Siemens SINUMERIK 802D sl Parts list manual

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Turning, Milling, Nibbling
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SINUMERIK
SINUMERIK 802D sl
Turning, Milling, Nibbling
Function Manual
Valid for
Control system Software version
SINUMERIK 802D sl G/N 1.4 SP7
SINUMERIK 802D sl T/M 1.4 SP7
11/2012
6FC5397-1CP10-5BA0
Preface
Various Interface Signals
(A2)
1
Axis Monitoring (A3)
2
Continuous Path Mode,
Exact Stop and LookAhead
(B1)
3
Acceleration (B2)
4
Travel to fixed stop (F1)
5
Gantry axes (G1)
6
Velocities, Setpoint/Actual
Value Systems, Closed-Loop
Control (G2)
7
Manual and Handwheel
Travel (H1)
8
A
uxiliary Function Outputs to
PLC (H2)
9
Operating Modes, Program
Operation (K1)
10
Compensation (K3)
11
Kinematic Transformation
(M1)
12
Measurement (M5)
13
EMERGENCY OFF (N2)
14
Punching and Nibbling (N4)
15
Transverse Axes (P1)
16
Continued on next page

Siemens AG
Industry Sector
Postfach 48 48
90026 NÜRNBERG
GERMANY
Order number: 6FC5397-1CP10-5BA0
Ⓟ 08/2013 Technical data subject to change
Copyright © Siemens AG 2005 - 2012.
All rights reserved

SINUMERIK 802D sl
Turning, Milling, Nibbling
Function Manual
Continuation
Positioning Axes (P2)
17
Reference Point Approach
(R1)
18
Rotary Axes (R2)
19
Spindle (S1)
20
Indexing Axes (T1)
21
Tangential Control (T3)
22
Speed/torque coupling,
master-slave (TE3)
23
Feed (V1)
24
Tool: Compensation and
Monitoring (W1)
25
Appendix
A

Siemens AG
Industry Sector
Postfach 48 48
90026 NÜRNBERG
GERMANY
Order number: 6FC5397-1CP10-5BA0
Ⓟ 08/2013 Technical data subject to change
Copyright © Siemens AG 2005 - 2012.
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.

Turning, Milling, Nibbling
Function Manual, 11/2012, 6FC5397-1CP10-5BA0 5
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
Turning, Milling, Nibbling
6 Function Manual, 11/2012, 6FC5397-1CP10-5BA0
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 scope
This documentation only describes the functionality of the standard version. Additions or
revisions made by the machine manufacturer are documented by the machine manufacturer.
Other functions not described in this documentation might be executable in the control.
However, no claim can be made regarding the availability of these functions when the
equipment is first supplied or in the event of servicing.
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.
Notes for the Reader
The function descriptions are only valid for the specific software version or up to the software
version specified. You should request valid function descriptions for new software versions.
Old function descriptions are only partly applicable for new software versions.
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
Turning, Milling, Nibbling
Function Manual, 11/2012, 6FC5397-1CP10-5BA0 7
EC Declaration of Conformity
The EC Declaration of Conformity for the EMC Directive can be found on the Internet at:
http://support.automation.siemens.com
Here, enter the number 15257461 as the search term or contact your local Siemens office.
Technical information
Notations
The following notation and abbreviations are used in this documentation:
● PLC interface signals -> IS "Signal name" (signal data)
Example: IS "Feedrate override" (VB380x 0000)
The variable byte is located in the "to axis" range, x stands for the axis:
0 Axis 1
1 Axis 2
n Axis n+1.
● Machine data -> MD MD_NR MD_NAME (description)
e.g.: MD30300 IS_ROT_AX (rotary axis)
● Setting data -> SD SD_NR SD_NAME (description)
e.g.: SD41200 JOG_SPIND_SET_VELO (JOG velocity for the spindle)
● The chapter titles are supplemented by a code in brackets (e.g. Chapter 1: EMERGENCY
STOP (N2)). This brief description is used in cross references to other chapters.
The machine and setting data are divided into the following areas:
Range Data area Meaning
200 - 399 $MM_ Display machine data
10,000 - 18,999 $MN_ General machine data
20,000 - 28,999 $MC_ Channelspecific machine data
30,000 - 38,999 $MA_ Axis-specific machine data
41,000 - 41,999 $SN_ General setting data
42,000 - 42,999 $SC_ Channel-specific setting data
43,000 - 43,999 $SA_ Axis-specific setting data

Preface
Turning, Milling, Nibbling
8 Function Manual, 11/2012, 6FC5397-1CP10-5BA0
Explanations for the technical data
Protection level:
Protection levels 0 to 7 have been used. The lock for protection levels 1 to 3 (4 to 7) can be
cancelled by entering the correct password and 4 to 7 via IS "Protection level" (e.g.
keyswitch position). Protection level 0 is not accessible. (refer to Chapter "Various Interface
Signals")
The operator only has access to information protected by one particular level and the levels
below it. Various protection levels are assigned to the machine data by default and are
marked with a write/read value (e.g. 4/7).
Note
Machine and setting data of protection levels 2 to 7 are described in this document.
Protection level 1 machine data is only referred to in special cases (expert mode).
Data types:
The following data types are used in the control:
● DOUBLE
Floating-point value (64-bit value)
Input limits from +/-4.19*10-307 to +/-1.67*10308
● DWORD
Integer values (32-bit values)
Input limits from -2,147,483,648 to +2,147,483,648 (decimal);
as hexadecimal value: 0000 through FFFF
● BYTE
Integer values (8-bit values)
Input limits from -128 to +127 (decimal); as hexadecimal value: 00 through FF
● BOOLEAN
Boolean value: TRUE (1) or FALSE (0)
● STRING
Consisting of max. 16 ASCII characters (upper-case letters, numbers and underscore)
Detailed explanations
● Detailed explanations for the machine/setting data and interface signals used can be
found in the
Reference: "Parameter Manual".
● Detailed explanations of the alarms which may occur can be found in the
References: "Diagnostics Manual".

