Siemens SINUMERIK 840D sl Parts list manual

SINUMERIK 840D sl Extended Functions
_
_____________
_
_____________
_
_____________
_
_____________
_
_____________
_
_____________
_
_____________
_
_____________
_
_____________
_
_____________
_
_____________
_
_____________
_
_____________
_
_____________
_
_____________
_
_____________
_
_____________
_
_____________
_
_____________
_
_____________
Preface
Digital and analog NCK I/Os
(A4)
1
Several Operator Panels on
Several NCUs, Distributed
Systems (B3)
2
Operation via PG/PC (B4)
3
Manual and Handwheel
Travel (H1)
4
Compensations (K3)
5
Mode Groups, Channels,
Axis Replacement (K5)
6
Kinematic Transformation
(M1)
7
Measurement (M5)
8
Software cams, position
switching signals (N3)
9
Punching and Nibbling (N4)
10
Positioning Axes (P2)
11
Oscillation (P5)
12
Rotary Axes (R2)
13
Synchronous Spindles (S3)
14
Memory Configuration (S7)
15
Indexing Axes (T1)
16
Tool Change (W3)
17
Grinding-specific tool offset
and tool monitoring (W4)
18
NC/PLC interface signals
(Z2)
19
Appendix
A
SINUMERIK 840D sl
Extended Functions
Function Manual
01/2008
6FC5397-1BP10-3BA0
Valid for
Controller
SINUMERIK 840D sl / 840DE sl
Software Version
NCU system software for 840D sl/840DE sl 1.5/2.5

Safety Guidelines
Safety Guidelines
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
with a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken.
CAUTION
without a safety alert symbol, indicates that property damage can result if proper precautions are not taken.
NOTICE
indicates that an unintended result or situation can occur if the corresponding information is not taken into
account.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.
Qualified Personnel
The device/system may only be set up and used in conjunction with this documentation. Commissioning and
operation of a device/system may only be performed by qualified personnel. Within the context of the safety notes
in this documentation qualified persons are defined as persons who are authorized to commission, ground and
label devices, systems and circuits in accordance with established safety practices and standards.
Prescribed Usage
Note the following:
WARNING
This device may only be used for the applications described in the catalog or the technical description and only
in connection with devices or components from other manufacturers which have been approved or
recommended by Siemens. Correct, reliable operation of the product requires proper transport, storage,
positioning and assembly as well as careful operation and maintenance.
Trademarks
All names identified by ® are registered trademarks of the Siemens AG. The remaining trademarks in this
publication may be trademarks whose use by third parties for their own purposes could violate the rights of the
owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software
described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
editions.
Siemens AG
Automation and Drives
Postfach 48 48
90327 NÜRNBERG
GERMANY
Order number: 6FC5397-1BP10-3BA0
Ⓟ 02/2008
Copyright © Siemens AG 2008.
Technical data subject to change

Extended Functions
Function Manual, 01/2008, 6FC5397-1BP10-3BA0 3
Preface
SINUMERIK® Documentation
The SINUMERIK documentation is organized in three parts:
● General documentation
● User documentation
● Manufacturer/service documentation
A monthly updated publications overview with respective available languages can be found
in the Internet under:
http://www.siemens.com/motioncontrol
Select the menu items "Support" → "Technical Documentation" → "Overview of Publications".
The Internet version of DOConCD (DOConWEB) is available under:
http://www.automation.siemens.com/doconweb
Information on the range of training courses and FAQs (frequently asked questions) are
available on the Internet under:
http://www.siemens.com/motioncontrol under menu item "Support".
Target group
This publication is intended for:
● Project engineers
● Technologists (from machine manufacturers)
● System startup engineers (Systems/Machines)
● Programmers
Benefits
The function manual describes the functions so that the target group knows them and can
select them. It provides the target group with the information required to implement the
functions.

