: RPM regulation circuit

Reference frequency The reference frequency response reading establishes the RPM
response regulator’s transfer behavior. The transfer range should be long
and if possible without magnifications. If necessary, stop or low-
pass filters (611D) must be used. Resonance in the RPM
regulation range should be specially noted (Stability limit approx.
200–500Hz).
Interference frequency As an alternative, the interference frequency step change can be

response recorded to evaluate the regulation’s interference suppression
capabilities.
Parameters for reference Amplitude

freq. response and This parameter determines the test signal amplitude. This should
interference freq. response produce only a low motor speed for just a few (1 to 2) RPM.
Offset
This measurement requires a slight speed offset of a few motor

revolutions per minute. The offset must be greater than the
selected amplitude.
Range
Analyzed frequency range
• 4.0 kHz on the 840D (Sampling rate 16.0 kHz).
Averaging
Settling time
of the nominal test value and the offset value stated here. A value
between 0.2 and 1 s is realistic.
Nominal value and The frequency step change can be used to evaluate the RPM
disturbance step change regulation settling time (reference or interference behavior) in a
time frame. To record the interference behavior, the test signal is
imposed onto the RPM regulation output.
Meas. parameters for Amplitude

nominal value and This parameter determines the size of the stated nominal value
disturbance step change jump or disturbance step change.
Measuring time
This parameter determines the measuring time range (maximum
2048 x RPM regulation cycles).
Offset
(in preparation)

Settling time
Recording of measuring data and output of nominal test value
begins with a delay relative to the activation of the offset.
Nominal value signal - RPM regulation circuit jump response
Additional information Measuring parameters and results (diagrams) can be saved by

pressing the File functions softkey.
Position control loop reading
Function The transfer behavior to the active positioning system is always

analyzed. If the function is activated for a spindle without a
positioning system, the NCK issues an error message. Various
measuring parameter lists are offered, depending on the selected
basic set-up.
Procedure 1. Set the travel range monitor and enable logic in the main menu
On of three possible measurements can be selected
• Reference frequency response
• Nominal value step change
• Nominal value ramp
2. Set the required parameters in the measuring parameters
menu
3. Display the measuring results on the screen with the Display
softkey

Display diagram: Position control loop
Reference frequency The reference frequency response reading establishes the position
response regulator’s transfer behavior in the frequency range (active ROD).
Parameters should be assigned to the nominal value filters, gain
value and pre-control in such a manner that no magnifications
occur in the entire frequency range. The setting of the precontrol
symmetry filter should be examined if frequency response is
inconsistent. The following measures must be taken if increases
are excessive:
1. Reduce the Kv gain value

2. Reduce the pre-control value
3. Use normal value filters
The effect of these measures can also be checked in the time

frame
Parameters for reference Amplitude

frequency response This parameter determines the test signal amplitude. The setting
should be as small as possible (e.g. 0.01 mm).
Offset
This measurement requires a slight speed offset of a few motor
revolutions per minute. The selected offset must assure that no
speed zeros occur at the chosen amplitude.
Range
The analyzed frequency range is set here (maximum half the
position regulation sampling frequency). The smaller the value
entered here, the finer the frequency resolution and the longer the
reading will last. Maximum value is limited by half the position
regulation sampling rate (e.g. 200 Hz at 2.5 ms position sampling
time).

Averaging
Settling time
of the nominal test value and offset to the stated settling time. A
suitable value is one between 0.2 and 1 s. If the settling time is too
short, distortions of the frequency response and phase diagrams
will result.
Nominal step change and With the step-change and ramp activation, the settling and
nominal value ramp positioning behavior of the position regulation can be assessed in a
time frame, in particular also the effect of nominal value filters. If an
offset other than zero is input, the test start will occur during travel.
For better representation, this constant part is extracted for the
actual position display. Possible measured variables:
• Actual position value (active ROD)

• System deviation (lag error)
Parameters for nominal Amplitude

step-change and ramp This parameter defines the amplitude of the specified nominal
step-change or nominal ramp.
Offset
Step-change is induced from the standstill or based on the
constant travel speed set with this parameter.
Measuring time:
This parameter determines the measuring time range (maximum:
2048 regulation cycles).
Settling time
Recording of measuring data and output of the nominal test value
begins with a delay (by this value) with respect to offset activation.
Ramp duration:
In basic setting nominal value ramp, the nominal position value is
specified according to the ramp duration setting. The current
acceleration limits for the axis/spindle are active.
A jolt motion can be set with the axis-specific NC–MD 32410

AX_JERK_TIME (with NC–MD 32400 AX_JERK_ENABLE set to
1).
The nominal position value and the actual value of the active ROD
are recorded.

