Siemens SINUMERIK 840D sl Parts list manual

SINUMERIK
SINUMERIK 840D sl / 828D
Basic Functions
Function Manual
01/2015
6FC5397-0BP40-5BA2
Preface
Fundamental safety
instructions 1
A2: Various NC/PLC
interface signals and
functions 2
A3: Axis Monitoring,
Protection Zones 3
B1: Continuous-path mode,
Exact stop, Look Ahead 4
B2: Acceleration 5
F1: Travel to fixed stop 6
G2: Velocities, setpoint /
actual value systems, closed-
loop control 7
H2: Auxiliary function outputs
to PLC 8
K1: Mode group, channel,
program operation, reset
response 9
K2: Axis Types, Coordinate
Systems, Frames 10
N2: Emergency stop 11
P1: Transverse axes 12
P3: Basic PLC program for
SINUMERIK 840D sl 13
P4: PLC for SINUMERIK
828D 14
R1: Referencing 15
S1: Spindles 16
V1: Feedrates 17
W1: Tool offset 18
Z1: NC/PLC interface signals 19
Appendix A
CNC software 4.7 SP1
Software Version
Controllers
SINUMERIK 828D
SINUMERIK 840D sl / 840DE sl
Valid for

Legal information
Warning notice system
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
indicates that minor personal injury can result if proper precautions are not taken.
NOTICE
indicates that property damage can result if proper precautions are not taken.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will be
used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to property
damage.
Qualified Personnel
The product/system described in this documentation may be operated only by personnel qualified for the specific
task in accordance with the relevant documentation, in particular its warning notices and safety instructions. Qualified
personnel are those who, based on their training and experience, are capable of identifying risks and avoiding
potential hazards when working with these products/systems.
Proper use of Siemens products
Note the following:
WARNING
Siemens products may only be used for the applications described in the catalog and in the relevant technical
documentation. If products and components from other manufacturers are used, these must be recommended or
approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and
maintenance are required to ensure that the products operate safely and without any problems. The permissible
ambient conditions must be complied with. The information in the relevant documentation must be observed.
Trademarks
All names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this publication
may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software described.
Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the information in
this publication is reviewed regularly and any necessary corrections are included in subsequent editions.
Siemens AG
Division Digital Factory
Postfach 48 48
90026 NÜRNBERG
GERMANY
Order number: 6FC5397-0BP40-5BA2
Ⓟ 02/2015 Subject to change
Copyright © Siemens AG 1994 - 2015.
All rights reserved

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:
[email protected]
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
Basic Functions
Function Manual, 01/2015, 6FC5397-0BP40-5BA2 3

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
Information on the 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.)
Preface
Basic Functions
4Function Manual, 01/2015, 6FC5397-0BP40-5BA2

● 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 Des‐
ignator> (<Meaning>)
Master spindle is the spindle stored in the machine data:
MD20090 $MC_SPIND_DEF_MASTER_SPIND (position of de‐
letion of the master spindle in the channel)
Setting data ... setting data:
<Type><Number> <Complete Des‐
ignator> (<Meaning>)
The logical master spindle is contained in the setting data:
SD42800 $SC_SPIND_ASSIGN_TAB[0] (spindle number con‐
verter)
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.
Preface
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Function Manual, 01/2015, 6FC5397-0BP40-5BA2 5

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 Value range
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.
Querying REAL variables
We recommend that querying REAL or DOUBLE variables in NC programs and synchronized
actions is programmed as limit value evaluation.
Example: Querying the actual value of an axis for a specific value
DEF REAL AXPOS = 123.456
IF ($VA_IM[<axis>] - 1ex-6) <= AXPOS <= ($VA_IM[<axis>] + 1ex-6) ; actual position
... == AXPOS
ELSE
... <> AXPOS
ENDIF
Preface
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Table of contents
Preface.........................................................................................................................................................3
1Fundamental safety instructions.................................................................................................................33
1.1 General safety instructions.....................................................................................................33
1.2 Industrial security...................................................................................................................33
2 A2: Various NC/PLC interface signals and functions.................................................................................35
2.1 Brief description.....................................................................................................................35
2.2 NC/PLC interface signals - only 840D sl................................................................................35
2.2.1 General..................................................................................................................................35
2.2.2 Ready signal to PLC..............................................................................................................37
2.2.3 Status signals to PLC.............................................................................................................37
2.2.4 Signals to/from the operator panel front.................................................................................38
2.2.5 Signals to channel..................................................................................................................40
2.2.6 Signals to axis/spindle............................................................................................................40
2.2.7 Signals from axis/spindle.......................................................................................................48
2.2.8 Signals to axis/spindle (digital drives)....................................................................................50
2.2.9 Signals from axis/spindle (digital drives)................................................................................51
2.3 Functions................................................................................................................................53
2.3.1 Screen refresh behavior for overload - only 840D sl..............................................................53
2.3.2 Settings for involute interpolation - only 840D sl....................................................................54
2.3.3 Activate DEFAULT memory - only 840D sl............................................................................57
2.3.4 Read and write PLC variable - only 840D sl..........................................................................57
2.3.5 Access protection via password and keyswitch.....................................................................60
2.3.5.1 Password...............................................................................................................................62
2.3.5.2 Keyswitch positions (DB10, DBX56.4 to 7)............................................................................63
2.3.5.3 Parameterizable protection levels..........................................................................................64
2.3.6 Switching over motor/drive data sets.....................................................................................65
2.3.6.1 General Information...............................................................................................................65
2.3.6.2 Formatting interfaces.............................................................................................................65
2.3.6.3 Request interface...................................................................................................................66
2.3.6.4 Display interface.....................................................................................................................67
2.3.6.5 Example.................................................................................................................................67
2.3.6.6 Overview of the interfaces......................................................................................................68
2.3.6.7 Supplementary conditions......................................................................................................69
2.4 Examples...............................................................................................................................70
2.4.1 Parameter set changeover.....................................................................................................70
2.5 Data lists................................................................................................................................72
2.5.1 Machine data..........................................................................................................................72
2.5.1.1 Display machine data.............................................................................................................72
2.5.1.2 NC-specific machine data......................................................................................................72
2.5.1.3 Channelspecific machine data...............................................................................................72
2.5.1.4 Axis/spindlespecific machine data.........................................................................................72
2.5.2 System variables....................................................................................................................74
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Function Manual, 01/2015, 6FC5397-0BP40-5BA2 7

2.5.3 Signals...................................................................................................................................74
2.5.3.1 Signals to NC.........................................................................................................................74
2.5.3.2 Signals from NC.....................................................................................................................74
2.5.3.3 Signals to operator panel front...............................................................................................75
2.5.3.4 Signals from operator panel front...........................................................................................75
2.5.3.5 Signals to channel..................................................................................................................76
2.5.3.6 Signals from channel..............................................................................................................76
2.5.3.7 Signals to axis/spindle............................................................................................................76
2.5.3.8 Signals from axis/spindle.......................................................................................................76
3 A3: Axis Monitoring, Protection Zones.......................................................................................................79
3.1 Brief description.....................................................................................................................79
