SINUMERIKSINUMERIK 840D sl / 828DBasic FunctionsFunction ManualValidfor ControlsystemSINUMERIK840Dsl/840DEslSINUMERIK828D Software Version CNCsoftware 2.702/20116FC5397-0BP40-0BA0PrefaceA2: Various NC/PLC interface signals and functions1A3: Axis Monitoring, Protection Zones2B1: Continuouspath Mode, Exact Stop, LookAhead3B2: Acceleration4D1: Diagnostics tools5F1: Travel to fixed stop6G2: Velocities, setpoint / actual value systems, closed-loop control7H2: Auxiliary function outputs to PLC8K1: Mode group, channel, program operation, reset response9K2: Axis Types, Coordinate Systems, Frames10N2: Emergency stop11P1: Transverse axes12P3: Basic PLC Program for SINUMERIK 840D sl13P4: PLC for SINUMERIK 828D14R1: Reference point approach15S1: Spindles16V1: Feedrates17W1: Tool offset18Z1: NC/PLC interface signals19AppendixALegal information- Warning notice systemLegal informationWarning notice systemThis 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.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 PersonnelThe product/system described in this documentation may be operated only by personnel qualified for the specific task in accordance with the relevant documentation for the specific task, 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 productsNote the following:TrademarksAll names identified by are registered trademarks of the SiemensAG. 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 LiabilityWe 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.DANGERindicates that death or severe personal injury will result if proper precautions are not taken.WARNINGindicates that death or severe personal injury may result if proper precautions are not taken.CAUTIONwith a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken.CAUTIONwithout a safety alert symbol, indicates that property damage can result if proper precautions are not taken.NOTICEindicates that an unintended result or situation can occur if the corresponding information is not taken into account.WARNINGSiemens 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 adhered to. The information in the relevant documentation must be observed.Siemens AGIndustry SectorPostfach 48 4890026 NRNBERGGERMANYorder number:6FC5397-0BP40-0BA0 02.2011Copyright SiemensAG2011.Technical data subject to changeBasic FunctionsFunction Manual 02/2011, 6FC5397-0BP40-0BA0 3PrefaceSINUMERIK documentationThe SINUMERIK documentation is organized in the following categories: General documentation User documentation Manufacturer/service documentationAdditional informationYou 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: docu.motioncontrol@siemens.comMy 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/sinutrainSinuTrain - training software for SINUMERIKFAQsYou can find Frequently Asked Questions in the Service&Support pages under Product Support. http://support.automation.siemens.comPreface Basic Functions4 Function Manual, 02/2011, 6FC5397-0BP40-0BA0SINUMERIKYou can find information on SINUMERIK under the following link: www.siemens.com/sinumerikTarget groupThis publication is intended for: Project engineers Technologists (from machine manufacturers) System startup engineers (Systems/Machines) ProgrammersBenefitsThe 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 versionThis 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 contentsInstallationStructure 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 FunctionsFunction Manual, 02/2011, 6FC5397-0BP40-0BA0 5 Appendix with:- List of abbreviations- Overview Index of termsNotation of system dataThe following notation is applicable for system data in this documentation:NoteFor detailed descriptions of data and alarm see: machine and setting data:Detailed description of machine data (only electronically on DOConCD or DOConWEB) NC/PLC interface signals:Function Manual Basic Functions; NC/PLC Interface Signals (Z1)Function Manual Basic Functions; NC/PLC Interface Signals (Z2)Function Manual Special Functions; NC/PLC Interface Signals (Z3) alarms:Diagnostics ManualSignal/Data Notation ExampleNC/PLC interface signals... NC/PLC interface signal: ()When the new gear step is engaged, the following NC/PLC interface signals are set by the PLC program:DB31, ... DBX16.0-2 (actual gear stage A to C)DB31, ... DBX16.3 (gear is changed)Machine data ... machine data: ()Master spindle is the spindle stored in the machine data:MD20090 $MC_SPIND_DEF_MASTER_SPIND (Position of deletion of the master spindle in the channel).Setting Data ... Setting data: ()The logical master spindle is contained in the setting data:SD42800 $SC_SPIND_ASSIGN_TAB[0] (Spindle number converter)NoteSignal addressThe description of functions include as 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 Basic Functions6 Function Manual, 02/2011, 6FC5397-0BP40-0BA0Quantity 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 typesThe following elementary data types are used in the control system:SINUMERIK 828D system performance (region) Type Meaning Value rangeINT Signed integers -2147483648 ... +2147483647REAL Figures with decimal point acc. to IEEE(2,2*10-308 1,8*10+308)BOOL Truth values TRUE (1) and FALSE (0) 1, 0CHAR ASCII characters Corresponding to code 0 to 255STRING Character string, number of characters in [...] Maximum of 200 characters (no special characters)AXIS Axis names only All axis identifiers in the channelFRAME Geometrical parameters for moving, rotating, scaling, and mirroringArrays can only be formed from similar elementary data types. Up to 3-dimensional arrays are possible.PPU240.2 / 241.2 PPU 260.2 / 261.2 PPU 280.2 / 281.2BASIC T BASIC M T M T MSystem performanceBasic quantity of axes/spindles 3 4 3 4 3 4Max. number of axes/spindles 5 5 6 6 8 6Max. number of interpolating axes 4 4 4 4 4 4Max. number: Channels / mode groups 1/1 1/1 1/1 1/1 1/1 1/1Min. block change time 9ms 9ms 6ms 6ms 6ms 3msSpeed/current control cycle 125s 125s 125s 125s 125s 125sCNC user memory (buffered) 1 MB 1 MB 3MB 3MB 5MB 5MBCNC functionsTool Management Number of tools/cutting edges 80/160 80/160 128/256 128/256 256/512 256/512Max. number of ASUBs (permanently set)2 2 2 2 2 2TRANSMIT / TRACYL Preface Basic FunctionsFunction Manual, 02/2011, 6FC5397-0BP40-0BA0 7Inclined Y axis - - - - -Synchronous spindle for counterspindle - - - - -Synchronous spindle for polygon machining - - -Gantry Temperature compensation Drive functionsSafety Integrated: Safe Torque Off, Safe Brake Control Safety Integrated: Safe velocity HMI, CNC programmingShopMill/ShopTurn HMI functions DIN/ISO programming with programGUIDE Online ISO dialect interpreter ShopMill/ShopTurn machining step programming Measuring cycles Simulation in surface display Simulation in 3D display PLCSIMATIC S7-200 (integrated) Basic I/O modules:PP 72/48D PNPP 72/48D 2/2A PN (being prepared) PLC cycle time 9ms 9ms 6ms 6ms 6ms 6msMax. number of PLC operations 24000 24000 24000 24000 24000 24000Servo-synchronous high-speed PLC task Reaction time to process interrupts (terminal to terminal)7.5ms 7.5ms 7.5ms 7.5ms 4.5ms 4.5msMax. number of digital inputs/outputs 216/144 216/144 288/192 288/192 360/240 360/240Max. number of analog inputs/outputs 6/6 6/6 8/8 8/8 10/10 10/10Commissioning functionsService Planner (maintenance scheduler) Easy Extend (for managing machine units) Easy Archive (data archiving) PPU240.2 / 241.2 PPU 260.2 / 261.2 PPU 280.2 / 281.2BASIC T BASIC M T M T MPreface Basic Functions8 Function Manual, 02/2011, 6FC5397-0BP40-0BA0T TurningM Milling Standard (basic scope) Option- Not availableBasic FunctionsFunction Manual 02/2011, 6FC5397-0BP40-0BA0 9Table of contentsPreface.........................................................................................................................................................31 A2: Various NC/PLC interface signals and functions ................................................................................351.1 Brief description......................................................................................................................... 351.2 NC/PLC interface signals .......................................................................................................... 361.2.1 General ...................................................................................................................................... 361.2.2 Ready signal to PLC .................................................................................................................. 381.2.3 Status signals to PLC ................................................................................................................ 381.2.4 Signals to/from panel front ......................................................................................................... 391.2.5 Signals to channel ..................................................................................................................... 411.2.6 Signals to axis/spindle ............................................................................................................... 411.2.7 Signals from axis/spindle ........................................................................................................... 501.2.8 Signals to axis/spindle (digital drives) ........................................................................................ 511.2.9 Signals from axis/spindle (digital drives) ................................................................................... 531.3 Functions................................................................................................................................... 551.3.1 Screen settings .......................................................................................................................... 551.3.2 Settings for involute interpolation - only 840D sl ....................................................................... 561.3.3 Activate DEFAULT memory ...................................................................................................... 591.3.4 Read/write PLC variable ............................................................................................................ 591.3.5 Access protection via password and keyswitch ......................................................................... 631.3.5.1 Access protection via password and keyswitch ......................................................................... 631.3.5.2 Password ................................................................................................................................... 641.3.5.3 Keyswitch settings (DB10, DBX56.4 to 7) ................................................................................. 