Siemens SINUMERIK Series Parts list manual

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Extended Functions
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SINUMERIK
SINUMERIK 840D sl / 828D
Extended Functions
Function Manual
Valid for
Controls
SINUMERIK 840D sl / 840DE sl
SINUMERIK 828D
Software version
CNC software 4.5 SP2
03/2013
6FC5397-1BP40-3BA1
Preface
A4: Digital and analog NCK
I/Os for SINUMERIK 840D sl
1
B3: Distributed systems
- 840D sl only
2
H1: Manual and handwheel
travel
3
K3: Compensations
4
K5: Mode groups, channels,
axis interchange
5
M1: Kinematic
transformation
6
M5: Measurement
7
N3: Software cams, position
switching cycles
- only 840D sl
8
N4: Own channel
- only 840D sl
9
P2: Positioning axes
10
P5: Oscillation - only 840D sl
11
R2: Rotary axes
12
S3: Synchronous spindle
13
S7: Memory configuration
14
T1: Indexing axes
15
W3: Tool change
16
W4: Grinding-specific tool
offset and tool monitoring
17
Z2: NC/PLC interface signals
18
Appendix
A

Siemens AG
Industry Sector
Postfach 48 48
90026 NÜRNBERG
GERMANY
Order number: 6FC5397-1BP40-3BA1
Ⓟ 05/2013 Technical data subject to change
Copyright © Siemens AG 1994 - 2013.
All rights reserved
Legal information
Warning notice system
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
indicates that minor personal injury can result if proper precautions are not taken.
NOTICE
indicates that property damage can result if proper precautions are not taken.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.
Qualified Personnel
The product/system described in this documentation may be operated only by personnel qualified for the specific
task in accordance with the relevant documentation, in particular its warning notices and safety instructions.
Qualified personnel are those who, based on their training and experience, are capable of identifying risks and
avoiding potential hazards when working with these products/systems.
Proper use of Siemens products
Note the following:
WARNING
Siemens products may only be used for the applications described in the catalog and in the relevant technical
documentation. If products and components from other manufacturers are used, these must be recommended
or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and
maintenance are required to ensure that the products operate safely and without any problems. The permissible
ambient conditions must be complied with. The information in the relevant documentation must be observed.
Trademarks
All names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this publication
may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software
described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
editions.

Extended Functions
Function Manual, 03/2013, 6FC5397-1BP40-3BA1 3
Preface
SINUMERIK documentation
The SINUMERIK documentation is organized in the following categories:
● General documentation
● User documentation
● Manufacturer/service documentation
Additional information
You can find information on the following topics at www.siemens.com/motioncontrol/docu:
● Ordering documentation/overview of documentation
● Additional links to download documents
● Using documentation online (find and search in manuals/information)
Please send any questions about the technical documentation (e.g. suggestions for
improvement, corrections) to the following address:
[e-mail]
My Documentation Manager (MDM)
Under the following link you will find information to individually compile OEM-specific
machine documentation based on the Siemens content:
www.siemens.com/mdm
Training
For information about the range of training courses, refer under:
● www.siemens.com/sitrain
SITRAIN - Siemens training for products, systems and solutions in automation technology
● www.siemens.com/sinutrain
SinuTrain - training software for SINUMERIK
FAQs
You can find Frequently Asked Questions in the Service&Support pages under Product
Support. http://support.automation.siemens.com

Preface
Extended Functions
4 Function Manual, 03/2013, 6FC5397-1BP40-3BA1
SINUMERIK
You can find information on SINUMERIK under the following link:
www.siemens.com/sinumerik
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.
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.
Technical Support
You will find telephone numbers for other countries for technical support in the Internet under
http://www.siemens.com/automation/service&support

Preface
Extended Functions
Function Manual, 03/2013, 6FC5397-1BP40-3BA1 5
Information on structure and contents
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
– Documentation overview
● Index of terms
Note
For detailed descriptions of data and alarms see:
•For machine and setting data:
Detailed description of machine data (only electronically on DOConCD or DOConWEB)
•For 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)
•For alarms:
Diagnostics Manual
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 address> (<signal name>)
When the new gear stage 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)

Preface
Extended Functions
6 Function Manual, 03/2013, 6FC5397-1BP40-3BA1
Note
Signal address
The description of functions include as <signal address> of an NC/PLC interface signal, only
the address valid for SINUMERIK 840D sl. The signal address for SINUMERIK 828D should
be taken from the data lists "Signals to/from ..." at the end of the particular description of
functions.
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.)
Data types
The control provides the following data types that can be used for programming in part
programs:
Type Meaning Range of values
INT Signed integers -2.147.483.648 ... +2.147.483.647
REAL Numbers with decimal point ≈ ±5,0*10-324 … ≈ ±1,7*10+308
BOOL Boolean values TRUE (≠0) , FALSE (0)
CHAR ASCII characters and bytes 0 ... 255 or -128 ... 127
STRING Character string, null-terminated Maximum of 400 characters + /0
(no special characters)
AXIS Axis names All axis names available in the control
system
FRAME Geometrical parameters for moving, rotating, scaling, and
mirroring
---
Note
Arrays can only be formed from similar elementary data types. Up to 3-dimensional arrays are possible.