3.1.1 Axis monitoring functions.......................................................................................................79
3.1.2 Protection zones....................................................................................................................79
3.2 Axis monitoring functions.......................................................................................................80
3.2.1 Contour monitoring.................................................................................................................80
3.2.1.1 Contour error..........................................................................................................................80
3.2.1.2 Following-error monitoring.....................................................................................................80
3.2.2 Positioning, zero speed and clamping monitoring..................................................................83
3.2.2.1 Correlation between positioning, zero-speed and clamping monitoring.................................83
3.2.2.2 Positioning monitoring............................................................................................................83
3.2.2.3 Zero-speed monitoring...........................................................................................................84
3.2.2.4 Parameter set-dependent exact stop and standstill tolerance...............................................85
3.2.2.5 Clamping monitoring..............................................................................................................86
3.2.3 Speed-setpoint monitoring.....................................................................................................93
3.2.4 Actual-velocity monitoring......................................................................................................94
3.2.5 Measuring system monitoring................................................................................................95
3.2.5.1 Encoder-limit-frequency monitoring.......................................................................................97
3.2.5.2 Plausibility check for absolute encoders................................................................................98
3.2.5.3 Customized error reactions..................................................................................................100
3.2.6 Limit-switch monitoring.........................................................................................................103
3.2.6.1 Hardware limit switch...........................................................................................................103
3.2.6.2 Software limit switch.............................................................................................................104
3.2.7 Monitoring of the working area limitation..............................................................................106
3.2.7.1 General................................................................................................................................106
3.2.7.2 Working area limitation in BKS.............................................................................................108
3.2.7.3 Working area limitation in WCS/SZS...................................................................................110
3.2.8 Parking a machine axis........................................................................................................113
3.2.9 Parking the passive position measuring system..................................................................115
3.2.9.1 Function...............................................................................................................................115
3.2.9.2 Supplementary conditions....................................................................................................118
3.2.9.3 Example: Changing an attachment head for a direct position measuring system...............119
3.2.9.4 Example: Changing an attachment head for two direct position measuring systems..........123
3.2.9.5 Example: Measuring system switchover when encoders are missing in certain parts of
the range..............................................................................................................................127
3.3 Protection zones..................................................................................................................130
3.3.1 General................................................................................................................................130
3.3.2 Types of protection zone......................................................................................................132
3.3.3 Definition via part program instruction..................................................................................135
3.3.4 Definition as per system variable.........................................................................................138
3.3.5 Activating and deactivating protection zones.......................................................................140
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3.3.6 Protection zone violation and temporary enabling of individual protection zones................144
3.3.7 Restrictions in protection zones...........................................................................................148
3.3.8 Checking for protection zone violation, working area limitation and software limit
switches (CALCPOSI)..........................................................................................................149
3.4 Supplementary conditions....................................................................................................159
3.4.1 Axis monitoring functions.....................................................................................................159
3.5 Examples.............................................................................................................................159
3.5.1 Axis monitoring functions.....................................................................................................159
3.5.1.1 Working area limitation in WCS/SZS...................................................................................159
3.5.2 Protection zones..................................................................................................................162
3.5.2.1 Definition and activation of protection zones........................................................................162
3.6 Data lists..............................................................................................................................171
3.6.1 Machine data........................................................................................................................171
3.6.1.1 NC-specific machine data....................................................................................................171
3.6.1.2 Channelspecific machine data.............................................................................................172
3.6.1.3 Axis/spindlespecific machine data.......................................................................................173
3.6.2 Setting data..........................................................................................................................174
3.6.2.1 Axis/spindlespecific setting data..........................................................................................174
3.6.3 Signals.................................................................................................................................174
3.6.3.1 Signals to channel................................................................................................................174
3.6.3.2 Signals from channel............................................................................................................175
3.6.3.3 Signals to axis/spindle..........................................................................................................175
3.6.3.4 Signals from axis/spindle.....................................................................................................176
4 B1: Continuous-path mode, Exact stop, Look Ahead...............................................................................177
4.1 Brief Description...................................................................................................................177
4.2 Exact stop mode..................................................................................................................180
4.3 Continuous-path mode.........................................................................................................184
4.3.1 General functionality............................................................................................................184
4.3.2 Velocity reduction according to overload factor...................................................................186
4.3.3 Rounding..............................................................................................................................188
4.3.3.1 Rounding according to a path criterion (G641)....................................................................190
4.3.3.2 Rounding in compliance with defined tolerances (G642/G643)...........................................192
4.3.3.3 Rounding with maximum possible axial dynamic response (G644).....................................195
4.3.3.4 Rounding of tangential block transitions (G645)..................................................................198
4.3.3.5 Rounding and repositioning (REPOS).................................................................................199
4.3.4 LookAhead...........................................................................................................................200
4.3.4.1 Standard functionality...........................................................................................................200
4.3.4.2 Free-form surface mode: Extension function.......................................................................206
4.4 Dynamic adaptations............................................................................................................210
4.4.1 Smoothing of the path velocity.............................................................................................210
4.4.2 Adaptation of the dynamic path response............................................................................213
4.4.3 Determination of the dynamic response limiting values.......................................................217
4.4.4 Interaction between the "smoothing of the path velocity" and "adaptation of the path
dynamic response" functions...............................................................................................218
4.4.5 Dynamic response mode for path interpolation....................................................................222
4.4.6 Free-form surface mode: Basic functions............................................................................224
4.5 Compressor functions..........................................................................................................227
4.5.1 Compression of blocks for linear and circular movement....................................................227
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4.5.2 Compression of short spline blocks.....................................................................................230
4.5.3 Supplementary conditions....................................................................................................231
4.6 Contour/Orientation tolerance..............................................................................................232