Turning, Milling, Nibbling
Function Manual, 11/2012, 6FC5397-1CP10-5BA0 9
Contents
Preface ...................................................................................................................................................... 5
1 Various Interface Signals (A2) ................................................................................................................. 19
1.1 General ........................................................................................................................................19
1.2 Signals from PLC to NCK ............................................................................................................20
1.2.1 Access authorization....................................................................................................................20
1.2.2 General signals ............................................................................................................................21
1.2.3 Signals for digital drives, to axis/spindle ......................................................................................24
1.3 Signals from NCK to PLC ............................................................................................................24
1.3.1 General signals ............................................................................................................................24
1.3.2 Signals for digital drives, from axis/spindle..................................................................................26
1.4 Signals from PLC to HMI .............................................................................................................27
1.5 Signals from HMI to PLC .............................................................................................................29
1.6 NC services..................................................................................................................................30
1.6.1 User interface...............................................................................................................................30
1.6.1.1 General information .....................................................................................................................30
1.6.1.2 PI service ASUB ..........................................................................................................................32
1.6.1.3 Reading variables from the NCK area .........................................................................................33
1.6.1.4 Writing variables from the NCK area ...........................................................................................34
1.6.2 NC variable ..................................................................................................................................36
1.7 Signals from PLC .........................................................................................................................40
2 Axis Monitoring (A3) ................................................................................................................................ 41
2.1 Overview of monitoring functions.................................................................................................41
2.2 Motion monitoring functions.........................................................................................................41
2.2.1 Contour monitoring ......................................................................................................................41
2.2.2 Position monitoring ......................................................................................................................42
2.2.3 Standstill monitoring.....................................................................................................................44
2.2.4 Clamping monitoring ....................................................................................................................45
2.2.5 Speed setpoint monitoring ...........................................................................................................46
2.2.6 Actual velocity monitoring ............................................................................................................47
2.3 Encoder monitoring functions ......................................................................................................48
2.3.1 Encoder limit frequency monitoring .............................................................................................48
2.3.2 Zero mark monitoring...................................................................................................................49
2.4 Monitoring of static limits..............................................................................................................50
2.4.1 Hardware limit switches ...............................................................................................................50
2.4.2 Software limit switches.................................................................................................................51
2.4.3 Working area limitation ................................................................................................................53
2.5 Supplementary conditions............................................................................................................55
2.6 Data lists ......................................................................................................................................56
2.6.1 Machine data................................................................................................................................56

Contents
Turning, Milling, Nibbling
10 Function Manual, 11/2012, 6FC5397-1CP10-5BA0
2.6.2 Setting data ................................................................................................................................. 57
2.6.3 Interface signals .......................................................................................................................... 57
3 Continuous Path Mode, Exact Stop and LookAhead (B1)........................................................................ 59
3.1 Brief description .......................................................................................................................... 59
3.2 General........................................................................................................................................ 59
3.3 Exact stop.................................................................................................................................... 60
3.4 Continuous-path mode................................................................................................................ 62
3.4.1 General........................................................................................................................................ 62
3.4.2 Velocity reduction according to overload factor ..........................................................................63
3.4.3 Jerk limiting along the path through velocity reduction............................................................... 64
3.4.4 Machine axis-specific jerk limiting............................................................................................... 65
3.5 LookAhead .................................................................................................................................. 66
3.6 Data lists...................................................................................................................................... 68
3.6.1 Machine data............................................................................................................................... 68
3.6.2 Interface signals .......................................................................................................................... 68
4 Acceleration (B2) ..................................................................................................................................... 69
4.1 Acceleration profiles.................................................................................................................... 69
4.2 Jerk limitation on interpolator level.............................................................................................. 69
4.3 Jerk limitation in JOG mode........................................................................................................ 70
4.4 Percentage acceleration correction, ACC................................................................................... 71
4.5 Data lists...................................................................................................................................... 72
5 Travel to fixed stop (F1)........................................................................................................................... 73
5.1 Brief description .......................................................................................................................... 73
5.2 Functionality ................................................................................................................................ 73
5.3 Response to RESET and function abort ..................................................................................... 80
5.4 Block-search response................................................................................................................ 80
5.5 Miscellaneous ............................................................................................................................. 81
5.6 Data lists...................................................................................................................................... 83
5.6.1 Machine data............................................................................................................................... 83
5.6.2 Setting data ................................................................................................................................. 83
5.6.3 Interface signals .......................................................................................................................... 83
6 Gantry axes (G1) ..................................................................................................................................... 85
6.1 Brief description .......................................................................................................................... 85
6.2 "Gantry axes" function................................................................................................................. 86
6.3 Referencing and synchronizing gantry axes............................................................................... 90
6.3.1 Introduction ................................................................................................................................. 90
6.3.2 Automatic synchronization .......................................................................................................... 96
6.3.3 Points to note .............................................................................................................................. 97
6.4 Start-up of gantry axes................................................................................................................ 99