Extended Functions
Function Manual, 03/2013, 6FC5397-1BP40-3BA1 7
Contents
Preface ...................................................................................................................................................... 3
1 A4: Digital and analog NCK I/Os for SINUMERIK 840D sl....................................................................... 25
1.1 Introduction ..................................................................................................................................25
1.2 Access via PLC............................................................................................................................27
1.2.1 Brief description ...........................................................................................................................27
1.2.2 Configuration of the NCK I/Os .....................................................................................................28
1.2.3 NCK digital inputs/outputs............................................................................................................31
1.2.3.1 NCK digital inputs ........................................................................................................................31
1.2.3.2 NCK digital outputs ......................................................................................................................32
1.2.3.3 Connection and logic operations of fast digital NCK I/Os............................................................35
1.2.4 NCK analog I/Os ..........................................................................................................................37
1.2.4.1 NCK analog inputs .......................................................................................................................37
1.2.4.2 NCK analog outputs.....................................................................................................................39
1.2.4.3 Representation of the NCK analog input/output values...............................................................43
1.2.5 Comparator inputs .......................................................................................................................45
1.2.6 Direct PLC I/Os, addressable from the NC..................................................................................48
1.2.6.1 Function .......................................................................................................................................48
1.2.6.2 Supplementary conditions............................................................................................................51
1.2.6.3 Examples .....................................................................................................................................52
1.3 Access via PROFIBUS ................................................................................................................54
1.3.1 Brief description ...........................................................................................................................54
1.3.2 Configuration of the I/O ranges....................................................................................................56
1.3.3 Data exchange.............................................................................................................................58
1.3.3.1 Communication via part programs/synchronous actions.............................................................58
1.3.3.2 Communication via compile cycles..............................................................................................61
1.3.4 Supplementary conditions............................................................................................................62
1.3.5 Examples .....................................................................................................................................63
1.3.5.1 PROFIBUS-I/O in write direction..................................................................................................63
1.3.5.2 PROFIBUS-I/O in read direction..................................................................................................65
1.3.5.3 Query of the RangeIndex in case of "PROFIBUS-I/O in write direction".....................................66
1.4 Data lists ......................................................................................................................................68
1.4.1 Machine data................................................................................................................................68
1.4.1.1 General machine data..................................................................................................................68
1.4.1.2 Channelspecific machine data.....................................................................................................69
1.4.2 Setting data..................................................................................................................................69
1.4.2.1 General setting data.....................................................................................................................69
1.4.3 Signals .........................................................................................................................................69
1.4.3.1 Signals to NC ...............................................................................................................................69
1.4.3.2 Signals from NC...........................................................................................................................70

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8 Function Manual, 03/2013, 6FC5397-1BP40-3BA1
2 B3: Distributed systems - 840D sl only .................................................................................................... 71
2.1 Brief description .......................................................................................................................... 71
2.1.1 Several operator panels on several NCUs (T:M:N) .................................................................... 71
2.1.2 NCU link ...................................................................................................................................... 74
2.1.2.1 Link communication .................................................................................................................... 74
2.1.2.2 Link variables .............................................................................................................................. 75
2.1.2.3 Link axes ..................................................................................................................................... 75
2.1.2.4 Lead link axes ............................................................................................................................. 76
2.1.2.5 Dependencies ............................................................................................................................. 76
2.1.2.6 Application example: Rotary indexing machine .......................................................................... 77
2.2 NCU link ...................................................................................................................................... 79
2.2.1 Link communication .................................................................................................................... 79
2.2.1.1 General information..................................................................................................................... 79
2.2.1.2 Link module................................................................................................................................. 83
2.2.1.3 Parameter assignment: NC system cycles .................................................................................83
2.2.1.4 Parameter assignment: Link communication.............................................................................. 85
2.2.1.5 Configuration............................................................................................................................... 85
2.2.1.6 Wiring the NCUs ......................................................................................................................... 86
2.2.1.7 Activation..................................................................................................................................... 86
2.2.2 Link variables .............................................................................................................................. 87
2.2.2.1 Properties of the link variables memory...................................................................................... 88
2.2.2.2 Properties of the link variables.................................................................................................... 88
2.2.2.3 Write elements ............................................................................................................................ 89
2.2.2.4 Dynamic response during write................................................................................................... 90
2.2.2.5 System variable........................................................................................................................... 90
2.2.2.6 Synchronization of a write request.............................................................................................. 91
2.2.2.7 Example: Structure of the link variables memory ....................................................................... 91
2.2.2.8 Example: Read drive data........................................................................................................... 93
2.2.3 Link axes ..................................................................................................................................... 94
2.2.3.1 General information..................................................................................................................... 94
2.2.3.2 Name of a link axis...................................................................................................................... 96
2.2.3.3 Parameterization ......................................................................................................................... 96
2.2.3.4 Auxiliary function output for spindles .......................................................................................... 97
2.2.3.5 Supplementary conditions........................................................................................................... 98
2.2.4 Axis container............................................................................................................................ 100
2.2.4.1 General information................................................................................................................... 100
2.2.4.2 Parameterization ....................................................................................................................... 103
2.2.4.3 Programming............................................................................................................................. 110
2.2.4.4 System variable......................................................................................................................... 111
2.2.4.5 Machining with axis container (schematic) ............................................................................... 112
2.2.4.6 Behavior in different operating states ....................................................................................... 113
2.2.4.7 Behavior when withdrawing the release for axis container rotation.......................................... 113
2.2.4.8 Supplementary conditions......................................................................................................... 115
2.2.5 Lead link axes ........................................................................................................................... 118
2.2.5.1 General information................................................................................................................... 118
2.2.5.2 Parameterization ....................................................................................................................... 119
2.2.5.3 System variables to enter a leading value ................................................................................ 120
2.2.5.4 Supplementary conditions......................................................................................................... 121
2.2.5.5 Example .................................................................................................................................... 121
2.2.6 System of units within a link group............................................................................................ 121