651.3.5.4 Parameterizable protection levels ............................................................................................. 661.4 Examples................................................................................................................................... 671.5 Data lists.................................................................................................................................... 691.5.1 Machine data ............................................................................................................................. 691.5.1.1 Display machine data ................................................................................................................ 691.5.1.2 NC-specific machine data .......................................................................................................... 701.5.1.3 Channelspecific machine data ................................................................................................. 701.5.1.4 Axis/spindlespecific machine data ............................................................................................ 711.5.2 System variables ....................................................................................................................... 721.5.3 Signals ....................................................................................................................................... 721.5.3.1 Signals to NC ............................................................................................................................. 721.5.3.2 Signals from NC ........................................................................................................................ 721.5.3.3 Signals to operator panel front .................................................................................................. 731.5.3.4 Signals from operator panel front .............................................................................................. 731.5.3.5 Signals to channel ..................................................................................................................... 731.5.3.6 Signals from channel ................................................................................................................. 741.5.3.7 Signals to axis/spindle ............................................................................................................... 741.5.3.8 Signals from axis/spindle ........................................................................................................... 742 A3: Axis Monitoring, Protection Zones ......................................................................................................772.1 Brief Description ........................................................................................................................ 772.1.1 Axis monitoring functions ........................................................................................................... 77Table of contentsBasic Functions10 Function Manual, 02/2011, 6FC5397-0BP40-0BA02.1.2 Protection zones ........................................................................................................................ 772.2 Axis monitoring.......................................................................................................................... 782.2.1 Contour monitoring .................................................................................................................... 782.2.1.1 Contour error ............................................................................................................................. 782.2.1.2 Following Error Monitoring ......................................................................................................... 782.2.2 Positioning, zero speed and clamping monitoring ..................................................................... 812.2.2.1 Correlation between positioning, zero-speed and clamping monitoring .................................... 812.2.2.2 Positioning monitoring ............................................................................................................... 812.2.2.3 Zero speed monitoring ............................................................................................................... 832.2.2.4 Exact stop and standstill tolerance dependent on the parameter set ........................................ 842.2.2.5 Clamping monitoring .................................................................................................................. 842.2.3 Speed-setpoint monitoring ......................................................................................................... 912.2.4 Actual velocity monitoring .......................................................................................................... 932.2.5 Measuring-system monitoring (systems with PROFIBUS drives) .............................................. 942.2.6 Limit switches-monitoring .......................................................................................................... 952.2.6.1 Hardware limit switches ............................................................................................................. 952.2.6.2 Software limit switch .................................................................................................................. 962.2.7 Monitoring of the working area limitation ................................................................................... 982.2.7.1 General ...................................................................................................................................... 982.2.7.2 Working area limitation in BKS ................................................................................................ 1002.2.7.3 Working area limitation in WKS/ENS ....................................................................................... 1022.2.8 Deactivating all monitoring functions: "Parking" ...................................................................... 1062.3 Protection zones...................................................................................................................... 1072.3.1 General .................................................................................................................................... 1072.3.2 Types of protection zone ......................................................................................................... 1082.3.3 Definition via part program instruction ..................................................................................... 1112.3.4 Definition via system variable .................................................................................................. 1142.3.5 Activation and deactivation of protection zones ....................................................................... 1162.3.6 Protection-zone violation and temporary enabling of individual protection zones ................... 1202.3.7 Restrictions in protection zones ............................................................................................... 1252.4 Supplementary conditions ....................................................................................................... 1272.4.1 Axis monitoring functions ......................................................................................................... 1272.5 Examples................................................................................................................................. 1282.5.1 Axis monitoring ........................................................................................................................ 1282.5.1.1 Working area limitation in WKS/ENS ....................................................................................... 1282.5.2 Protection zones ...................................................................................................................... 1302.5.2.1 Definition and activation of protection zones ........................................................................... 1302.6 Data lists.................................................................................................................................. 1412.6.1 Machine data ........................................................................................................................... 1412.6.1.1 NC-specific machine data ........................................................................................................ 1412.6.1.2 Channelspecific machine data ................................................................................................ 1412.6.1.3 Axis/spindlespecific machine data .......................................................................................... 1422.6.2 Setting data ............................................................................................................................. 1432.6.2.1 Axis/spindlespecific setting data ............................................................................................. 1432.6.3 Signals ..................................................................................................................................... 1442.6.3.1 Signals to channel ................................................................................................................... 1442.6.3.2 Signals from channel ............................................................................................................... 1442.6.3.3 Signals to axis/spindle ............................................................................................................. 145Basic FunctionsFunction Manual, 02/2011, 6FC5397-0BP40-0BA0 11Table of contents3 B1: Continuouspath Mode, Exact Stop, LookAhead ..............................................................................1473.1 Brief Description ...................................................................................................................... 1473.2 Exact stop mode...................................................................................................................... 1503.3 Continuous-path mode ............................................................................................................ 1543.3.1 General functionality ................................................................................................................ 1543.3.2 Velocity reduction according to overload factor ....................................................................... 