Preface
Extended Functions
4 Function Manual, 01/2008, 6FC5397-1BP10-3BA0
Standard version
This documentation only describes the functionality of the standard version. Extensions or
changes made by the machine tool manufacturer are documented by the machine tool
manufacturer.
Other functions not described in this documentation might be executable in the control. This
does not, however, represent an obligation to supply such functions with a new control or
when servicing.
Further, for the sake of simplicity, this documentation does not contain all detailed
information about all types of the product and cannot cover every conceivable case of
installation, operation or maintenance.
Installation
Structure of this Function Manual:
● Inner title (page 3) with the title of the Function Manual, the SINUMERIK controls as well
as the software and the version for which this version of the Function Manual is
applicable and the overview of the individual functional descriptions.
● Description of the functions in alphabetical order (e.g. A2, A3, B1 etc.)
● Appendix with:
– List of abbreviations
– Fax template for feedback for documentation
– Overview
● Index of terms
Note
For detailed descriptions of data and alarm see:
•machine and setting data:
Detailed description of machine data (only electronically on DOConCD or
DOConWEB)
•NC/PLC interface signals:
Function Manual Basic Functions; NC/PLC Interface Signals (Z1)
Function Manual Basic Functions; NC/PLC Interface Signals (Z2)
Function Manual Special Functions; NC/PLC Interface Signals (Z3)
•alarms:
Diagnostics Manual

Preface
Extended Functions
Function Manual, 01/2008, 6FC5397-1BP10-3BA0 5
Notation of system data
The following notation is applicable for system data in this documentation:
Signal/Data Notation Example
NC/PLC interface
signals
... NC/PLC interface signal:
Signal data (signal name)
When the new gear step is engaged, the following NC/PLC
interface signals are set by the PLC program:
DB31, ... DBX16.0-2 (actual gear stage A to C)
DB31, ... DBX16.3 (gear is changed)
Machine data ... machine data:
<Type><Number> <Complete
Designator> (<Meaning>)
Master spindle is the spindle stored in the machine data:
MD20090 $MC_SPIND_DEF_MASTER_SPIND (Position of
deletion of the master spindle in the channel).
Setting Data ... setting data:
<Type><Number> <Complete
Designator> (<Meaning>)
The logical master spindle is contained in the setting data:
SD42800 $SC_SPIND_ASSIGN_TAB[0] (Spindle number
converter)
Data types
The following elementary data types are used in the control system:
Type Meaning Value range
INT Signed integers -2147483646 ... [phone]
REAL Figures with decimal point acc. to IEEE ±(2,2*10-308 … 1,8*10+308)
BOOL Boolean values: TRUE/FALSE TRUE ≠ 0; FALSE = 0
CHAR 1 ASCII character corresponding to the code 0 … 255
STRING Character string, number of characters in [...], maximum of
200 characters
Sequence of values with 0 ... 255
AXIS Axis identifier Axis identifier for all channel axes
FRAME Geometrical parameters for translation, rotation, scaling,
and mirroring
Arrays can only be formed from similar elementary data types. Up to 3-dimensional arrays are possible.
Quantity structure
Explanations concerning the NC/PLC interface are based on the absolute maximum number
of sequential components:
● Mode groups (DB11)
● Channels (DB21, etc.)
● Axes/spindles (DB31, etc.)

Preface
Extended Functions
6 Function Manual, 01/2008, 6FC5397-1BP10-3BA0
Technical Support
If you have any technical questions, please contact our hotline:
Europe / Africa
Phone [phone]
Fax [phone]
Internet http://www.siemens.com/automation/support-request
America
Phone [phone]
Fax [phone]
E-Mail mailto:[email protected]
Asia/Pacific
Phone [phone]
Fax [phone]
E-mail mailto:adsupport.a[email protected]
Note
Country specific telephone numbers for technical support are provided under the following
Internet address:
http://www.siemens.com/automation/service&support
Calls from the German fixed line network are charged (e.g. at 0.14 €/min). Charges of other
phone services may be different and may vary.
Questions about the manual
If you have any queries (suggestions, corrections) in relation to this documentation, please
send a fax or e-mail to the following address:
Fax: +49 9131 - 98 63315
Email: mailto:[email protected]m
A fax form is available in the appendix of this document.
SINUMERIK Internet address
http://www.siemens.com/sinumerik