Signal response in measuring function Nominal position/Ramp
In the case of maximum axis acceleration, the speed changes

(almost) abruptly (continuous line).
The dotted lines reflect a realistic value: The offset share is

extracted from the display graphics in order to highlight the
transition processes.
5.6 Graphic display
Explanation Press softkey Display in the respective measuring function menu.
Display diagrams 1 and 2 of a speed control circuit

Softkeys Graphiic1, These softkeys let you toggle between single and double graphic
Graphic 2 display.
Softkeys X Marker and When these softkeys are pressed, a vertical or horizontal line
Y Marker appears in the diagram, serving to mark the abscissa or ordinate,
resp. The pertaining coordinates are displayed. To deactivate the
marker, press softkey X Marker or Y Marker again. The markers
are moved with the cursor keys.
Display diagram: Application X or Y Marker
Softkey Expand To customize the time scale, softkey Expand is used to mark the
current position of the X marker as the beginning of the area you
wish to expand. Pressing softkey Expand a second time allows you
to shift the X marker to the end point of the expansion area. The
marked area is then displayed over the full screen width when you
now press Expand again. Press Expand again for a normal display.
The Expand function is always effective for the currently selected
diagram.
Softkey X Lin/Log Softkey X Lin/Log is used to switch between linear or logarithmic

abscissa in the selected diagram
Y scaling Scaling in Y is normally automatic. Moreover, softkey Scale can be

used to manually specify the scale settings
In the case of GANTRY axes, the function generator and

measuring function may be activated only for the master axis
in SW versions including 3.1. Through coupling, the slave
axis automatically assumes the actual value of the master. If
stop monitoring is desired for the slave axis, the monitoring
window must be temporarily enlarged. Although activation of
the function generator and measuring function for the slave
axis or simultaneously for master and slave axis is not
prevented, it is not recommended and may result in damage
to the machine if not handled properly. If activation for the
slave axis is absolutely necessary for the purpose of

machine measurement, swap the master and slave
temporarily.
5.7 Analog output (DAU)
Function All important regulation circuit signals (nominal and actual values,
system deviation) can also be output to external devices
(oscilloscope or signal recorder), e.g. during Automatic mode. The
611D regulation modules offer three 8–Bit–DAU channels. The
output voltage of the DAUs is between 0 and 5 V.
Layout of DAU output channels on the 611D regulation module
The 3 DAU channels are pre-assigned with the following

drive signals on slot 1:
DAU1 Nominal current after filter. 1 Volt § 3.2 ampere
DAU2 Nominal speed 1 Volt § 1499.99 RPM
DAU3 Actual speed 1 Volt § 1499.99 RPM
These must be deactivated prior to re-configuration.
Activating the analog output Configuration is activated with Start. Active DAUs are indicated in
the left half of the display (active/inactive). Stop (active/inactive)
terminates output.
Before re-selecting DAU output, always use softkey Stop to

cancel any outputs that may still be active for any axis
before pressing softkey Start.
DAU configuration Channel assignment and output signal selection takes place in the
DAU configuration menu:
• Select the Drive No. of the drive module to whose DAU

channels output is directed.
• Select the Axis name of the axis/spindle providing the signal to
be output.
• Assign a shift factor for customizing the resolution. The shift

factor serves to define an 8-bit wide output window across the
storage cell being output (range: –7 ... 31 or 24 in the case of
drive signals). If the shift factor is 0, the output window is
always on the byte with the highest value.