1563.3.3 Blending ................................................................................................................................... 1583.3.3.1 Rounding according to a path criterion (G641) ........................................................................ 1613.3.3.2 Rounding in compliance with defined tolerances (G642/G643) .............................................. 1633.3.3.3 Rounding with maximum possible axial dynamic response (G644) ........................................ 1663.3.3.4 Rounding of tangential block transitions (G645) ...................................................................... 1693.3.4 LookAhead .............................................................................................................................. 1713.3.4.1 Standard functionality .............................................................................................................. 1713.3.4.2 Free-form surface mode: Extension function ........................................................................... 1763.4 Dynamic adaptations............................................................................................................... 1803.4.1 Smoothing the path velocity .................................................................................................... 1803.4.2 Adaptation of the dynamic path response ............................................................................... 1833.4.3 Determination of the dynamic response limiting values .......................................................... 1873.4.4 Interaction between the "smoothing of the path velocity" and "adaptation of the path dynamic response" functions ................................................................................................................. 1883.4.5 Dynamic response mode for path interpolation ....................................................................... 1913.4.6 Free-form surface mode: Basic functions ................................................................................ 1933.5 Compressor functions.............................................................................................................. 1973.5.1 NC block compression ............................................................................................................. 1973.5.2 Combining short spline blocks (option for 828D) ..................................................................... 2013.6 Contour/Orientation tolerance ................................................................................................. 2033.7 Tolerance and compression of G0 blocks ............................................................................... 2063.8 RESET response..................................................................................................................... 2093.9 Supplementary conditions ....................................................................................................... 2103.9.1 Block change and positioning axes ......................................................................................... 2103.9.2 Block change delay ................................................................................................................. 2103.9.3 Rounding and repositioning (REPOS) ..................................................................................... 2103.10 Data lists.................................................................................................................................. 2123.10.1 Machine data ........................................................................................................................... 2123.10.1.1 General machine data ............................................................................................................. 2123.10.1.2 Channelspecific machine data ............................................................................................... 2123.10.1.3 Axis/spindlespecific machine data .......................................................................................... 2133.10.2 Setting data ............................................................................................................................. 2133.10.2.1 Channelspecific setting data .................................................................................................. 2133.10.3 Signals ..................................................................................................................................... 2143.10.3.1 Signals from channel ............................................................................................................... 2143.10.3.2 Signals from axis/spindle ......................................................................................................... 2144 B2: Acceleration ......................................................................................................................................2154.1 Brief description....................................................................................................................... 2154.1.1 General .................................................................................................................................... 2154.1.2 Features .................................................................................................................................. 215Table of contentsBasic Functions12 Function Manual, 02/2011, 6FC5397-0BP40-0BA04.2 Functions ................................................................................................................................. 2174.2.1 Acceleration and jerk for positioning motion to fixed points ..................................................... 2174.2.1.1 General Information ................................................................................................................. 2174.2.1.2 Parameterization ...................................................................................................................... 2174.2.2 Acceleration without jerk limitation (BRISK/BRISKA) (channel-/axis-specific) ........................ 2184.2.2.1 General Information ................................................................................................................. 2184.2.2.2 Programmable maximum value (axis-specific) ........................................................................ 2194.2.2.3 Parameterization ...................................................................................................................... 2194.2.2.4 Programming ........................................................................................................................... 2204.2.3 Constant travel time (channel-specific) .................................................................................... 2214.2.3.1 General Information ................................................................................................................. 2214.2.3.2 Parameterization ...................................................................................................................... 2224.2.4 Acceleration matching (ACC) (axis-specific) ........................................................................... 2234.2.4.1 General Information ................................................................................................................. 2234.2.4.2 Programming ........................................................................................................................... 2234.2.5 Acceleration margin (channel-specific) .................................................................................... 2244.2.5.1 General Information ................................................................................................................. 2244.2.5.2 Parameterization ...................................................................................................................... 2244.2.6 Path-acceleration limitation (channel-specific) ........................................................................ 2244.2.6.1 General Information ................................................................................................................. 2244.2.6.2 Parameterization ...................................................................................................................... 2244.2.6.3 Programming ........................................................................................................................... 2254.2.7 Path acceleration for real-time events (channel-specific) ........................................................ 2264.2.7.1 General Information ................................................................................................................. 2264.2.7.2 Programming ........................................................................................................................... 2274.2.8 Acceleration with programmed rapid traverse (G00) (axis-specific) ........................................ 2284.2.8.1 General Information ................................................................................................................. 2284.2.8.2 Parameterization ...................................................................................................................... 2284.2.9 Acceleration with active jerk limitation (SOFT/SOFTA) (axis-specific) .................................... 2294.2.9.1 General Information ................................................................................................................. 2294.2.9.2 Parameterization ...................................................................................................................... 2294.2.10 Excessive acceleration for non-tangential block transitions (axis-specific) ............................. 2294.2.10.1 General Information ................................................................................................................. 2294.2.10.2 Parameterization ...................................................................................................................... 2304.2.11 Acceleration margin for radial acceleration (channel-specific) ................................................ 2304.2.11.1 General Information ................................................................................................................. 2304.2.11.2 Parameterization ...................................................................................................................... 