Extended Functions
Function Manual, 01/2008, 6FC5397-1BP10-3BA0 7
Contents
Preface ...................................................................................................................................................... 3
1 Digital and analog NCK I/Os (A4) ............................................................................................................ 25
1.1 Brief Description...........................................................................................................................25
1.2 NCK I/O via PLC ..........................................................................................................................26
1.2.1 General functionality ....................................................................................................................26
1.2.2 NCK digital inputs/outputs............................................................................................................33
1.2.2.1 NCK digital inputs ........................................................................................................................33
1.2.2.2 NCK digital outputs ......................................................................................................................35
1.2.3 Connection and logic operations of fast NCK inputs/outputs ......................................................38
1.2.4 NCK analog inputs/outputs ..........................................................................................................40
1.2.4.1 NCK analog inputs .......................................................................................................................40
1.2.4.2 NCK analog outputs.....................................................................................................................43
1.2.5 Direct PLC I/Os, addressable from the NC..................................................................................46
1.2.6 Analog-value representation of the NCK analog input/output values..........................................49
1.2.7 Comparator inputs .......................................................................................................................51
1.3 NCK I/O via PROFIBUS...............................................................................................................54
1.3.1 Functionality.................................................................................................................................54
1.3.2 Parameter assignment.................................................................................................................55
1.3.3 Programming................................................................................................................................57
1.3.3.1 Communication via part programs/synchronous actions.............................................................57
1.3.3.2 Communication via compile cycles..............................................................................................59
1.4 Constraints...................................................................................................................................61
1.4.1 NCK I/O via PLC ..........................................................................................................................61
1.4.2 NCK I/O via PROFIBUS...............................................................................................................62
1.5 Examples .....................................................................................................................................63
1.5.1 NCK I/O via PLC ..........................................................................................................................63
1.5.1.1 Writing to PLC-I/Os ......................................................................................................................63
1.5.1.2 Reading from PLC-I/Os................................................................................................................64
1.5.2 NCK I/O via PROFIBUS...............................................................................................................65
1.5.2.1 PROFIBUS-I/O in write direction..................................................................................................65
1.5.2.2 PROFIBUS-I/O in read direction..................................................................................................67
1.5.2.3 Query of the RangeIndex in case of "PROFIBUS-I/O in write direction" .....................................68
1.6 Data lists ......................................................................................................................................70
1.6.1 Machine data................................................................................................................................70
1.6.1.1 General machine data..................................................................................................................70
1.6.1.2 Channel-specific machine data....................................................................................................71
1.6.2 Setting data..................................................................................................................................71
1.6.2.1 General setting data.....................................................................................................................71
1.6.3 Signals .........................................................................................................................................71
1.6.3.1 Signals to NC ...............................................................................................................................71
1.6.3.2 Signals from NC...........................................................................................................................72

Contents
Extended Functions
8 Function Manual, 01/2008, 6FC5397-1BP10-3BA0
2 Several Operator Panels on Several NCUs, Distributed Systems (B3).................................................... 73
2.1 Brief Description.......................................................................................................................... 73
2.1.1 Topology of distributed system configurations............................................................................73
2.1.2 Several operator panels and NCUs with control unit management (option)............................... 78
2.1.2.1 General information..................................................................................................................... 78
2.1.2.2 System Features ......................................................................................................................... 79
2.1.2.3 Hardware..................................................................................................................................... 80
2.1.2.4 Functions..................................................................................................................................... 82
2.1.2.5 Configurability ............................................................................................................................. 84
2.1.3 Several operator panel fronts and NCUs, standard functionality................................................ 84
2.1.3.1 System Features ......................................................................................................................... 84
2.1.3.2 Functions..................................................................................................................................... 85
2.1.3.3 Configurability ............................................................................................................................. 87
2.1.3.4 MPI/OPI network rules ................................................................................................................ 92
2.1.4 NCU link ...................................................................................................................................... 93
2.1.4.1 General information..................................................................................................................... 93
2.1.4.2 Types of distributed machines .................................................................................................... 94
2.1.4.3 Link axes ..................................................................................................................................... 96
2.1.4.4 Flexible configuration .................................................................................................................. 97
2.1.4.5 User communication across the NCUs ....................................................................................... 98
2.1.4.6 Lead link axes ............................................................................................................................. 99
2.1.4.7 NCU link with different interpolation cycles............................................................................... 100
2.2 Several operator panel fronts and NCUs with control unit management option....................... 102
2.2.1 Hardware structure.................................................................................................................... 102
2.2.2 Properties.................................................................................................................................. 102
2.2.3 Configuration file NETNAMES.INI ............................................................................................ 104
2.2.4 Structure of the configuration file .............................................................................................. 105
2.2.5 Creating and using the configuration file................................................................................... 109
2.2.6 Power up ................................................................................................................................... 110
2.2.7 HMI switchover.......................................................................................................................... 113
2.2.8 Suppression .............................................................................................................................. 113
2.2.9 Connection and switchover conditions...................................................................................... 115
2.2.10 Implementation of control unit switchover................................................................................. 116
2.2.11 Operator interface ..................................................................................................................... 116
2.2.12 Operating mode switchover ...................................................................................................... 117
2.2.13 MCP switchover ........................................................................................................................ 119
2.2.14 PLC program "Control Unit Switchover" ...................................................................................120
2.3 Several operator panel fronts and NCUs, standard functionality.............................................. 125
2.3.1 Configurations ........................................................................................................................... 125
2.3.2 Switchover of connection to another NCU................................................................................ 129
2.3.3 Creating and using the configuration file................................................................................... 130
2.3.4 Power up ................................................................................................................................... 130
2.3.5 NCU replacement...................................................................................................................... 131
2.4 Restrictions for switchover of operator components................................................................. 133
2.5 NCU link .................................................................................................................................... 134
2.5.1 Introduction ............................................................................................................................... 134
2.5.2 Technological description.......................................................................................................... 135
2.6 Link axes ................................................................................................................................... 137
2.6.1 Configuration of link axes and container axes .......................................................................... 139
2.6.2 Axis data and signals ................................................................................................................ 143
2.6.3 Output of predefined auxiliary functions in the case of an NCU link......................................... 146
2.6.4 Supplementary conditions for link axes .................................................................................... 147