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Function Manual, 03/2013, 6FC5397-1BP40-3BA1 9
2.3 Examples ...................................................................................................................................122
2.3.1 Link axis .....................................................................................................................................122
2.3.2 Axis container coordination........................................................................................................123
2.3.2.1 Axis container rotation without a part program wait...................................................................123
2.3.2.2 Axis container rotation with an implicit part program wait..........................................................124
2.3.2.3 Axis container rotation by one channel only (e.g. during power up)..........................................124
2.3.3 Evaluating axis container system variables ...............................................................................124
2.3.3.1 Conditional branch .....................................................................................................................124
2.3.3.2 Static synchronized action with $AN_AXCTSWA......................................................................124
2.3.3.3 Wait for certain completion of axis container rotation................................................................125
2.3.4 Configuration of a multi-spindle turning machine.......................................................................126
2.3.5 Lead link axis .............................................................................................................................135
2.3.5.1 Configuration..............................................................................................................................135
2.3.5.2 Programming..............................................................................................................................137
2.4 Data lists ....................................................................................................................................138
2.4.1 Machine data..............................................................................................................................138
2.4.1.1 General machine data................................................................................................................138
2.4.1.2 Channelspecific machine data...................................................................................................138
2.4.1.3 Axis/spindlespecific machine data .............................................................................................139
2.4.2 Setting data................................................................................................................................139
2.4.2.1 General setting data...................................................................................................................139
2.4.2.2 Axis/spindle-specific setting data...............................................................................................139
2.4.3 Signals .......................................................................................................................................139
2.4.3.1 Signals from NC.........................................................................................................................139
2.4.3.2 Signals from HMI/PLC ...............................................................................................................140
2.4.3.3 General online interface.............................................................................................................140
2.4.3.4 Signals from axis/spindle ...........................................................................................................142
2.4.4 System variables........................................................................................................................142
3 H1: Manual and handwheel travel ......................................................................................................... 143
3.1 Introduction ................................................................................................................................143
3.1.1 Overview ....................................................................................................................................143
3.1.2 General characteristics when traversing in the JOG mode .......................................................144
3.1.3 Control of manual-travel functions via PLC interface.................................................................147
3.2 Continuous (JOG CONT)...........................................................................................................148
3.2.1 General functionality ..................................................................................................................148
3.2.2 Distinction between inching mode continuous mode.................................................................149
3.2.3 Supplementary conditions..........................................................................................................150
3.3 Incremental (JOG INC) ..............................................................................................................151
3.3.1 General functionality ..................................................................................................................151
3.3.2 Distinction between jogging mode and continuous mode .........................................................152
3.3.3 Supplementary conditions..........................................................................................................153
3.4 Handwheel travel in JOG...........................................................................................................154
3.4.1 Function .....................................................................................................................................154
3.4.2 Parameter assignment...............................................................................................................161
3.4.3 Travel request ............................................................................................................................166
3.4.4 Double use of the handwheel ....................................................................................................169

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10 Function Manual, 03/2013, 6FC5397-1BP40-3BA1
3.5 Handwheel override in automatic mode.................................................................................... 170
3.5.1 General functionality ................................................................................................................. 170
3.5.2 Programming and activating handwheel override..................................................................... 175
3.5.3 Special features of handwheel override in automatic mode ..................................................... 177
3.6 Contour handwheel/path input using handwheel (option)......................................................... 178
3.7 DRF offset ................................................................................................................................. 180
3.8 Approaching a fixed point in JOG ............................................................................................. 183
3.8.1 Introduction ............................................................................................................................... 183
3.8.2 Functionality .............................................................................................................................. 184
3.8.3 Parameterization ....................................................................................................................... 186
3.8.4 Programming............................................................................................................................. 188
3.8.5 Supplementary Conditions........................................................................................................ 188
3.8.6 Application example .................................................................................................................. 189
3.9 Retraction in the tool direction (JOG retract) ............................................................................ 190
3.9.1 Overview ................................................................................................................................... 190
3.9.2 Parameter assignment.............................................................................................................. 191
3.9.3 Selection.................................................................................................................................... 193
3.9.4 Tool retraction ........................................................................................................................... 195
3.9.5 Deselection ............................................................................................................................... 196
3.9.6 Repeated selection ................................................................................................................... 196
3.9.7 Continuing machining................................................................................................................ 197
3.9.8 State diagram............................................................................................................................ 198
3.9.9 System data .............................................................................................................................. 198
3.9.10 Supplementary conditions......................................................................................................... 199
3.10 Start-up: Handwheels................................................................................................................ 200
3.10.1 General information................................................................................................................... 200
3.10.2 Connection via PPU (only 828D) .............................................................................................. 201
3.10.3 Connection via PROFIBUS (828D)........................................................................................... 202
3.10.4 Connection via PROFIBUS (840D sl) .......................................................................................203
3.10.5 Connected via Ethernet (only 840D sl) ..................................................................................... 206
3.11 Special features relating to manual and handwheel travel ....................................................... 209
3.11.1 Manual travel of geometry/orientation axes..............................................................................209
3.11.2 Spindle manual travel................................................................................................................ 211
3.11.3 Monitoring functions .................................................................................................................. 213
3.11.4 Other ......................................................................................................................................... 214
3.12 Data lists.................................................................................................................................... 215
3.12.1 Machine data............................................................................................................................. 215
3.12.1.1 General machine data............................................................................................................... 215
3.12.1.2 Channel-specific machine data................................................................................................. 216
3.12.1.3 Axis/spindlespecific machine data ............................................................................................ 216
3.12.2 Setting data ............................................................................................................................... 217
3.12.2.1 General setting data.................................................................................................................. 217
3.12.3 Signals....................................................................................................................................... 218
3.12.3.1 Signals from NC ........................................................................................................................ 218
3.12.3.2 Signals to mode group .............................................................................................................. 218
3.12.3.3 Signals from mode group.......................................................................................................... 218
3.12.3.4 Signals to channel..................................................................................................................... 219
3.12.3.5 Signals from channel................................................................................................................. 220