Shift factor for analog output of a storage cell
• Select the signal assignment for each channel used. Activate

the signal selection field for this, and choose the desired
signals from the list offered (feed rive, main spindle drive,
servo) (use cursor or mouse to mark).
Additional information 611D drive signals can be output only on the channels of the
pertaining drive.
Input field Axis name is not relevant for drive signals.
5.8 File functions
Description The Setup Tool offers simple file functions for storing not only the
measuring and functions parameters but also the results onto the
hard disk of the PG or PC.
To facilitate primary setup, the NC and drive machine data can

also be loaded/saved separately for each axis or area, or
transferred to another axis or control. Your confirmation is always
required before an existing file is overwritten.
These file functions are not for making a complete copy of system
and user data for, e.g. archiving or serial setup.

Index
Database drivers
• Adding ...........................................1-42
• Checking for completeness...........1-38
• Connect with database..................1-38
Database errors..........................................1-36
A Database repair..........................................1-46
Activating PLC configuration data.......6-8, 6-27 Databases
Addressing the S7-300 modules................ 2-54 • Backup by the operator .................1-37
Axes-specific machine data ..................... 5-114 • Definition .......................................1-29
Datasbases
• Structure........................................1-29
DB 21 .........................................................3-21
DB 87 .........................................................3-23
DH-Server ..................................................1-25
B Diagnose
Bitbus • Laserfunktionen.............................3-23
• Data flow ....................................... 4-37 Diagnose MMC
• Principle of function....................... 4-37 • Automatic start ..............................1-57
Bitbus module ............................................ 2-42 • Fatal System Error 1 .....................1-55
• Interfaces ...................................... 2-44 • Fatal System Error 2 ......................See
• Jumper configuration .................... 2-45 Diagnosis with R-parameters .....................3-51
• Technical Data .............................. 2-44 Diagnostics
• Axis positioning .............................3-52
• DIAS ..............................................3-54
• Rail assignment check ..................3-54
• Table programming .......................3-52
• Tapping diagnostics ......................3-55
C • Tool management .........................3-53
Changing the PCMCIA card....................... 6-22 Diagnostics MMC
Channel specific machine data.................. 5-89 • 7-segment display .........................1-54
Checking regulator settings at the TASC2006- Diagnostics via machine data ....................3-52
28 Diagnostics with data blocks ......................3-17
Circuitry Digital input module SM 321; DI 16 x DC 24V
• DMP Compact Module 1E Analog ..............................................................2-60
(Slow) ............................................ 2-35 Digital input module SM 321; DI 32 x DC 24V
Communication systems.............................. 4-3 ..............................................................2-62
Complete file Digital module
• Management ................................. 1-50 • Addressing ....................................2-55
• Splitting ......................................... 1-52 Digital output module SM 322; DO 16 x DC
• Structure........................................ 1-51 24V/0.5A................................................2-67
Confidential selection menu....................... 1-19 Digital output module SM 322; DO 32 x DC 24
Configuring the network adapter................ 4-24 V/0.5 A...................................................2-64
Connecting to a computer in the network .. 4-34 Digital output module SM 322; DO 8 x DC
24V/2A...................................................2-70
Disconnecting from the network.................4-35
Display elements
• DMP compact module 1A Analog .2-40
• DMP Compact Module 1E Analog
D (Slow).............................................2-35
• DMP compact module 1E NC Analog
Data blocks
• Diagnostics ................................... 3-17 (rapid) ............................................2-38
H274E8.DOC Index
• NCU .............................................. 2-19 I
DMP compact module 1A Analog
• Display elements........................... 2-40 Interface signals PLC .................................3-59
• Interfaces ...................................... 2-39 Interfaces
• Technical Data .............................. 2-40 • Bitbus module................................2-44
DMP compact module 1E Analog (slow) ... 2-34 • DMP compact module 1A Analog .2-39
DMP Compact Module 1E Analog (Slow) • DMP Compact Module 1E Analog
• Circuit example ............................. 2-35 (Slow).............................................2-35
• Circuitry ......................................... 2-35 • DMP compact module 1E NC (rapid)2-
• Display elements........................... 2-35 37
• Interfaces ...................................... 2-35 ISA-Adapter................................................1-11
• Technical data............................... 2-36
DMP compact module 1E NC
• Display elements........................... 2-38
DMP compact module 1E NC (rapid)
• Interfaces ...................................... 2-37
DMP compact module 1E NC Analog (rapid)2-
L
37 Labels and decals ......................................2-28
DMP compact module 1E NC-Analog (rapid) Language change.......................................1-26
• Circuit example ............................. 2-38 Language-Server........................................1-26
DMP Compact Module 1E NC-Analog (rapid) Loading machine data ..................................6-7
• Technical Data .............................. 2-38 Loading NCK software ...............................6-22
Dual-Port-RAM........................................... 4-36 Loading PLC programs ................................6-8
Loading PLC software ................................6-26
Loading software for NCK and PLC .............6-3
E
ELSP_VSS.H Files .................................... 3-56 M
Machine control panel
• Hardware.........................................1-7
• Pushbutton assignment............1-5, 1-6
Machine data
F • 5-axes transformation (TLC 1005) 5-42
Floppy disk drive 3.5“................................. 1-12 • Analog NCK periphery...................5-38