4.7 Tolerance and compression of G0 blocks............................................................................235
4.8 RESET behavior..................................................................................................................238
4.9 Supplementary conditions....................................................................................................238
4.9.1 Block change and positioning axes......................................................................................238
4.9.2 Block change delay..............................................................................................................239
4.10 Data lists..............................................................................................................................239
4.10.1 Machine data........................................................................................................................239
4.10.1.1 General machine data..........................................................................................................239
4.10.1.2 Channelspecific machine data.............................................................................................239
4.10.1.3 Axis/spindlespecific machine data.......................................................................................240
4.10.2 Setting data..........................................................................................................................241
4.10.2.1 Channelspecific setting data................................................................................................241
4.10.3 Signals.................................................................................................................................241
4.10.3.1 Signals from channel............................................................................................................241
4.10.3.2 Signals from axis/spindle.....................................................................................................241
5 B2: Acceleration.......................................................................................................................................243
5.1 Brief description...................................................................................................................243
5.1.1 General................................................................................................................................243
5.1.2 Features...............................................................................................................................243
5.2 Functions..............................................................................................................................245
5.2.1 Acceleration without jerk limitation (BRISK/BRISKA) (channel/axis-specific)......................245
5.2.1.1 General Information.............................................................................................................245
5.2.1.2 Parameterization..................................................................................................................246
5.2.1.3 Programming........................................................................................................................247
5.2.2 Constant travel time (channel-specific)................................................................................248
5.2.2.1 General Information.............................................................................................................248
5.2.2.2 Parameterization..................................................................................................................249
5.2.3 Acceleration matching (ACC) (axis-specific)........................................................................250
5.2.3.1 General Information.............................................................................................................250
5.2.3.2 Programming........................................................................................................................250
5.2.4 Acceleration margin (channel-specific)................................................................................251
5.2.4.1 General Information.............................................................................................................251
5.2.4.2 Parameterization..................................................................................................................251
5.2.5 Path-acceleration limitation (channel-specific).....................................................................251
5.2.5.1 General Information.............................................................................................................251
5.2.5.2 Parameterization..................................................................................................................252
5.2.5.3 Programming........................................................................................................................252
5.2.6 Path acceleration for real-time events (channel-specific)....................................................253
5.2.6.1 General Information.............................................................................................................253
5.2.6.2 Programming........................................................................................................................254
5.2.7 Acceleration with programmed rapid traverse (G00) (axis-specific)....................................255
5.2.7.1 General Information.............................................................................................................255
5.2.7.2 Parameterization..................................................................................................................255
5.2.8 Acceleration with active jerk limitation (SOFT/SOFTA) (axis-specific).................................256
5.2.8.1 General Information.............................................................................................................256
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5.2.8.2 Parameterization..................................................................................................................256
5.2.9 Excessive acceleration for non-tangential block transitions (axis-specific)..........................256
5.2.9.1 General Information.............................................................................................................256
5.2.9.2 Parameterization..................................................................................................................257
5.2.10 Acceleration margin for radial acceleration (channel-specific).............................................257
5.2.10.1 General Information.............................................................................................................257
5.2.10.2 Parameterization..................................................................................................................258
5.2.11 Jerk limitation with path interpolation (SOFT) (channel-specific).........................................259
5.2.11.1 General Information.............................................................................................................259
5.2.11.2 Parameterization..................................................................................................................261
5.2.11.3 Programming........................................................................................................................261
5.2.12 Jerk limitation with single-axis interpolation (SOFTA) (axis-specific)...................................262
5.2.12.1 Parameterization..................................................................................................................262
5.2.12.2 Programming........................................................................................................................263
5.2.13 Path-jerk limitation (channel-specific)..................................................................................263
5.2.13.1 General Information.............................................................................................................263
5.2.13.2 Parameterization..................................................................................................................264
5.2.13.3 Programming........................................................................................................................264
5.2.14 Path jerk for real-time events (channel-specific)..................................................................265
5.2.14.1 General Information.............................................................................................................265
5.2.14.2 Programming........................................................................................................................266
5.2.15 Jerk with programmed rapid traverse (G00) (axis-specific).................................................267
5.2.15.1 General Information.............................................................................................................267
5.2.15.2 Parameterization..................................................................................................................267
5.2.16 Excessive jerk for block transitions without constant curvature (axis-specific)....................268
5.2.16.1 General Information.............................................................................................................268
5.2.16.2 Parameterization..................................................................................................................268
5.2.17 Velocity-dependent jerk adaptation (axis-specific)...............................................................268
5.2.18 Jerk filter (axis-specific)........................................................................................................270
5.2.18.1 General Information.............................................................................................................270
5.2.18.2 Parameterization..................................................................................................................272
5.2.19 Kneeshaped acceleration characteristic curve.....................................................................274
5.2.19.1 Adaptation to the motor characteristic curve........................................................................274
5.2.19.2 Effects on path acceleration.................................................................................................276
5.2.19.3 Substitute characteristic curve.............................................................................................276
5.2.19.4 Parameterization..................................................................................................................279
5.2.19.5 Programming........................................................................................................................280
5.2.19.6 Boundary conditions.............................................................................................................281
5.2.20 Acceleration and jerk for JOG motions................................................................................282
5.2.20.1 Parameterization..................................................................................................................282
5.2.20.2 Supplementary conditions....................................................................................................284
5.3 Examples.............................................................................................................................285