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3.12.3.6 Signals to axis/spindle ...............................................................................................................221
3.12.3.7 Signals from axis/spindle ...........................................................................................................221
3.12.4 System variable..........................................................................................................................222
3.12.4.1 System variable..........................................................................................................................222
3.12.5 OPI variable ...............................................................................................................................222
3.12.5.1 OPI variable ...............................................................................................................................222
4 K3: Compensations ............................................................................................................................... 223
4.1 Introduction ................................................................................................................................223
4.2 Temperature compensation .......................................................................................................224
4.2.1 Description of functions..............................................................................................................224
4.2.2 Commissioning...........................................................................................................................227
4.2.3 Example .....................................................................................................................................229
4.2.3.1 Commissioning the temperature compensation for the Z axis of a lathe ..................................229
4.3 Backlash compensation .............................................................................................................231
4.3.1 Mechanical backlash compensation ..........................................................................................231
4.3.1.1 Description of functions..............................................................................................................231
4.3.1.2 Commissioning...........................................................................................................................233
4.3.2 Dynamic backlash compensation ..............................................................................................234
4.3.2.1 Description of functions..............................................................................................................234
4.3.2.2 Commissioning...........................................................................................................................235
4.4 Interpolatory compensation........................................................................................................235
4.4.1 General properties .....................................................................................................................235
4.4.2 Compensation of leadscrew errors and measuring system errors ............................................238
4.4.2.1 Measuring system error compensation (MSEC)........................................................................238
4.4.2.2 Commissioning...........................................................................................................................239
4.4.2.3 Example .....................................................................................................................................242
4.4.3 Compensation of sag and angularity errors...............................................................................243
4.4.3.1 Description of functions..............................................................................................................243
4.4.3.2 Commissioning...........................................................................................................................247
4.4.3.3 Examples ...................................................................................................................................251
4.4.4 Direction-dependent leadscrew error compensation .................................................................259
4.4.4.1 Description of functions..............................................................................................................259
4.4.4.2 Commissioning...........................................................................................................................260
4.4.4.3 Example .....................................................................................................................................264
4.4.5 Extension of the sag compensation with NCU link - only 840D sl.............................................267
4.4.6 Special features of interpolatory compensation.........................................................................277
4.5 Dynamic feedforward control (following error compensation) ...................................................278
4.5.1 General properties .....................................................................................................................278
4.5.2 Speed feedforward control.........................................................................................................280
4.5.3 Torque feedforward control........................................................................................................282
4.5.4 Dynamic response adaptation ...................................................................................................283
4.5.5 Forward feed control for command- and PLC axes...................................................................284
4.5.6 Secondary conditions.................................................................................................................286
4.6 Friction compensation (quadrant error compensation)..............................................................287
4.6.1 General function description ......................................................................................................287
4.6.2 Supplementary conditions..........................................................................................................288
4.6.3 Friction compensation with a constant compensation value .....................................................288
4.6.3.1 Function activation .....................................................................................................................288
4.6.3.2 commissioning ...........................................................................................................................289

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4.6.4 Friction compensation with acceleration-dependent compensation value ............................... 294
4.6.4.1 Description of functions............................................................................................................. 294
4.6.4.2 Function activation .................................................................................................................... 295
4.6.4.3 commissioning .......................................................................................................................... 295
4.6.5 Compensation value for short traversing blocks....................................................................... 296
4.7 Measures for hanging (suspended axes).................................................................................. 297
4.7.1 Electronic counterweight........................................................................................................... 297
4.7.2 Reboot delay ............................................................................................................................. 299
4.8 Data lists.................................................................................................................................... 301
4.8.1 Machine data............................................................................................................................. 301
4.8.1.1 General machine data............................................................................................................... 301
4.8.1.2 Channelspecific machine data .................................................................................................. 301
4.8.1.3 Axis/spindlespecific machine data ............................................................................................ 301
4.8.2 Setting data ............................................................................................................................... 302
4.8.2.1 General setting data.................................................................................................................. 302
4.8.2.2 Axis/spindle-specific setting data .............................................................................................. 303
4.8.3 Signals....................................................................................................................................... 303
4.8.3.1 Signals from NC ........................................................................................................................ 303
4.8.3.2 Signals from mode group.......................................................................................................... 303
4.8.3.3 Signals from channel................................................................................................................. 303
4.8.3.4 Signals to axis/spindle............................................................................................................... 303
4.8.3.5 Signals from axis/spindle .......................................................................................................... 304
5 K5: Mode groups, channels, axis interchange ....................................................................................... 305
5.1 Brief description ........................................................................................................................ 305
5.2 Mode groups - only 840D sl ...................................................................................................... 306
5.3 Channels - only 840D sl............................................................................................................ 307
5.3.1 Channel synchronization (program coordination) ..................................................................... 308
5.3.2 Channel synchronization: Conditional wait in path controlled operation .................................. 311
5.3.3 Running-in channel-by-channel ................................................................................................ 315
5.4 Axis/spindle replacement .......................................................................................................... 320
5.4.1 Introduction ............................................................................................................................... 320
5.4.2 Example of an axis replacement............................................................................................... 322
5.4.3 Axis replacement options.......................................................................................................... 323
5.4.4 Replacement behavior NC program ......................................................................................... 324
5.4.5 Transition the axis into the neutral state (RELEASE)............................................................... 325
5.4.6 Transferring an axis or spindle into the part program (GET, GETD) ........................................ 326
5.4.7 Automatic axis replacement...................................................................................................... 327
5.4.8 Axis replacement via PLC ......................................................................................................... 329
5.4.9 Set axis replacement behavior variable.................................................................................... 332
5.4.10 Axis interchange via axis container rotation.............................................................................. 333
5.4.11 Axis replacement with and without preprocessing stop ............................................................ 333
5.4.12 Axis exclusively controlled from the PLC.................................................................................. 335
5.4.13 Axis permanently assigned to the PLC..................................................................................... 336
5.4.14 Geometry axis in rotated frame and axis replacement ............................................................. 337
5.4.15 Axis replacement from synchronized actions............................................................................ 338
5.4.16 Axis interchange for leading axes (gantry)................................................................................ 341
5.5 Marginal conditions ................................................................................................................... 341