2314.2.12 Jerk limitation with path interpolation (SOFT) (channel-specific) ............................................. 2324.2.12.1 General Information ................................................................................................................. 2324.2.12.2 Maximum jerk value (axis-specific) .......................................................................................... 2344.2.12.3 Maximum jerk value (channel-specific) .................................................................................... 2344.2.12.4 Parameterization ...................................................................................................................... 2344.2.12.5 Programming ........................................................................................................................... 2344.2.13 Jerk limitation with single-axis interpolation (SOFTA) (axis-specific) ...................................... 2354.2.13.1 General Information ................................................................................................................. 2354.2.13.2 Parameterization ...................................................................................................................... 2354.2.13.3 Programming ........................................................................................................................... 2364.2.14 Path-jerk limitation (channel-specific) ...................................................................................... 2364.2.14.1 General Information ................................................................................................................. 2364.2.14.2 Parameterization ...................................................................................................................... 2374.2.14.3 Programming ........................................................................................................................... 2374.2.15 Path jerk for real-time events (channel-specific) ...................................................................... 238Basic FunctionsFunction Manual, 02/2011, 6FC5397-0BP40-0BA0 13Table of contents4.2.15.1 General Information ................................................................................................................. 2384.2.15.2 Programming ........................................................................................................................... 2394.2.16 Jerk with programmed rapid traverse (G00) (axis-specific) ..................................................... 2404.2.16.1 General Information ................................................................................................................. 2404.2.16.2 Parameterization ..................................................................................................................... 2404.2.17 Excessive jerk for block transitions without constant curvature (axis-specific) ........................ 2404.2.17.1 General Information ................................................................................................................. 2404.2.17.2 Parameterization ..................................................................................................................... 2414.2.18 Velocity-dependent jerk adaptation (axisspecific) .................................................................. 2414.2.19 Jerk filter (axis-specific) ........................................................................................................... 2434.2.19.1 General Information ................................................................................................................. 2434.2.19.2 Parameterization ..................................................................................................................... 2464.2.20 Kneeshaped acceleration characteristic curve ....................................................................... 2474.2.20.1 Adaptation to the motor characteristic curve ........................................................................... 2474.2.20.2 Effects on path acceleration .................................................................................................... 2494.2.20.3 Substitute characteristic curve ................................................................................................. 2494.2.20.4 Parameterization ..................................................................................................................... 2524.2.20.5 Programming ........................................................................................................................... 2534.2.20.6 Boundary conditions ................................................................................................................ 2544.3 Examples................................................................................................................................. 2564.3.1 Acceleration ............................................................................................................................. 2564.3.1.1 Path velocity characteristic ...................................................................................................... 2564.3.2 Jerk .......................................................................................................................................... 2584.3.2.1 Path velocity characteristic ...................................................................................................... 2584.3.3 Acceleration and jerk ............................................................................................................... 2594.3.4 Kneeshaped acceleration characteristic curve ....................................................................... 2614.3.4.1 Activation ................................................................................................................................. 2614.4 Data lists.................................................................................................................................. 2634.4.1 Machine data ........................................................................................................................... 2634.4.1.1 Channelspecific machine data ............................................................................................... 2634.4.1.2 Axis/spindlespecific machine data .......................................................................................... 2634.4.2 Setting data ............................................................................................................................. 2644.4.2.1 Channelspecific setting data .................................................................................................. 2644.4.3 System variables ..................................................................................................................... 2645 D1: Diagnostics tools ..............................................................................................................................2655.1 Brief description....................................................................................................................... 2655.2 Description of diagnostic tools................................................................................................. 2665.3 Service overview ..................................................................................................................... 2695.3.1 Axis/spindle service display ..................................................................................................... 2695.3.2 Drive service display (for digital drives only) ........................................................................... 2765.3.3 Service display PROFIBUS DP 840Di ..................................................................................... 2875.4 Communication log.................................................................................................................. 2915.5 PLC status............................................................................................................................... 2925.6 Identifying defective drive modules ......................................................................................... 2935.7 Data lists.................................................................................................................................. 2965.7.1 Machine data ........................................................................................................................... 2965.7.1.1 Drive-specific machine data .................................................................................................... 296Table of contentsBasic Functions14 Function Manual, 02/2011, 6FC5397-0BP40-0BA05.7.1.2 NC-specific machine data ........................................................................................................ 2965.7.1.3 Axis/spindlespecific machine data .......................................................................................... 2975.7.2 Setting data ............................................................................................................................. 2975.7.2.1 Axis/spindle-specific setting data ............................................................................................ 2975.7.3 Signals ..................................................................................................................................... 2975.7.3.1 Signals to axis/spindle ............................................................................................................. 2975.7.3.2 Signals from axis/spindle ......................................................................................................... 2976 F1: Travel to fixed stop ............................................................................................................................2996.1 Product brief ............................................................................................................................ 2996.2 General functionality................................................................................................................ 3006.2.1 Functional sequence, programming, parameterization ............................................................ 3006.2.2 Response to RESET and function abort .................................................................................. 3076.2.3 Block search response ............................................................................................................ 