Contents
Extended Functions
Function Manual, 01/2008, 6FC5397-1BP10-3BA0 9
2.6.5 Programming with channel and machine axis identifiers...........................................................149
2.6.6 Flexible configuration .................................................................................................................149
2.7 Axis container.............................................................................................................................150
2.7.1 System variables for axis containers .........................................................................................156
2.7.2 Machining with axis container (schematic) ................................................................................158
2.7.3 Axis container behavior after Power ON....................................................................................159
2.7.4 Axis container response to mode switchover ............................................................................159
2.7.5 Axis container behavior in relation to ASUBs ............................................................................159
2.7.6 Axis container response to RESET ...........................................................................................159
2.7.7 Axis container response to block searches ...............................................................................159
2.7.8 Supplementary conditions for axis container rotations ..............................................................159
2.8 Cross-NCU user communication, link variables ........................................................................163
2.8.1 Link variables .............................................................................................................................163
2.8.2 System variables of the link memory .........................................................................................167
2.8.3 Link axis drive information .........................................................................................................168
2.9 Configuration of a link grouping .................................................................................................170
2.10 Communication in link grouping.................................................................................................173
2.11 Lead link axis .............................................................................................................................176
2.11.1 Programming a lead link axis.....................................................................................................180
2.12 NCU link with different interpolation cycles................................................................................181
2.12.1 Diagram of general solution.......................................................................................................183
2.12.2 Different position control cycles .................................................................................................186
2.12.3 Supplementary conditions..........................................................................................................188
2.12.4 Activating NCU links with different interpolation cycles .............................................................188
2.12.5 Different IPO cycles, behavior at power ON, RESET, etc. ........................................................188
2.12.6 System variable with different interpolation cycles ....................................................................189
2.13 Link grouping system of units ....................................................................................................190
2.14 Supplementary conditions..........................................................................................................191
2.14.1 Several operator panels and NCUs with control unit management option................................191
2.14.2 Several operator panel fronts and NCUs, standard functionality...............................................191
2.14.3 Link axes....................................................................................................................................192
2.14.4 Axis container.............................................................................................................................192
2.14.5 Lead link axis .............................................................................................................................192
2.14.6 NCU link with different interpolation cycles................................................................................193
2.15 Examples ...................................................................................................................................194
2.15.1 Configuration file NETNAMES.INI with control unit management option ..................................194
2.15.2 User-specific reconfiguring of PLC program control unit switchover.........................................197
2.15.2.1 Description of operational sequences (overview)......................................................................197
2.15.2.2 Description of operational sequences (details)..........................................................................198
2.15.2.3 Defined logical functions/defines ...............................................................................................206
2.15.2.4 Graphical representation of function sequences .......................................................................206
2.15.3 Configuration file NETNAMES.INI, standard functionality .........................................................214
2.15.3.1 Two operator panel fronts and one NCU ...................................................................................214
2.15.3.2 One operator panel front and three NCUs.................................................................................215
2.15.4 Quick M:N commissioning based on examples.........................................................................216
2.15.4.1 Example 1 ..................................................................................................................................216
2.15.4.2 Example 2 ..................................................................................................................................219
2.15.4.3 Example 3 ..................................................................................................................................225
2.15.4.4 Description of FB9 .....................................................................................................................229
2.15.4.5 Example of calling FB9 ..............................................................................................................232
2.15.4.6 Example of override switchover.................................................................................................233