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5.6 Data lists ....................................................................................................................................343
5.6.1 Machine data..............................................................................................................................343
5.6.1.1 General machine data................................................................................................................343
5.6.1.2 Channel-specific machine data..................................................................................................343
5.6.1.3 Axis/spindlespecific machine data .............................................................................................345
5.6.2 Setting data................................................................................................................................346
5.6.2.1 Channelspecific setting data......................................................................................................346
5.6.3 Signals .......................................................................................................................................346
5.6.3.1 Signals to/from BAG ..................................................................................................................346
5.6.3.2 Signals to/from Channel.............................................................................................................346
6 M1: Kinematic transformation ................................................................................................................ 347
6.1 Brief description .........................................................................................................................347
6.1.1 TRANSMIT (option) ...................................................................................................................347
6.1.2 TRACYL (option)........................................................................................................................348
6.1.3 TRAANG (option).......................................................................................................................349
6.1.4 Chained transformations............................................................................................................349
6.1.5 Activating transformation machine data via parts program/softkey...........................................350
6.2 TRANSMIT face end transformation (option) ............................................................................350
6.2.1 Specific settings .........................................................................................................................351
6.2.2 Switch on....................................................................................................................................354
6.2.3 Deactivation ...............................................................................................................................354
6.2.4 Applications................................................................................................................................355
6.2.5 Working area limitations.............................................................................................................361
6.2.6 Overlaid motions with TRANSMIT .............................................................................................362
6.2.7 Monitoring of rotary axis rotations over 360º .............................................................................362
6.2.8 Constraints.................................................................................................................................362
6.2.9 Example: Axis configuration.......................................................................................................363
6.3 TRACYL cylinder surface transformation (option) .....................................................................366
6.3.1 Preconditions .............................................................................................................................368
6.3.2 Specific settings .........................................................................................................................371
6.3.3 Switch on....................................................................................................................................375
6.3.4 Deactivation ...............................................................................................................................376
6.3.5 Boundary conditions ..................................................................................................................376
6.4 TRAANG oblique angle transformation (option) ........................................................................378
6.4.1 Preconditions .............................................................................................................................379
6.4.2 Specific settings .........................................................................................................................381
6.4.3 Switch on....................................................................................................................................383
6.4.4 Deactivation ...............................................................................................................................383
6.4.5 Boundary conditions ..................................................................................................................384
6.4.6 Programming (G05, G07) ..........................................................................................................385
6.5 Chained transformations............................................................................................................387
6.5.1 Activating chained transformations............................................................................................389
6.5.2 Switching off a chained transformation......................................................................................389
6.5.3 Special characteristics of chained transformations....................................................................389
6.5.4 Persistent transformation ...........................................................................................................390
6.5.5 Axis positions in the transformation chain .................................................................................395
6.6 Cartesian PTP travel..................................................................................................................398
6.6.1 Programming of position ............................................................................................................401
6.6.2 Overlap areas of axis angles .....................................................................................................402

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6.6.3 Examples of ambiguities of position.......................................................................................... 403
6.6.4 Example of ambiguity in rotary axis position.............................................................................404
6.6.5 PTP/CP switchover in JOG mode............................................................................................. 404
6.7 Cartesian manual travel (optional) ............................................................................................ 405
6.8 Activating transformation machine data via part program/softkey............................................ 412
6.8.1 Functionality .............................................................................................................................. 412
6.8.2 Constraints ................................................................................................................................ 413
6.8.3 Control response to power ON, mode change, RESET, block search, REPOS ...................... 415
6.8.4 List of machine data affected .................................................................................................... 415
6.9 Constraints ................................................................................................................................ 418
6.9.1 Chained transformations........................................................................................................... 418
6.10 Examples................................................................................................................................... 419
6.10.1 TRANSMIT................................................................................................................................ 419
6.10.2 TRACYL .................................................................................................................................... 420
6.10.3 TRAANG ................................................................................................................................... 426
6.10.4 Chained transformations........................................................................................................... 427
6.10.5 Activating transformation MD via a part program...................................................................... 431
6.10.6 Axis positions in the transformation chain................................................................................. 432
6.11 Data lists.................................................................................................................................... 435
6.11.1 Machine data............................................................................................................................. 435
6.11.1.1 TRANSMIT................................................................................................................................ 435
6.11.1.2 TRACYL .................................................................................................................................... 436
6.11.1.3 TRAANG ................................................................................................................................... 438
6.11.1.4 Chained transformations........................................................................................................... 439
6.11.1.5 Non transformation-specific machine data................................................................................ 439
6.11.2 Signals....................................................................................................................................... 439
6.11.2.1 Signals from channel................................................................................................................. 439
7 M5: Measurement.................................................................................................................................. 441
7.1 Brief description ........................................................................................................................ 441
7.2 Hardware requirements............................................................................................................. 442
7.2.1 Probes that can be used ........................................................................................................... 442
7.3 Channel-specific measuring...................................................................................................... 444
7.3.1 Measurement ............................................................................................................................ 444
7.3.2 Measurement results................................................................................................................. 445
7.4 Axial measurement ................................................................................................................... 446
7.4.1 Measurement ............................................................................................................................ 446
7.4.2 Telegram selection.................................................................................................................... 449
7.4.3 Measurement results................................................................................................................. 449
7.5 Setting zeros, workpiece measuring and tool measuring ......................................................... 451
7.5.1 Preset actual value memory and scratching............................................................................. 451
7.5.2 Workpiece measuring ............................................................................................................... 452
7.5.2.1 Input values............................................................................................................................... 452
7.5.2.2 Measurement selection............................................................................................................. 459
7.5.2.3 Output values ............................................................................................................................ 460
7.5.2.4 Calculation method ................................................................................................................... 461
7.5.2.5 Units of measurement and measurement variables for the calculation.................................... 464
7.5.2.6 Diagnostics................................................................................................................................ 465