3086.2.4 Miscellaneous .......................................................................................................................... 3126.2.5 Supplementary conditions for expansions ............................................................................... 3156.2.6 Travel with limited torque/force FOC (option for 828D) ........................................................... 3176.3 Travel to fixed stop .................................................................................................................. 3206.4 Examples................................................................................................................................. 3246.5 Data lists.................................................................................................................................. 3266.5.1 Machine data ........................................................................................................................... 3266.5.1.1 Axis/spindlespecific machine data .......................................................................................... 3266.5.2 Setting data ............................................................................................................................. 3266.5.2.1 Axis/spindle-specific setting data ............................................................................................. 3266.5.3 Signals ..................................................................................................................................... 3266.5.3.1 Signals to axis/spindle ............................................................................................................. 3266.5.3.2 Signals from axis/spindle ......................................................................................................... 3277 G2: Velocities, setpoint / actual value systems, closed-loop control ..................................................................................................................................3297.1 Brief description....................................................................................................................... 3297.2 Velocities, traversing ranges, accuracies ................................................................................ 3307.2.1 Velocities ................................................................................................................................. 3307.2.2 Traversing ranges .................................................................................................................... 3327.2.3 Positioning accuracy of the control system .............................................................................. 3337.2.4 Block diagram of resolutions and scaling values ..................................................................... 3337.2.5 Input/display resolution, computational resolution ................................................................... 3357.2.6 Scaling of physical quantities of machine and setting data ..................................................... 3367.3 Metric/inch measuring system................................................................................................. 3407.3.1 Conversion of basic system by parts program ......................................................................... 3407.3.2 Manual switchover of the basic system ................................................................................... 3447.3.3 FGROUP and FGREF ............................................................................................................. 3497.4 Setpoint/actual-value system................................................................................................... 3537.4.1 General .................................................................................................................................... 3537.4.2 Setpoint and encoder assignment ........................................................................................... 3567.4.3 Adapting the motor/load ratios ................................................................................................. 3597.4.4 Speed setpoint output .............................................................................................................. 3617.4.5 Actual-value processing ........................................................................................................... 3637.4.6 Adjustments to actual-value resolution .................................................................................... 366Basic FunctionsFunction Manual, 02/2011, 6FC5397-0BP40-0BA0 15Table of contents7.5 Closed-loop control.................................................................................................................. 3747.5.1 General .................................................................................................................................... 3747.5.2 Parameter sets of the position controller ................................................................................. 3777.6 Optimization of the control ....................................................................................................... 3807.6.1 Position controller, position setpoint filter: Balancing filter ....................................................... 3807.6.2 Position controller, position setpoint filter: Jerk filter ................................................................ 3837.6.3 Position control with proportional-plus-integral-action controller ............................................. 3867.7 Data lists.................................................................................................................................. 3887.7.1 Machine data ........................................................................................................................... 3887.7.1.1 Displaying machine data ......................................................................................................... 3887.7.1.2 NC-specific machine data ........................................................................................................ 3887.7.1.3 Channelspecific machine data ............................................................................................... 3887.7.1.4 Axis/spindlespecific machine data .......................................................................................... 3898 H2: Auxiliary function outputs to PLC ......................................................................................................3918.1 Brief description....................................................................................................................... 3918.1.1 Function ................................................................................................................................... 3918.1.2 Definition of an auxiliary function ............................................................................................. 3928.1.3 Overview of auxiliary functions ................................................................................................ 3938.2 Predefined auxiliary functions.................................................................................................. 4008.2.1 Overview: Predefined auxiliary functions ................................................................................. 4008.2.2 Overview: Output behavior ...................................................................................................... 4128.2.3 Parameter assignment ............................................................................................................ 4158.2.3.1 Group assignment ................................................................................................................... 4158.2.3.2 Type, address extension and value ......................................................................................... 4168.2.3.3 Output behavior ....................................................................................................................... 4178.3 Userdefined auxiliary functions .............................................................................................. 4228.3.1 Parameter assignment ............................................................................................................ 4238.3.1.1 Maximum number of user-defined auxiliary functions ............................................................. 4238.3.1.2 Group assignment ................................................................................................................... 4238.3.1.3 Type, address extension and value ......................................................................................... 4248.3.1.4 Output behavior ....................................................................................................................... 4258.4 Associated auxiliary functions ................................................................................................. 4268.5 Type-specific output behavior.................................................................................................. 4288.6 Priorities of the output behavior for which parameters have been assigned........................... 4308.7 Programming an auxiliary function .......................................................................................... 4318.8 Programmable output duration................................................................................................ 4338.9 Auxiliary function output to the PLC ........................................................................................ 4358.10 Auxiliary functions without block change delay ....................................................................... 4368.11 M function with an implicit preprocessing stop ........................................................................ 4378.12 Response to overstore ............................................................................................................ 4388.13 Block-search response............................................................................................................ 4398.13.1 Auxiliary function output during type 1, 2, and 4 block searches ............................................. 4398.13.2 Assignment of an auxiliary function to a number of groups ..................................................... 4408.13.3 Time stamp of the active M auxiliary function .......................................................................... 