Contents
Extended Functions
10 Function Manual, 01/2008, 6FC5397-1BP10-3BA0
2.15.4.7 Switchover between MCP and HT6 .......................................................................................... 234
2.15.4.8 General Information .................................................................................................................. 235
2.15.5 Link axis .................................................................................................................................... 237
2.15.6 Axis container coordination....................................................................................................... 238
2.15.6.1 Axis container rotation without a part program wait.................................................................. 238
2.15.6.2 Axis container rotation with an implicit part program wait......................................................... 239
2.15.6.3 Axis container rotation by one channel only (e.g. during power up)......................................... 239
2.15.7 Evaluating axis container system variables ..............................................................................239
2.15.7.1 Conditional branch .................................................................................................................... 239
2.15.7.2 Static synchronized action with $AN_AXCTSWA ..................................................................... 239
2.15.7.3 Wait for certain completion of axis container rotation ............................................................... 240
2.15.8 Configuration of a multi-spindle turning machine...................................................................... 241
2.15.9 Lead link axis ............................................................................................................................ 250
2.15.9.1 Configuration............................................................................................................................. 250
2.15.9.2 Programming............................................................................................................................. 252
2.15.10 NCU link with different interpolation cycles............................................................................... 253
2.15.10.1 Example of eccentric turning..................................................................................................... 253
2.16 Data lists.................................................................................................................................... 254
2.16.1 Machine data............................................................................................................................. 254
2.16.1.1 General machine data............................................................................................................... 254
2.16.1.2 Channel-specific machine data................................................................................................. 254
2.16.1.3 Axis/spindle-specific machine data ........................................................................................... 255
2.16.2 Setting data ............................................................................................................................... 255
2.16.2.1 General setting data.................................................................................................................. 255
2.16.2.2 Axis/spindle-specific setting data .............................................................................................. 255
2.16.3 Signals....................................................................................................................................... 255
2.16.3.1 Signals from NC ........................................................................................................................ 255
2.16.3.2 Signals from HMI/PLC............................................................................................................... 256
2.16.3.3 General online interface............................................................................................................ 256
2.16.3.4 Signals to axis/spindle............................................................................................................... 257
3 Operation via PG/PC (B4)...................................................................................................................... 259
3.1 Brief Description........................................................................................................................ 259
3.2 Software installation.................................................................................................................. 261
3.2.1 System requirements ................................................................................................................ 261
3.2.2 Installation ................................................................................................................................. 262
3.2.3 Supplementary software conditions.......................................................................................... 268
3.2.4 Start program ............................................................................................................................ 268
3.2.5 Close program........................................................................................................................... 269
3.3 Operation via PG/PC................................................................................................................. 270
3.3.1 General operation ..................................................................................................................... 270
3.3.2 Additional information................................................................................................................ 272
3.3.3 Operation of operator panel fronts ............................................................................................ 273
3.4 Simulation of part programs...................................................................................................... 273
3.5 Marginal conditions ................................................................................................................... 274
3.6 Data lists.................................................................................................................................... 274
4 Manual and Handwheel Travel (H1) ...................................................................................................... 275
4.1 Product brief.............................................................................................................................. 275
4.1.1 Overview ................................................................................................................................... 275
4.1.2 General characteristics of manual travel in JOG ...................................................................... 276
4.1.3 Control of manual-travel functions via PLC interface................................................................ 279