• Axis dynamics ...............................5-30
• Channel assignment, system cycles5-
40
• Digital NCK periphery....................5-38
• Drive data ......................................5-17
G • Exact stop, axis monitoring ...........5-36
General machine data................................ 5-74 • Manual configuration .....................5-18
• Memory areas ...............................5-41
• Nibbling .........................................5-41
• Offsets ...........................................5-42
• Referencing ...................................5-32
• Saving ...........................................5-11
H • TRUMPF .......................................5-43
Hard disk check ......................................... 1-20 Machine drive data .....................................5-45
Hook-Server ............................................... 1-25 Manual C-axis motion.................................3-55
MASCHINE.INI .........................................5-11
• Deleting an entry ...........................5-14
MB-DDE-Server .........................................1-25
Index H274E8.DOC
MMC P
• Boot sequence .............................. 1-18
• Directory structure................1-22, 1-50 Passwords and exclusions.........................1-27
• Hardware......................................... 1-8 PCMCIA card .............................................2-22
• Interfaces ........................................ 1-9 PLC
• Operating elements....................... 1-11 • Module replacement......................2-56
• Pushbutton assignment .................. 1-6 PLC Interface
• Software structure......................... 1-24 • Overview .........................................3-4
MMC maintenance PLC Modules..............................................3-57
• Battery replacement...................... 1-73 PLC-Debugger ...........................................3-14
• Replacing the complete MMC unit 1-73 Primary installation of MMC .......................6-30
• Replacing the hard disk (only possible
with MMC 103) .............................. 1-75
Modem ....................................................... 1-14
Modem connection....................................... 4-4
Modifying configuration data for operation R
environment software ............................. 5-5
Modifying machine configuration data ......... 5-3 R56 .............................................................3-55
Modifying machine data ............................... 5-7 R57 .............................................................3-55
MPI interface................................................ 4-3 R58 .............................................................3-55
R59 .............................................................3-55
R60 .............................................................3-55
R61 .............................................................3-55
R62 .............................................................3-55
R63 .............................................................3-55
N R64 .............................................................3-55
NC R65 .............................................................3-55
• Directory structure......................... 1-53 R66 .............................................................3-55
• Software ........................................ 2-22 R67 .............................................................3-55
NC-DDE-Server ......................................... 1-25 R68 .............................................................3-55
NCK boot-up diagnostics ........................... 2-20 R69 .............................................................3-55
NCU R80 .............................................................3-54
• Battery and ventilator replacement2-30 R81 .............................................................3-54
• Operation and display elements ... 2-19 R82 .............................................................3-54
• Routine upkeep and maintenance 2-28 R83 .............................................................3-54
NCU rack R84 .............................................................3-54
• Hardware......................................... 2-9 R85 .............................................................3-54
• Interfaces ...................................... 2-12 R86 .............................................................3-54
NCU Terminal block................................... 2-32 R87 .............................................................3-54
• Interfaces ...................................... 2-33 Recording telegrams ..................................4-39
Network technology Remote diagnostics
• Cable types / Connections ............ 4-14 • Establishing a connection ...............4-4
• Primary setup at the machine control4-
5
• Software ..........................................4-4
Restoring a data backup ............................6-14
O
ODBC-Administrator .................................. 1-35
ODBC-interface.......................................... 1-35
Opening the ODBC-Administrator ............. 1-38 S
Operating panel
• Hardware components.................... 1-4 S7-300 power rating ...................................2-59
Operation elements Scandisk.....................................................1-20
• NCU .............................................. 2-19 Scrubbing the NCK.......................................6-6
H274E8.DOC Index
Scrubbing the PLC....................................... 6-7 T
Server......................................................... 1-25
Setting data.............................................. 5-133 Technical data
Sharing directories ..................................... 4-32 • DMP Compact Module 1E Analog
SIMATIC (Slow).............................................2-36
• Module replacement ..................... 2-56 Technical Data
Software selection sheet............................ 6-17 • Bitbus module................................2-44
Software update MMC ............................... 6-18 • DMP compact module 1A Analog .2-40
Software update NC................................... 6-21 • DMP Compact Module 1E NC-Analog
Status graphs............................................. 3-10 (rapid) ............................................2-38
Subsequent NC Start-Up ............................. 6-6 TELE.COM-File ..........................................4-43
Switching module IM 361........................... 2-50 Telegram Diagnostics
• R parameters.................................4-41
TYPE.H-File ...............................................3-18
Index H274E8.DOC