5.3.1 Acceleration.........................................................................................................................285
5.3.1.1 Path velocity characteristic...................................................................................................285
5.3.2 Jerk......................................................................................................................................286
5.3.2.1 Path velocity characteristic...................................................................................................286
5.3.3 Acceleration and jerk............................................................................................................288
5.3.4 Knee-shaped acceleration characteristic curve...................................................................289
5.3.4.1 Activation..............................................................................................................................289
5.4 Data lists..............................................................................................................................290
5.4.1 Machine data........................................................................................................................290
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5.4.1.1 NC-specific machine data....................................................................................................290
5.4.1.2 Channel-specific machine data............................................................................................290
5.4.1.3 Axis/spindlespecific machine data.......................................................................................291
5.4.2 Setting data..........................................................................................................................292
5.4.2.1 Channelspecific setting data................................................................................................292
5.4.3 System variables..................................................................................................................292
6 F1: Travel to fixed stop.............................................................................................................................293
6.1 Brief description...................................................................................................................293
6.2 Detailed description..............................................................................................................294
6.2.1 Programming........................................................................................................................294
6.2.2 Functional sequence............................................................................................................296
6.2.2.1 Selection..............................................................................................................................296
6.2.2.2 Fixed stop is reached...........................................................................................................297
6.2.2.3 Fixed stop is not reached.....................................................................................................299
6.2.2.4 Deselection..........................................................................................................................300
6.2.3 Behavior during block search...............................................................................................302
6.2.4 Behavior for reset and function abort...................................................................................305
6.2.5 Behavior with regard to other functions................................................................................306
6.2.6 Setting data..........................................................................................................................307
6.2.7 System variables..................................................................................................................308
6.2.8 Alarms..................................................................................................................................310
6.2.9 Travel with limited torque/force FOC....................................................................................311
6.3 Examples.............................................................................................................................314
6.4 Data lists..............................................................................................................................315
6.4.1 Machine data........................................................................................................................315
6.4.1.1 Axis/spindlespecific machine data.......................................................................................315
6.4.2 Setting data..........................................................................................................................316
6.4.2.1 Axis/spindle-specific setting data.........................................................................................316
6.4.3 Signals.................................................................................................................................316
6.4.3.1 Signals to axis/spindle..........................................................................................................316
6.4.3.2 Signals from axis/spindle.....................................................................................................316
7 G2: Velocities, setpoint / actual value systems, closed-loop control........................................................317
7.1 Brief description...................................................................................................................317
7.2 Velocities, traversing ranges, accuracies.............................................................................317
7.2.1 Velocities..............................................................................................................................317
7.2.2 Traversing ranges................................................................................................................319
7.2.3 Positioning accuracy of the control system .........................................................................320
7.2.4 Input/display resolution, computational resolution...............................................................320
7.2.5 Scaling of physical quantities of machine and setting data..................................................322
7.3 Metric/inch measuring system..............................................................................................325
7.3.1 Conversion of basic system by part program.......................................................................325
7.3.2 Manual switchover of the basic system................................................................................329
7.3.3 FGROUP and FGREF..........................................................................................................333
7.4 Setpoint/actual-value system...............................................................................................336
7.4.1 General................................................................................................................................336
7.4.2 Setpoint and encoder assignment........................................................................................339
7.4.3 Adapting the motor/load ratios.............................................................................................342
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7.4.4 Speed setpoint output..........................................................................................................345
7.4.5 Machine data of the actual value system.............................................................................347
7.4.6 Actual-value resolution.........................................................................................................348
7.4.6.1 Machine data of the actual value resolution.........................................................................348
7.4.6.2 Example: Linear axis with linear scale.................................................................................351
7.4.6.3 Example: Linear axis with rotary encoder on motor.............................................................352
7.4.6.4 Example: Linear axis with rotary encoder on the machine...................................................353
7.4.6.5 Example: Rotary axis with rotary encoder on motor............................................................354
7.4.6.6 Example: Rotary axis with rotary encoder on the machine..................................................356
7.4.6.7 Example: Intermediate gear with encoder on the tool..........................................................357
7.5 Closed-loop control..............................................................................................................357
7.5.1 General................................................................................................................................357
7.5.2 Parameter sets of the position controller..............................................................................361
7.6 Optimization of the control...................................................................................................362
7.6.1 Position controller, position setpoint filter: Balancing filter...................................................362
7.6.2 Position controller, position setpoint filter: Jerk filter............................................................365
7.6.3 Position controller, position setpoint filter: Phase filter.........................................................368
7.6.4 Position controller: injection of positional deviation..............................................................370
7.6.5 Position control with proportional-plus-integral-action controller..........................................371
7.7 Data lists..............................................................................................................................374
7.7.1 Machine data........................................................................................................................374
7.7.1.1 Displaying machine data......................................................................................................374
7.7.1.2 NC-specific machine data....................................................................................................374
7.7.1.3 Channelspecific machine data.............................................................................................374
7.7.1.4 Axis/spindlespecific machine data.......................................................................................375
8 H2: Auxiliary function outputs to PLC.......................................................................................................377
8.1 Brief description...................................................................................................................377
8.1.1 Function...............................................................................................................................377
8.1.2 Definition of an auxiliary function.........................................................................................378
8.1.3 Overview of the auxiliary functions.......................................................................................378
8.2 Predefined auxiliary functions..............................................................................................384
