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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