442Table of contentsBasic Functions16 Function Manual, 02/2011, 6FC5397-0BP40-0BA08.13.4 Determining the output sequence ............................................................................................ 4428.13.5 Output suppression of spindle-specific auxiliary functions ...................................................... 4448.13.6 Auxiliary function output with a type 5 block search (SERUPRO) ........................................... 4478.13.7 ASUB at the end of the SERUPRO ......................................................................................... 4528.14 Implicitly output auxiliary functions .......................................................................................... 4598.15 Information options .................................................................................................................. 4608.15.1 Group-specific modal M auxiliary function display ................................................................... 4608.15.2 Querying system variables ...................................................................................................... 4618.16 Supplementary conditions ....................................................................................................... 4648.16.1 General constraints .................................................................................................................. 4648.16.2 Output behavior ....................................................................................................................... 4658.17 Examples................................................................................................................................. 4678.17.1 Extension of predefined auxiliary functions ............................................................................. 4678.17.2 Defining auxiliary functions ...................................................................................................... 4698.18 Data lists.................................................................................................................................. 4738.18.1 Machine data ........................................................................................................................... 4738.18.1.1 NC-specific machine data ........................................................................................................ 4738.18.1.2 Channelspecific machine data ................................................................................................ 4738.18.2 Signals ..................................................................................................................................... 4748.18.2.1 Signals to channel ................................................................................................................... 4748.18.2.2 Signals from channel ............................................................................................................... 4748.18.2.3 Signals to axis/spindle ............................................................................................................. 4768.18.2.4 Signals from axis/spindle ......................................................................................................... 4769 K1: Mode group, channel, program operation, reset response ...............................................................4779.1 Product brief ............................................................................................................................ 4779.2 Mode group (MG) .................................................................................................................... 4809.2.1 Mode group Stop ..................................................................................................................... 4829.2.2 Mode group RESET ................................................................................................................. 4839.3 Mode types and mode type change......................................................................................... 4849.3.1 Monitoring functions and interlocks of the individual modes .................................................... 4909.3.2 Mode change ........................................................................................................................... 4909.4 Channel ................................................................................................................................... 4929.4.1 Global start disable for channel ............................................................................................... 4959.5 Program test ............................................................................................................................ 4969.5.1 Program execution without setpoint outputs ............................................................................ 4969.5.2 Program execution in singleblock mode ................................................................................. 4989.5.3 Program execution with dry run feedrate ................................................................................. 5009.5.4 Skip part-program blocks ......................................................................................................... 5019.6 Workpiece simulation............................................................................................................... 5039.7 Block search ............................................................................................................................ 5049.7.1 Sequence for block search of Type 1, 2 and 4 ........................................................................ 5059.7.2 Block search in connection with other NCK functions ............................................................. 5079.7.2.1 ASUB after and during block search ........................................................................................ 5079.7.2.2 PLC actions after block search ................................................................................................ 5089.7.2.3 Spindle functions after block search ........................................................................................ 5099.7.2.4 Reading system variables for a block search .......................................................................... 510Basic FunctionsFunction Manual, 02/2011, 6FC5397-0BP40-0BA0 17Table of contents9.7.3 Automatic start of an ASUB after a block search .................................................................... 5109.7.4 Cascaded block search ........................................................................................................... 5129.7.5 Examples of block search with calculation .............................................................................. 5149.8 Block search Type 5 SERUPRO............................................................................................. 5189.8.1 REPOS .................................................................................................................................... 5249.8.1.1 Continue machining after SERUPRO search target found ...................................................... 5259.8.1.2 Repositioning on contour with controlled REPOS ................................................................... 5349.8.2 Acceleration measures via MD ................................................................................................ 5379.8.3 SERUPRO ASUP .................................................................................................................... 5389.8.4 Selfacting SERUPRO ............................................................................................................. 5419.8.5 Inhibit specific part of the program in the part program for SERUPRO ................................... 5429.8.6 Special features in the part-program target block .................................................................... 5469.8.6.1 STOPRE in the part-program target block ............................................................................... 5469.8.6.2 SPOS in target block ............................................................................................................... 5479.8.7 Behavior during POWER ON, mode change and RESET ....................................................... 5479.8.8 Special features of functions supported during SERUPRO ..................................................... 5489.8.8.1 Travel to fixed stop (FXS) ........................................................................................................ 5489.8.8.2 Force Control (FOC) ................................................................................................................ 5499.8.8.3 Synchronous spindle ............................................................................................................... 5499.8.8.4 Couplings and master-slave .................................................................................................... 5509.8.8.5 Axis functions .......................................................................................................................... 5539.8.8.6 Gear stage change .................................................................................................................. 5549.8.8.7 Superimposed motion .............................................................................................................. 5549.8.8.8 REPOS offset in the interface .................................................................................................. 5559.8.8.9 Making the initial settings more flexible ................................................................................... 5559.8.9 System variables and variables for SERUPRO sequence ...................................................... 5569.8.10 Restrictions .............................................................................................................................. 5579.9 Program operation mode......................................................................................................... 5589.9.1 Initial settings ........................................................................................................................... 5589.9.2 Selection and start of part program or part-program block ...................................................... 5619.9.3 Part-program interruption ........................................................................................................ 5639.9.4 RESET command .................................................................................................................... 