8.2.1 Overview: Predefined auxiliary functions.............................................................................385
8.2.2 Overview: Output behavior...................................................................................................396
8.2.3 Parameterization..................................................................................................................399
8.2.3.1 Group assignment................................................................................................................399
8.2.3.2 Type, address extension and value.....................................................................................399
8.2.3.3 Output behavior....................................................................................................................401
8.3 Userdefined auxiliary functions............................................................................................404
8.3.1 Parameterization..................................................................................................................406
8.3.1.1 Maximum number of user-defined auxiliary functions..........................................................406
8.3.1.2 Group assignment................................................................................................................406
8.3.1.3 Type, address extension and value.....................................................................................406
8.3.1.4 Output behavior....................................................................................................................408
8.4 Associated auxiliary functions..............................................................................................408
8.5 Type-specific output behavior..............................................................................................410
8.6 Priorities of the output behavior for which parameters have been assigned........................411
8.7 Programming an auxiliary function.......................................................................................412
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8.8 Programmable output duration.............................................................................................414
8.9 Auxiliary function output to the PLC.....................................................................................415
8.10 Auxiliary functions without block change delay....................................................................416
8.11 M function with an implicit preprocessing stop.....................................................................417
8.12 Response to overstore.........................................................................................................417
8.13 Behavior during block search...............................................................................................418
8.13.1 Auxiliary function output during type 1, 2, and 4 block searches.........................................418
8.13.2 Assignment of an auxiliary function to a number of groups.................................................420
8.13.3 Time stamp of the active M auxiliary function......................................................................421
8.13.4 Determining the output sequence........................................................................................421
8.13.5 Output suppression of spindle-specific auxiliary functions...................................................423
8.13.6 Auxiliary function output with a type 5 block search (SERUPRO).......................................426
8.13.7 ASUB at the end of the SERUPRO......................................................................................431
8.14 Implicitly output auxiliary functions.......................................................................................437
8.15 Information options...............................................................................................................438
8.15.1 Group-specific modal M auxiliary function display...............................................................439
8.15.2 Querying system variables...................................................................................................440
8.16 Supplementary conditions....................................................................................................442
8.16.1 General constraints..............................................................................................................442
8.16.2 Output behavior....................................................................................................................443
8.17 Examples.............................................................................................................................444
8.17.1 Extension of predefined auxiliary functions..........................................................................444
8.17.2 Defining auxiliary functions..................................................................................................446
8.18 Data lists..............................................................................................................................450
8.18.1 Machine data........................................................................................................................450
8.18.1.1 NC-specific machine data....................................................................................................450
8.18.1.2 Channelspecific machine data.............................................................................................450
8.18.2 Signals.................................................................................................................................451
8.18.2.1 Signals to channel................................................................................................................451
8.18.2.2 Signals from channel............................................................................................................451
8.18.2.3 Signals to axis/spindle..........................................................................................................453
8.18.2.4 Signals from axis/spindle.....................................................................................................454
9 K1: Mode group, channel, program operation, reset response................................................................455
9.1 Product brief.........................................................................................................................455
9.2 Mode group..........................................................................................................................457
9.2.1 Mode group stop..................................................................................................................460
9.2.2 Mode group reset.................................................................................................................460
9.3 Mode types and mode type change.....................................................................................461
9.3.1 Monitoring functions and interlocks of the individual modes................................................466
9.3.2 Mode change.......................................................................................................................466
9.4 Channel................................................................................................................................467
9.4.1 Global start disable for channel............................................................................................470
9.5 Program test.........................................................................................................................471
9.5.1 Program execution without setpoint outputs........................................................................471
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9.5.2 Program execution in single-block mode.............................................................................473
9.5.3 Program execution with dry run feedrate.............................................................................475
9.5.4 Skip part-program blocks.....................................................................................................477
9.6 Workpiece simulation...........................................................................................................478
9.7 Block search, types 1, 2, and 4:...........................................................................................479
9.7.1 Description of the function....................................................................................................480
9.7.2 Block search in connection with other NCK functions..........................................................482
9.7.2.1 ASUB after and during block search....................................................................................482
9.7.2.2 PLC actions after block search............................................................................................483
9.7.2.3 Spindle functions after block search....................................................................................484
9.7.2.4 Reading system variables for a block search.......................................................................485
9.7.3 Automatic start of an ASUB after a block search.................................................................485
9.7.4 Cascaded block search........................................................................................................487
9.7.5 Examples for block search with calculation..........................................................................488
9.7.6 Supplementary conditions....................................................................................................493
9.7.6.1 Compressor functions (COMPON, COMPCURV, COMPCAD)...........................................493
9.8 Block search Type 5 (SERUPRO).......................................................................................493
9.8.1 Description of the function....................................................................................................493
9.8.2 Repositioning to the contour (REPOS)................................................................................497
9.8.2.1 Repositioning with controlled REPOS..................................................................................505
9.8.3 Accelerate block search.......................................................................................................506
9.8.4 SERUPRO ASUB.................................................................................................................508
9.8.5 Selfacting SERUPRO...........................................................................................................511
9.8.6 Locking a program section for "Continue machining at the contour"...................................512
9.8.7 Behavior during POWER ON, mode change and RESET...................................................515
9.8.8 Supplementary conditions....................................................................................................516
9.8.8.1 STOPRE in the target block.................................................................................................516
9.8.8.2 SPOS in target block............................................................................................................517
9.8.8.3 Travel to fixed stop (FXS)....................................................................................................517