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7.5.3 Types of workpiece measurement.............................................................................................466
7.5.3.1 Measurement of an edge (measurement type 1, 2, 3) ..............................................................466
7.5.3.2 Measurement of an angle (measurement type 4, 5, 6, 7)..........................................................470
7.5.3.3 Measurement of a hole (measurement type 8)..........................................................................473
7.5.3.4 Measurement of a shaft (measurement type 9).........................................................................476
7.5.3.5 Measurement of a groove (measurement type 12)....................................................................477
7.5.3.6 Measurement of a web (measurement type 13)........................................................................480
7.5.3.7 Measurement of geo axes and special axes (measurement type 14, 15).................................481
7.5.3.8 Measurement of an oblique edge (measurement type 16)........................................................483
7.5.3.9 Measurement of an oblique angle in a plane (measurement type 17) ......................................485
7.5.3.10 Redefine measurement around a WCS reference frame (measurement type 18)....................488
7.5.3.11 Measurement of a 1-, 2- and 3-dimensional setpoint selection (measurement type 19, 20,
21) ..............................................................................................................................................492
7.5.3.12 Measuring a measuring point in any coordinate system (measurement type 24).....................496
7.5.3.13 Measurement of a rectangle (measurement type 25)................................................................500
7.5.3.14 Measurement for saving data management frames (measurement type 26)............................501
7.5.3.15 Measurement for restoring backed-up data management frames (measurement type 27) ......502
7.5.3.16 Measurement for defining an additive rotation for taper turning (measurement type 28)..........503
7.5.4 Tool measuring ..........................................................................................................................504
7.5.5 Types of workpiece measurement.............................................................................................505
7.5.5.1 Measurement of tool lengths (measurement type 10) ...............................................................505
7.5.5.2 Measurement of tool diameter (measurement type 11).............................................................507
7.5.5.3 Measurement of tool lengths with zoom-in function (measurement type 22) ............................508
7.5.5.4 Measuring a tool length with stored or current position (measurement type 23).......................509
7.5.5.5 Measurement of a tool length of two tools with the following orientation: .................................511
7.6 Measurement accuracy and functional testing ..........................................................................523
7.6.1 Measurement accuracy..............................................................................................................523
7.6.2 Probe function test .....................................................................................................................524
7.7 Simulated measuring .................................................................................................................525
7.7.1 General functionality ..................................................................................................................525
7.7.2 Position-related switch request..................................................................................................525
7.7.3 External switch request..............................................................................................................527
7.7.4 System variable..........................................................................................................................528
7.8 Channels - only 840D sl.............................................................................................................528
7.8.1 Measuring mode 1 .....................................................................................................................528
7.8.2 Measuring mode 2 .....................................................................................................................529
7.8.3 Continuous measurement..........................................................................................................529
7.8.4 Functional test and repeat accuracy..........................................................................................531
7.9 Data lists ....................................................................................................................................532
7.9.1 Machine data..............................................................................................................................532
7.9.1.1 General machine data................................................................................................................532
7.9.1.2 Channel-specific machine data..................................................................................................533
7.9.2 System variables........................................................................................................................533
8 N3: Software cams, position switching cycles - only 840D sl................................................................. 535
8.1 Brief Description.........................................................................................................................535
8.2 Cam signals and cam positions .................................................................................................536
8.2.1 Generation of cam signals for separate output..........................................................................536
8.2.2 Generation of cam signals with gated output.............................................................................539

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8.2.3 Cam positions ........................................................................................................................... 543
8.2.4 Lead/delay times (dynamic cam) .............................................................................................. 545
8.3 Output of cam signals ............................................................................................................... 546
8.3.1 Activating................................................................................................................................... 546
8.3.2 Output of cam signals to PLC ................................................................................................... 547
8.3.3 Output of cam signals to NCK I/Os in position control cycle..................................................... 547
8.3.4 Timer-controlled cam signal output........................................................................................... 549
8.3.5 Independent, timer-controlled output of cam signals................................................................ 550
8.4 Position-time cams.................................................................................................................... 551
8.5 Supplementary Conditions........................................................................................................ 553
8.6 Data lists.................................................................................................................................... 553
8.6.1 Machine data............................................................................................................................. 553
8.6.1.1 General machine data............................................................................................................... 553
8.6.2 Setting data ............................................................................................................................... 554
8.6.2.1 General setting data.................................................................................................................. 554
8.6.3 Signals....................................................................................................................................... 554
8.6.3.1 Signals to axis/spindle............................................................................................................... 554
8.6.3.2 Signals from axis/spindle .......................................................................................................... 554
9 N4: Own channel - only 840D sl ............................................................................................................ 555
9.1 Brief Description........................................................................................................................ 555
9.2 Stroke control ............................................................................................................................ 555
9.2.1 General information................................................................................................................... 555
9.2.2 High-speed signals.................................................................................................................... 556
9.2.3 Criteria for stroke initiation ........................................................................................................ 558
9.2.4 Axis start after punching............................................................................................................ 560
9.2.5 PLC signals specific to punching and nibbling.......................................................................... 561
9.2.6 Punching and nibbling-specific reactions to standard PLC signals .......................................... 561
9.2.7 Signal monitoring ...................................................................................................................... 562
9.3 Activation and deactivation ....................................................................................................... 562
9.3.1 Language commands................................................................................................................ 562
9.3.2 Functional expansions .............................................................................................................. 567
9.3.3 Compatibility with earlier systems............................................................................................. 571
9.4 Automatic path segmentation.................................................................................................... 573
9.4.1 General information................................................................................................................... 573
9.4.2 Operating characteristics with path axes .................................................................................. 575
9.4.3 Response in connection with single axes ................................................................................. 579
9.5 Rotatable tool ............................................................................................................................ 584
9.5.1 General information................................................................................................................... 584
9.5.2 Coupled motion of punch and die ............................................................................................. 585
9.5.3 Tangential control...................................................................................................................... 586
9.6 Protection zones ....................................................................................................................... 590
9.7 Supplementary conditions......................................................................................................... 590
9.8 Examples................................................................................................................................... 591
9.8.1 Examples of defined start of nibbling operation........................................................................ 591