5649.9.5 Program status ........................................................................................................................ 5659.9.6 Channel status ......................................................................................................................... 5669.9.7 Responses to operator or program actions ............................................................................. 5679.9.8 Part-Program Start .................................................................................................................. 5689.9.9 Example of timing diagram for a program run ......................................................................... 5699.9.10 Program jumps ........................................................................................................................ 5709.9.10.1 Jump back to start of program ................................................................................................. 5709.9.11 Program section repetitions ..................................................................................................... 5729.9.11.1 Overview .................................................................................................................................. 5729.9.11.2 Individual part program block .................................................................................................. 5729.9.11.3 A part program section after a start label ................................................................................ 5739.9.11.4 A part program section between a start label and end label ................................................... 5749.9.11.5 A part program section between a Start label and the key word: ENDLABEL ........................ 5759.9.12 Eventdriven program calls ...................................................................................................... 5769.9.12.1 Function ................................................................................................................................... 5769.9.12.2 Parameter assignment ............................................................................................................ 5819.9.12.3 Programming ........................................................................................................................... 5859.9.12.4 Boundary conditions ................................................................................................................ 5869.9.12.5 Examples ................................................................................................................................. 586Table of contentsBasic Functions18 Function Manual, 02/2011, 6FC5397-0BP40-0BA09.9.13 Influencing the Stop events through Stop delay area .............................................................. 5889.10 Asynchronous subroutines (ASUBs), interrupt routines .......................................................... 5919.10.1 Function ................................................................................................................................... 5919.10.1.1 General functionality ................................................................................................................ 5919.10.1.2 Sequence of an interrupt routine in program operation ........................................................... 5939.10.1.3 Interrupt routine with REPOSA ................................................................................................ 5949.10.1.4 NC response ............................................................................................................................ 5959.10.2 Parameter assignment ............................................................................................................. 5969.10.3 Programming ........................................................................................................................... 6019.10.4 Restrictions .............................................................................................................................. 6039.10.5 Examples ................................................................................................................................. 6039.11 User-specific ASUB for RET and REPOS............................................................................... 6049.11.1 Function ................................................................................................................................... 6049.11.2 Parameter assignment ............................................................................................................. 6049.11.3 Programming ........................................................................................................................... 6059.12 Single block ............................................................................................................................. 6079.12.1 Decoding single block SBL2 with implicit preprocessing stop ................................................. 6089.12.2 Single block stop: Suppression using SBLOF ......................................................................... 6089.12.3 Single block stop: inhibit according to situation ....................................................................... 6119.12.4 Single-block behavior in mode group with type A/B ................................................................ 6129.13 Program control ....................................................................................................................... 6149.13.1 Function selection (via operator panel front or PLC) ............................................................... 6149.13.2 Activation of skip levels ............................................................................................................ 6159.13.3 Adapting the size of the interpolation buffer ............................................................................ 6169.13.4 Program display modes via an additional basic block display ................................................. 6189.13.5 Basic block display for ShopMill/ShopTurn .............................................................................. 6199.13.6 Structure for a DIN block ......................................................................................................... 6219.13.7 Execution from external ........................................................................................................... 6249.13.8 Execution from external subroutines ....................................................................................... 6259.14 System settings for power-up, RESET/part-program end and part-program start................... 6289.14.1 Tool withdrawal after POWER OFF with orientation transformation ........................................ 6339.15 Replacing functions by subprograms....................................................................................... 6369.15.1 Overview .................................................................................................................................. 6369.15.2 Replacement of M, T/TCA and D/DL functions ........................................................................ 6379.15.2.1 Replacement of M functions .................................................................................................... 6379.15.2.2 Replacing T/TCA and D/DL functions ...................................................................................... 6399.15.2.3 System variable ....................................................................................................................... 6419.15.2.4 Example: Replacement of an M function ................................................................................. 6439.15.2.5 Example: Replacement of a T and D function ......................................................................... 6459.15.2.6 Behavior in the event of a conflict ............................................................................................ 6479.15.3 Replacement of spindle functions ............................................................................................ 6489.15.3.1 General .................................................................................................................................... 6489.15.3.2 Replacement of M40 - M45 (gear stage change) .................................................................... 6509.15.3.3 Replacement of SPOS, SPOSA, M19 (spindle positioning) .................................................... 6519.15.3.4 System variable ....................................................................................................................... 6529.15.3.5 Example: Gear stage change .................................................................................................. 6539.15.3.6 Example: Spindle positioning ................................................................................................... 6559.15.4 Properties of the subprograms ................................................................................................ 6589.15.5 Restrictions .............................................................................................................................. 660Basic FunctionsFunction Manual, 02/2011, 6FC5397-0BP40-0BA0 19Table of contents9.16 Program runtime / Part counter ............................................................................................... 6619.16.1 Program runtime ...................................................................................................................... 6619.16.2 Workpiece counter ................................................................................................................... 6689.17 Data lists.................................................................................................................................. 6739.17.1 Machine data ........................................................................................................................... 6739.17.1.1 General machine data ............................................................................................................. 6739.17.1.2 Channelspecific machine data ............................................................................................... 6749.17.1.3 Axis/spindlespecific machine data .......................................................................................... 