9.8.8.4 Travel with limited torque/force (FOC).................................................................................518
9.8.8.5 Synchronous spindle............................................................................................................518
9.8.8.6 Couplings and master-slave.................................................................................................519
9.8.8.7 Axis functions.......................................................................................................................522
9.8.8.8 Gear stage change...............................................................................................................523
9.8.8.9 Superimposed motion..........................................................................................................524
9.8.8.10 NC/PLC interface signals.....................................................................................................524
9.8.8.11 Making the initial settings more flexible................................................................................525
9.8.8.12 Compressor functions (COMPON, COMPCURV, COMPCAD)...........................................525
9.8.9 System variable....................................................................................................................526
9.9 Program operation...............................................................................................................526
9.9.1 Initial settings.......................................................................................................................527
9.9.2 Selection and start of part program or part program block...................................................529
9.9.3 Part program interruption.....................................................................................................531
9.9.4 RESET command................................................................................................................532
9.9.5 Program status.....................................................................................................................533
9.9.6 Channel status.....................................................................................................................534
9.9.7 Responses to operator or program actions..........................................................................535
9.9.8 Part-Program Start...............................................................................................................537
9.9.9 Example of a timing diagram for a program run...................................................................538
9.9.10 Program jumps.....................................................................................................................538
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9.9.10.1 Jump back to start of program.............................................................................................538
9.9.11 Program section repetitions.................................................................................................540
9.9.11.1 Overview..............................................................................................................................540
9.9.11.2 Individual part program block...............................................................................................541
9.9.11.3 A part program section after a start label.............................................................................542
9.9.11.4 A part program section between a start label and end label................................................543
9.9.11.5 A part program section between a Start label and the key word: ENDLABEL.....................544
9.9.12 Event-driven program call (PROG_EVENT)........................................................................545
9.9.12.1 Function...............................................................................................................................545
9.9.12.2 Parameterization..................................................................................................................549
9.9.12.3 Programming........................................................................................................................552
9.9.12.4 Boundary conditions.............................................................................................................554
9.9.12.5 Examples.............................................................................................................................554
9.9.13 Influencing the Stop events through Stop delay area..........................................................556
9.10 Asynchronous subprograms (ASUBs), interrupt routines....................................................558
9.10.1 Function...............................................................................................................................558
9.10.1.1 General functionality............................................................................................................558
9.10.1.2 Sequence of an interrupt routine in program operation........................................................561
9.10.1.3 Interrupt routine with REPOSA............................................................................................562
9.10.1.4 NC response........................................................................................................................563
9.10.2 Parameterization..................................................................................................................564
9.10.3 Programming........................................................................................................................568
9.10.4 Restrictions..........................................................................................................................570
9.10.5 Examples.............................................................................................................................570
9.11 User-specific ASUB for RET and REPOS............................................................................571
9.11.1 Function...............................................................................................................................571
9.11.2 Parameter assignment.........................................................................................................571
9.11.3 Programming........................................................................................................................573
9.12 Perform ASUB start for user alarms.....................................................................................574
9.12.1 Function...............................................................................................................................574
9.12.2 Activation..............................................................................................................................575
9.12.3 Examples.............................................................................................................................575
9.12.3.1 User ASUB from reset - example 1......................................................................................575
9.12.3.2 User ASUB from reset - example 2......................................................................................576
9.12.3.3 User ASUB with M0.............................................................................................................577
9.12.3.4 User ASUB with stop............................................................................................................579
9.12.3.5 User ASUB from stopped.....................................................................................................580
9.13 Single block..........................................................................................................................581
9.13.1 Parameterization..................................................................................................................581
9.13.2 Programming........................................................................................................................582
9.13.3 Supplementary conditions....................................................................................................586
9.13.4 Single-block behavior in mode group with type A/B.............................................................586
9.14 Program control....................................................................................................................587
9.14.1 Function selection (via operator panel front or PLC)............................................................588
9.14.2 Activation of skip levels........................................................................................................589
9.14.3 Adapting the size of the interpolation buffer.........................................................................590
9.14.4 Program display modes via an additional basic block display.............................................592
9.14.5 Basic block display for ShopMill/ShopTurn..........................................................................592
9.14.6 Structure for a DIN block......................................................................................................595
9.14.7 Execution from external.......................................................................................................598
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9.14.8 Executing external subprograms (EXTCALL)......................................................................600
9.15 EES (optional)......................................................................................................................603
9.15.1 Function...............................................................................................................................603
9.15.2 Commissioning.....................................................................................................................604
9.15.2.1 Preconditions.......................................................................................................................604
9.15.2.2 Global part program memory (GDIR)...................................................................................606
9.15.2.3 Settings for file handling in the part program for EES..........................................................607
9.15.2.4 Memory configuration...........................................................................................................609
9.16 System settings for power-up, RESET / part program end and part program start.............609
9.16.1 Tool withdrawal after POWER ON with orientation transformation......................................614
9.17 Replacing functions by subprograms...................................................................................617
9.17.1 Overview..............................................................................................................................617
9.17.2 Replacement of M, T/TCA and D/DL functions....................................................................618
9.17.2.1 Replacement of M functions.................................................................................................618
9.17.2.2 Replacing T/TCA and D/DL functions..................................................................................620
9.17.2.3 System variable....................................................................................................................623
9.17.2.4 Example: Replacement of an M function.............................................................................624