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9.9 Data lists ....................................................................................................................................596
9.9.1 Machine data..............................................................................................................................596
9.9.1.1 General machine data................................................................................................................596
9.9.1.2 Channelspecific machine data...................................................................................................596
9.9.2 Setting data................................................................................................................................596
9.9.2.1 Channelspecific setting data......................................................................................................596
9.9.3 Signals .......................................................................................................................................597
9.9.3.1 Signals to channel......................................................................................................................597
9.9.3.2 Signals from channel .................................................................................................................597
9.9.4 Language commands ................................................................................................................597
10 P2: Positioning axes .............................................................................................................................. 599
10.1 Product brief...............................................................................................................................599
10.2 Own channel, positioning axis or concurrent positioning axis ...................................................601
10.2.1 Own channel - only 840D sl.......................................................................................................602
10.2.2 Positioning axis ..........................................................................................................................602
10.2.3 Concurrent positioning axis........................................................................................................605
10.3 Motion behavior and interpolation functions ..............................................................................606
10.3.1 Path interpolator and axis interpolator .......................................................................................606
10.3.2 Interpolation response of path axis in G0 ..................................................................................606
10.3.3 Autonomous singleaxis operations ............................................................................................608
10.3.4 Autonomous single-axis functions with NC-controlled ESR ......................................................613
10.4 Positioning axis dynamic response............................................................................................615
10.5 Programming..............................................................................................................................617
10.5.1 General ......................................................................................................................................617
10.5.2 Revolutional feed rate in external programming........................................................................620
10.6 Block change..............................................................................................................................621
10.6.1 Settable block change time........................................................................................................623
10.6.2 End of motion criterion with block search ..................................................................................628
10.7 Control by the PLC.....................................................................................................................629
10.7.1 Starting concurrent positioning axes from the PLC ...................................................................631
10.7.2 PLC-controlled axes...................................................................................................................632
10.7.3 Control response of PLC-controlled axes ..................................................................................633
10.8 Response with special functions................................................................................................635
10.8.1 Dry run (DRY RUN) ...................................................................................................................635
10.8.2 Single block................................................................................................................................635
10.9 Examples ...................................................................................................................................636
10.9.1 Motion behavior and interpolation functions ..............................................................................636
10.9.1.1 Traversing path axes without interpolation with G0...................................................................637
10.10 Data lists ....................................................................................................................................637
10.10.1 Machine data..............................................................................................................................637
10.10.1.1 NC-specific machine data.....................................................................................................637
10.10.1.2 Channelspecific machine data..............................................................................................637
10.10.1.3 Axis/spindlespecific machine data ........................................................................................638
10.10.2 Setting data................................................................................................................................638
10.10.2.1 Axis/spindle-specific setting data..........................................................................................638

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10.10.3 Signals....................................................................................................................................... 638
10.10.3.1 Signals to channel................................................................................................................ 638
10.10.3.2 Signals from channel ........................................................................................................... 639
10.10.3.3 Signals to axis/spindle ......................................................................................................... 639
10.10.3.4 Signals from axis/spindle ..................................................................................................... 639
11 P5: Oscillation - only 840D sl................................................................................................................. 641
11.1 Brief description ........................................................................................................................ 641
11.2 Asynchronous oscillation........................................................................................................... 642
11.2.1 Influences on asynchronous oscillation .................................................................................... 643
11.2.2 Asynchronous oscillation under PLC control ............................................................................ 650
11.2.3 Special reactions during asynchronous oscillation ................................................................... 650
11.3 Oscillation controlled by synchronized actions ......................................................................... 653
11.3.1 Infeed at reversal point 1 or 2 ................................................................................................... 656
11.3.2 Infeed in reversal point range.................................................................................................... 657
11.3.3 Infeed at both reversal points.................................................................................................... 659
11.3.4 Stop oscillation movement at the reversal point ....................................................................... 660
11.3.5 Oscillation movement restarting................................................................................................ 661
11.3.6 Do not start partial infeed too early ........................................................................................... 662
11.3.7 Assignment of oscillation and infeed axes OSCILL .................................................................. 662
11.3.8 Definition of infeeds POSP........................................................................................................ 663
11.3.9 External oscillation reversal ...................................................................................................... 664
11.4 Marginal conditions ................................................................................................................... 665
11.5 Examples................................................................................................................................... 665
11.5.1 Example of asynchronous oscillation........................................................................................ 666
11.5.2 Example 1 of oscillation with synchronized actions.................................................................. 667
11.5.3 Example 2 of oscillation with synchronized actions.................................................................. 670
11.5.4 Examples for starting position................................................................................................... 672
11.5.4.1 Define starting position via language command ....................................................................... 672
11.5.4.2 Start oscillation via setting data ................................................................................................ 672
11.5.4.3 Non-modal oscillation (starting position = reversal point 1) ...................................................... 673
11.5.5 Example of external oscillation reversal.................................................................................... 676
11.5.5.1 Change reversal position via synchronized action with "external oscillation reversal"............. 676
11.6 Data lists.................................................................................................................................... 676
11.6.1 Machine data............................................................................................................................. 676
11.6.1.1 General machine data............................................................................................................... 676
11.6.2 Setting data ............................................................................................................................... 677
11.6.2.1 Axis/spindle-specific setting data .............................................................................................. 677
11.6.3 Signals....................................................................................................................................... 677
11.6.3.1 Signals to axis/spindle............................................................................................................... 677
11.6.3.2 Signals from axis/spindle .......................................................................................................... 677
11.6.4 System variables....................................................................................................................... 678
11.6.4.1 Main run variables for motion-synchronous actions ................................................................. 678
12 R2: Rotary axes..................................................................................................................................... 681
12.1 Brief Description........................................................................................................................ 681
12.2 Modulo 360 degrees ................................................................................................................. 685