6779.17.2 Setting data ............................................................................................................................. 6779.17.2.1 Channelspecific setting data .................................................................................................. 6779.17.3 Signals ..................................................................................................................................... 6789.17.3.1 Signals to NC ........................................................................................................................... 6789.17.3.2 Signals to NC ........................................................................................................................... 6789.17.3.3 Signals to NC ........................................................................................................................... 6789.17.3.4 Signals to NC ........................................................................................................................... 6799.17.3.5 Signals from channel ............................................................................................................... 6799.17.3.6 Signals to NC ........................................................................................................................... 6819.17.3.7 Signals from axis/spindle ......................................................................................................... 68110 K2: Axis Types, Coordinate Systems, Frames ........................................................................................68310.1 Brief description....................................................................................................................... 68310.1.1 Axes ......................................................................................................................................... 68310.1.2 Coordinate systems ................................................................................................................. 68510.1.3 Frames .................................................................................................................................. 68710.2 Axes......................................................................................................................................... 69110.2.1 Overview .................................................................................................................................. 69110.2.2 Machine axes .......................................................................................................................... 69210.2.3 Channel axes ........................................................................................................................... 69310.2.4 Geometry axes ........................................................................................................................ 69310.2.5 Replaceable geometry axes .................................................................................................... 69410.2.6 Special axes ............................................................................................................................ 69810.2.7 Path axes ................................................................................................................................. 69910.2.8 Positioning axes ...................................................................................................................... 69910.2.9 Main axes ................................................................................................................................ 70010.2.10 Synchronized axes .................................................................................................................. 70110.2.11 Axis configuration .................................................................................................................... 70310.2.12 Link axes ................................................................................................................................. 70510.3 Zeros and reference points...................................................................................................... 70610.3.1 Reference points in working space .......................................................................................... 70610.3.2 Position of coordinate systems and reference points .............................................................. 70810.4 Coordinate systems................................................................................................................. 70910.4.1 Overview .................................................................................................................................. 70910.4.2 Machine coordinate system (MCS) ......................................................................................... 71210.4.3 Basic coordinate system (BCS) ............................................................................................... 71310.4.4 Additive offsets ........................................................................................................................ 71510.4.5 Basic zero system (BZS) ......................................................................................................... 71810.4.6 Settable zero system (SZS) ..................................................................................................... 72010.4.7 Workpiece coordinate system (WCS) ...................................................................................... 72110.5 Frames .................................................................................................................................. 72210.5.1 Frame types ............................................................................................................................. 722Table of contentsBasic Functions20 Function Manual, 02/2011, 6FC5397-0BP40-0BA010.5.2 Frame components .................................................................................................................. 72310.5.2.1 Translation ............................................................................................................................... 72310.5.2.2 Fine offset ................................................................................................................................ 72410.5.2.3 Rotations for geometry axes .................................................................................................... 72510.5.2.4 Scaling ..................................................................................................................................... 72910.5.2.5 Mirroring ................................................................................................................................... 72910.5.2.6 Chain operator ......................................................................................................................... 73010.5.2.7 Programmable axis identifiers ................................................................................................. 73010.5.2.8 Coordinate transformation ....................................................................................................... 73110.5.3 Frames in data management and active frames ..................................................................... 73110.5.3.1 Overview .................................................................................................................................. 73110.5.3.2 Activating data management frames ....................................................................................... 73310.5.3.3 NCU global frames .................................................................................................................. 73410.5.4 Frame chain and coordinate systems ...................................................................................... 73510.5.4.1 Overview .................................................................................................................................. 73510.5.4.2 Relative coordinate systems .................................................................................................... 73610.5.4.3 Configurable SZS .................................................................................................................... 73810.5.4.4 Manual traverse in the SZS coordinate system ....................................................................... 73910.5.4.5 Suppression of frames ............................................................................................................. 74010.5.5 Frame chain frames ................................................................................................................. 74210.5.5.1 Overview .................................................................................................................................. 74210.5.5.2 Settable frames $P_UIFR[n] .................................................................................................... 74210.5.5.3 Channel basic frames $P_CHBFR[n] ...................................................................................... 74310.5.5.4 NCU global basic frames $P_NCBFR[n] ................................................................................. 74410.5.5.5 Complete basic frame $P_ACTBFRAME ................................................................................ 74510.5.5.6 Programmable frame $P_PFRAME ......................................................................................... 74610.5.5.7 Channelspecific system frames .............................................................................................. 74810.5.6 Implicit frame changes ............................................................................................................. 75210.5.6.1 Frames and switchover of geometry axes ............................................................................... 75210.5.6.2 Frame for selection and deselection of transformations .......................................................... 75510.5.6.3 Adapting active frames ............................................................................................................ 77110.5.6.4 Mapped Frames ....................................................................................................................... 77210.5.7 Predefined frame functions ...................................................................................................... 77610.5.7.1 Inverse frame ......................................................................................................................