9.17.2.5 Example: Replacement of a T and D function......................................................................627
9.17.2.6 Behavior in the event of a conflict........................................................................................628
9.17.3 Replacement of spindle functions........................................................................................629
9.17.3.1 General................................................................................................................................629
9.17.3.2 Replacement of M40 - M45 (gear stage change).................................................................630
9.17.3.3 Replacement of SPOS, SPOSA, M19 (spindle positioning).................................................631
9.17.3.4 System variable....................................................................................................................632
9.17.3.5 Example: Gear stage change...............................................................................................633
9.17.3.6 Example: Spindle positioning...............................................................................................635
9.17.4 Properties of the subprograms.............................................................................................638
9.17.5 Restrictions..........................................................................................................................640
9.18 Program runtime / part counter............................................................................................640
9.18.1 Program runtime..................................................................................................................641
9.18.2 Workpiece counter...............................................................................................................647
9.19 Data lists..............................................................................................................................651
9.19.1 Machine data........................................................................................................................651
9.19.1.1 General machine data..........................................................................................................651
9.19.1.2 Channel-specific machine data............................................................................................653
9.19.1.3 Axis/spindlespecific machine data.......................................................................................656
9.19.2 Setting data..........................................................................................................................656
9.19.2.1 Channelspecific setting data................................................................................................656
9.19.3 Signals.................................................................................................................................656
9.19.3.1 Signals to NC.......................................................................................................................656
9.19.3.2 Signals to mode group.........................................................................................................657
9.19.3.3 Signals to NC.......................................................................................................................657
9.19.3.4 Signals to channel................................................................................................................657
9.19.3.5 Signals from channel............................................................................................................658
9.19.3.6 Signals to NC.......................................................................................................................659
9.19.3.7 Signals from axis/spindle.....................................................................................................659
10 K2: Axis Types, Coordinate Systems, Frames.........................................................................................661
10.1 Brief description...................................................................................................................661
10.1.1 Axes.....................................................................................................................................661
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10.1.2 Coordinate systems.............................................................................................................663
10.1.3 Frames.................................................................................................................................664
10.2 Axes.....................................................................................................................................667
10.2.1 Overview..............................................................................................................................667
10.2.2 Machine axes.......................................................................................................................669
10.2.3 Channel axes.......................................................................................................................670
10.2.4 Geometry axes.....................................................................................................................670
10.2.5 Special axes.........................................................................................................................670
10.2.6 Path axes.............................................................................................................................671
10.2.7 Positioning axes...................................................................................................................671
10.2.8 Main axes.............................................................................................................................672
10.2.9 Synchronized axes...............................................................................................................673
10.2.10 Axis configuration.................................................................................................................675
10.2.11 Link axes..............................................................................................................................677
10.3 Zeros and reference points..................................................................................................678
10.3.1 Reference points in working space......................................................................................678
10.3.2 Position of coordinate systems and reference points...........................................................680
10.4 Coordinate systems.............................................................................................................681
10.4.1 Overview..............................................................................................................................681
10.4.2 Machine coordinate system (MCS)......................................................................................685
10.4.2.1 Actual value setting with loss of the referencing status (PRESETON)................................686
10.4.2.2 Actual value setting without loss of the referencing status (PRESETONS).........................691
10.4.3 Basic coordinate system (BCS)...........................................................................................696
10.4.4 Additive offsets.....................................................................................................................698
10.4.5 Basic zero system (BZS)......................................................................................................700
10.4.6 Settable zero system (SZS).................................................................................................702
10.4.7 Workpiece coordinate system (WCS)..................................................................................703
10.5 Frames.................................................................................................................................704
10.5.1 Frame types.........................................................................................................................704
10.5.2 Frame components..............................................................................................................705
10.5.2.1 Translation...........................................................................................................................705
10.5.2.2 Fine offset............................................................................................................................706
10.5.2.3 Rotation Overview (geometry axes only).............................................................................707
10.5.2.4 Rotation with a Euler angles: ZY'X" convention (RPY angles).............................................708
10.5.2.5 Rotation with a Euler angles: ZX'Z" convention...................................................................713
10.5.2.6 Rotation in any plane...........................................................................................................714
10.5.2.7 Scaling.................................................................................................................................715
10.5.2.8 Mirroring...............................................................................................................................716
10.5.2.9 Chain operator.....................................................................................................................716
10.5.2.10 Programmable axis name....................................................................................................716
10.5.2.11 Coordinate transformation....................................................................................................718
10.5.3 Data management frames and active frames......................................................................718
10.5.3.1 Overview..............................................................................................................................718
10.5.3.2 Activating data management frames....................................................................................720
10.5.3.3 NCU-global and channel-specific frames.............................................................................721
10.5.4 Frame chain and coordinate systems..................................................................................722
10.5.4.1 Overview..............................................................................................................................722
10.5.4.2 Relative coordinate systems................................................................................................723
10.5.4.3 Selectable SZS....................................................................................................................725
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10.5.4.4 Manual traversing of geometry axes either in the WCS or in the SZS
($AC_JOG_COORD)...........................................................................................................726
10.5.4.5 Suppression of frames.........................................................................................................727
10.5.5 Frames of the frame chain...................................................................................................728
10.5.5.1 Overview..............................................................................................................................728