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12.3 Programming rotary axes...........................................................................................................688
12.3.1 General information ...................................................................................................................688
12.3.2 Rotary axis with active modulo conversion (continuously-turning rotary axis). .........................688
12.3.3 Rotary axis without modulo conversion .....................................................................................694
12.3.4 Other programming features relating to rotary axes..................................................................696
12.4 Activating rotary axes.................................................................................................................697
12.5 Special features of rotary axes ..................................................................................................698
12.6 Examples ...................................................................................................................................699
12.7 Data lists ....................................................................................................................................700
12.7.1 Machine data..............................................................................................................................700
12.7.1.1 General machine data................................................................................................................700
12.7.1.2 Axis/spindlespecific machine data .............................................................................................700
12.7.2 Setting data................................................................................................................................700
12.7.2.1 General setting data...................................................................................................................700
12.7.2.2 Axis/spindle-specific setting data...............................................................................................700
12.7.3 Signals .......................................................................................................................................701
12.7.3.1 Signals to axis/spindle ...............................................................................................................701
12.7.3.2 Signals from axis/spindle ...........................................................................................................701
13 S3: Synchronous spindle ....................................................................................................................... 703
13.1 Brief description .........................................................................................................................703
13.1.1 Function .....................................................................................................................................703
13.1.2 Synchronous mode ....................................................................................................................705
13.1.3 Prerequisites for synchronous mode .........................................................................................711
13.1.4 Selecting synchronous mode for a part program.......................................................................712
13.1.5 Deselecting the synchronous mode for the part program..........................................................714
13.1.6 Controlling synchronous spindle coupling via PLC....................................................................716
13.1.7 Monitoring of synchronous operation.........................................................................................718
13.2 Programming..............................................................................................................................720
13.2.1 Definition (COUPDEF) ...............................................................................................................721
13.2.2 Switch the coupling (COUPON, COUPONC, COUPOF) on and off..........................................724
13.2.3 Axial system variables for synchronous spindle ........................................................................726
13.2.4 Automatic selection and deselection of position control ............................................................727
13.3 Configuration..............................................................................................................................728
13.3.1 Response of the synchronous-spindle coupling for NC Start ....................................................729
13.3.2 Behavior of the synchronous-spindle coupling for reset............................................................729
13.4 Points to note .............................................................................................................................730
13.4.1 Special features of synchronous mode in general.....................................................................730
13.4.2 Restore synchronism of following spindle..................................................................................732
13.4.3 Synchronous mode and NC/PLC interface signals....................................................................734
13.4.4 Differential speed between leading and following spindles .......................................................738
13.4.5 Behavior of synchronism signals during synchronism correction..............................................743
13.4.6 Delete synchronism correction and NC reset ............................................................................743
13.4.7 Special points regarding start-up of a synchronous spindle coupling........................................743
13.5 Boundary conditions ..................................................................................................................749
13.6 Examples ...................................................................................................................................749

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13.7 Data lists.................................................................................................................................... 750
13.7.1 Machine data............................................................................................................................. 750
13.7.1.1 NC-specific machine data ......................................................................................................... 750
13.7.1.2 Channelspecific machine data .................................................................................................. 750
13.7.1.3 Axis/spindlespecific machine data ............................................................................................ 751
13.7.2 Setting data ............................................................................................................................... 751
13.7.2.1 Channelspecific setting data ..................................................................................................... 751
13.7.3 Signals....................................................................................................................................... 752
13.7.3.1 Signals to channel..................................................................................................................... 752
13.7.3.2 Signals from channel................................................................................................................. 752
13.7.3.3 Signals to axis/spindle............................................................................................................... 752
13.7.3.4 Signals from axis/spindle .......................................................................................................... 753
13.7.4 System variables....................................................................................................................... 753
14 S7: Memory configuration...................................................................................................................... 755
14.1 Brief description ........................................................................................................................ 755
14.2 Memory organization................................................................................................................. 756
14.2.1 Active and passive file system .................................................................................................. 756
14.2.2 Reconfiguration ......................................................................................................................... 757
14.3 Configuration of the static user memory ...................................................................................758
14.3.1 Division of the static NC memory.............................................................................................. 758
14.3.2 Commissioning.......................................................................................................................... 761
14.4 Configuration of the dynamic user memory .............................................................................. 762
14.4.1 Division of the dynamic NC memory......................................................................................... 762
14.4.2 Commissioning.......................................................................................................................... 763
14.5 Data lists.................................................................................................................................... 764
14.5.1 Machine data............................................................................................................................. 764
14.5.1.1 General machine data............................................................................................................... 764
14.5.1.2 Channelspecific machine data .................................................................................................. 767
14.5.1.3 Axis/spindlespecific machine data ............................................................................................ 769
15 T1: Indexing axes .................................................................................................................................. 771
15.1 Brief Description........................................................................................................................ 771
15.2 Traversing of indexing axes ...................................................................................................... 771
15.2.1 Traversing of indexing axes in the JOG mode.......................................................................... 772
15.2.2 Traversing of indexing axes in the AUTOMATIC mode............................................................ 774
15.2.3 Traversing of indexing axes by PLC ......................................................................................... 775
15.3 Parameterization of indexing axes............................................................................................ 775
15.4 Programming of indexing axes.................................................................................................. 777
15.5 Equidistant index intervals ........................................................................................................ 782
15.5.1 Features .................................................................................................................................... 782
15.5.2 Hirth tooth system ..................................................................................................................... 783
15.5.3 Response of the Hirth axes in particular situations................................................................... 784
15.5.4 Restrictions ............................................................................................................................... 785
15.5.5 Modified activation of machine data.......................................................................................... 786
15.6 Starting up indexing axes.......................................................................................................... 786
15.7 Special features of indexing axes ............................................................................................. 790