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Service Manual

TRUMPF GmbH + Co. KG

This document was compiled by the Technical Documentation Dept. of TRUMPF

All rights, in particular the right to reproduce, distribute or translate this

 TRUMPF GmbH + Co. KG

TRUMPF GmbH + Co. KG assumes no responsibility for possible errors in this

The controlled is employed in the following machines:

Contents Chapter 1: Operating panel

Supplementary The machine documentation also includes the following:

Manuals for programming systems and documentation for use in

Online-Help The documents in paper form are supplemented by Online Help at

H274e0.doc Before you continue... 0-3

Chapter 1 Operating panel

1. Hardware components .................................................. 1-4

2. MMC Boot sequence.................................................... 1-18

3. TRUMPF operation environment ................................ 1-21

4. Databases ..................................................................... 1-29

5. ODBC interface............................................................. 1-35

0-4 Table of Contents H274e0.doc

7. Complete files............................................................... 1-50

8. Diagnostic possibilities ............................................... 1-54

2. NCU Rack........................................................................ 2-9

H274e0.doc Table of Contents 0-5

3. NCU Terminal block ..................................................... 2-32

3.4 Diagnostics for the Analog NCK Peripheral Devices2-40

4. Bitbus module .............................................................. 2-42

5. SIMATIC S7-300 PLC periphery module .................... 2-48

0-6 Table of Contents H274e0.doc

1. Interface Overview ......................................................... 3-4

2. Alarms ............................................................................. 3-6

3. PLC diagnostic possibilities ....................................... 3-10

H274e0.doc Table of Contents 0-7

4. Interface signals........................................................... 3-59

0-8 Table of Contents H274e0.doc

Chapter 4 Data Communication

1. Communication systems............................................... 4-3

2. MPI interface................................................................... 4-3

3. Modem connection ........................................................ 4-4

4. Network connection..................................................... 4-13

6. Bitbus ............................................................................ 4-37

H274e0.doc Table of Contents 0-9

Chapter 5 Configuration and Machine Data

1. Configuration data ......................................................... 5-3

2. Machine data .................................................................. 5-7

3. List of machine and setting data ................................ 5-45

0-10 Table of Contents H274e0.doc

Chapter 6 Setup / Update

1. Loading software for NCK and PLC ............................. 6-3

2. Subsequent NC Start-Up ............................................... 6-6

3. Data Backup ................................................................... 6-9

4. Software selection sheet ............................................. 6-17

5. Software update ........................................................... 6-18

H274e0.doc Table of Contents 0-11

6. Primary installation of MMC........................................ 6-30

Chapter 7 SIMODRIVE 611D Drives

1. Power Supply (NE) ......................................................... 7-3

2. Servo drive modules.................................................... 7-16

3. Three-phase servo motor ............................................ 7-29

4. Diagnostic aids............................................................. 7-31

0-12 Table of Contents H274e0.doc

5. Setup Tool..................................................................... 7-46

H274e0.doc Table of Contents 0-13

H274E1.DOC Operating panel 1-1