10.5.5.2 Settable frames ($P_UIFR[<n>])..........................................................................................729
10.5.5.3 Grinding frames $P_GFR[<n>].............................................................................................730
10.5.5.4 Channel-specific basic frames[<n>].....................................................................................732
10.5.5.5 NCU-global basic frames $P_NCBFR[<n>].........................................................................734
10.5.5.6 Active complete basic frame $P_ACTBFRAME...................................................................735
10.5.5.7 Programmable frame $P_PFRAME.....................................................................................736
10.5.5.8 Channelspecific system frames...........................................................................................738
10.5.6 Implicit frame changes.........................................................................................................740
10.5.6.1 Frames and switchover of geometry axes...........................................................................740
10.5.6.2 Frame for selection and deselection of transformations......................................................743
10.5.6.3 Adapting active frames.........................................................................................................760
10.5.6.4 Mapped Frames...................................................................................................................761
10.5.7 Predefined frame functions..................................................................................................765
10.5.7.1 Inverse frame.......................................................................................................................765
10.5.7.2 Additive frame in frame chain...............................................................................................767
10.5.8 Functions..............................................................................................................................768
10.5.8.1 Setting zeros, workpiece measuring and tool measuring.....................................................768
10.5.8.2 Zero offset external via system frames................................................................................769
10.5.8.3 Toolholder............................................................................................................................770
10.5.9 Subprograms with SAVE attribute (SAVE)...........................................................................780
10.5.10 Data backup.........................................................................................................................781
10.5.11 Positions in the coordinate system.......................................................................................782
10.5.12 Control system response ....................................................................................................783
10.5.12.1 POWER ON.........................................................................................................................783
10.5.12.2 Mode change.......................................................................................................................783
10.5.12.3 RESET, end of part program ...............................................................................................784
10.5.12.4 Part program start................................................................................................................786
10.5.12.5 Block search.........................................................................................................................787
10.5.12.6 REPOS.................................................................................................................................787
10.6 Workpiece-related actual value system...............................................................................788
10.6.1 Overview..............................................................................................................................788
10.6.2 Use of the workpiece-related actual value system...............................................................788
10.6.3 Special reactions..................................................................................................................790
10.7 Restrictions..........................................................................................................................792
10.8 Examples.............................................................................................................................792
10.8.1 Axes.....................................................................................................................................792
10.8.2 Coordinate systems.............................................................................................................794
10.8.3 Frames ...............................................................................................................................796
10.9 Data lists..............................................................................................................................798
10.9.1 Machine data........................................................................................................................798
10.9.1.1 Displaying machine data......................................................................................................798
10.9.1.2 NC-specific machine data....................................................................................................798
10.9.1.3 Channel-specific machine data............................................................................................799
10.9.1.4 Axis/spindlespecific machine data.......................................................................................800
10.9.2 Setting data..........................................................................................................................800
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10.9.2.1 Channelspecific setting data................................................................................................800
10.9.3 System variables..................................................................................................................800
10.9.4 Signals.................................................................................................................................802
10.9.4.1 Signals from channel............................................................................................................802
10.9.4.2 Signals to axis/spindle..........................................................................................................802
10.9.4.3 Signals from axis/spindle.....................................................................................................802
11 N2: Emergency stop.................................................................................................................................803
11.1 Brief Description...................................................................................................................803
11.2 Relevant standards..............................................................................................................803
11.3 Emergency stop control elements........................................................................................804
11.4 Emergency stop sequence...................................................................................................805
11.5 Emergency stop acknowledgement.....................................................................................806
11.6 Data lists..............................................................................................................................808
11.6.1 Machine data........................................................................................................................808
11.6.1.1 Axis/spindlespecific machine data.......................................................................................808
11.6.2 Signals.................................................................................................................................809
11.6.2.1 Signals to NC.......................................................................................................................809
11.6.2.2 Signals from NC...................................................................................................................809
11.6.2.3 Signals to BAG.....................................................................................................................809
12 P1: Transverse axes.................................................................................................................................811
12.1 Function...............................................................................................................................811
12.2 Parameterization..................................................................................................................814
12.3 Programming........................................................................................................................817
12.4 Supplementary conditions....................................................................................................818
12.5 Examples.............................................................................................................................819
12.6 Data lists..............................................................................................................................820
12.6.1 Machine data........................................................................................................................820
12.6.1.1 Channelspecific machine data.............................................................................................820
12.6.1.2 Axis/spindlespecific machine data.......................................................................................820
13 P3: Basic PLC program for SINUMERIK 840D sl.....................................................................................821
13.1 Brief description...................................................................................................................821
13.2 Key data of the PLC CPU....................................................................................................823
13.3 PLC operating system version.............................................................................................824
13.4 PLC mode selector...............................................................................................................824
13.5 Reserve resources (timers, counters, FC, FB, DB, I/O).......................................................825
13.6 Commissioning hardware configuration of the PLC CPU....................................................825
13.7 Starting up the PLC program...............................................................................................825
13.7.1 Installation of the basic program..........................................................................................825
13.7.2 Application of the basic program..........................................................................................826
13.7.3 Version codes......................................................................................................................827
13.7.4 Machine program.................................................................................................................827
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