Turning and Milling Error!

Preface Hyperlink

Scope of delivery and

Error! Hyperlink
requirements 1
Introduction and use of data
Error!
classes Hyperlink 2
SINUMERIK
Error! Hyperlink
Operating software settings 3
SINUMERIK 828D
Turning and Milling Error! Hyperlink
Commissioning the I/O 4
Parameterizing machine
Error!
data Hyperlink 5
Commissioning Manual
Error! Hyperlink
Commissioning the drive 6

Error!
OptimizingHyperlink
a drive 7

Error! Hyperlink
Service Planner 8

Error! Hyperlink
Easy Extend 9

Error! Hyperlink
Tool management 10

Error! Hyperlink
Easy Archive 11

Error!
Appendix Hyperlink A

Valid for:

CNC software Version 4.5 SP2

03/2013
6FC5397-3DP40-3BA1
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 Order number: 6FC5397-3DP40-3BA1 Copyright © Siemens AG 2009 - 2013.

Industry Sector Ⓟ 01/2013 Technical data subject to change All rights reserved
Postfach 48 48
90026 NÜRNBERG
GERMANY
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 under the link
(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:
(mailto:docu.motioncontrol@siemens.com)

My Documentation Manager (MDM)

Under the following link you will find information to individually compile OEM-specific
machine documentation based on the Siemens content: MDM (www.siemens.com/mdm)

Training
For information about the range of training courses, refer under:
● SITRAIN (www.siemens.com/sitrain) - training courses from Siemens for automation
products, systems and solutions
● SinuTrain (www.siemens.com/sinutrain) - training software for SINUMERIK

FAQs
You can find Frequently Asked Questions in the Service&Support pages under Product
Support (www.siemens.com/automation/service&support).

SINUMERIK
You can find information on SINUMERIK under the following link:
(www.siemens.com/sinumerik)

Turning and Milling

Commissioning Manual, 03/2013, 6FC5397-3DP40-3BA1 3
Preface

Target group
This documentation is intended for commissioning personnel.
The plant or system is readily assembled and wired. For the following steps, e.g. configuring
the individual components, the Commissioning Manual contains all necessary information or
at least references.

Benefits
The intended target group can use the Commissioning Manual to test and commission the
system or the plant correctly and safely.
Utilization phase: Setup and commissioning phase

Standard version
This documentation only describes the functionality of the standard version. Extensions or
changes made by the machine manufacturer are documented by the machine 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
Country-specific telephone numbers for technical support are provided in the Internet under
"Contact" (www.siemens.com/automation/service&support).

EC Declaration of Conformity
The EC declaration of conformity for the EMC directive can be found in the Internet
(www.siemens.com/automation/service&support).
There, as search term, enter the number 15257461 or contact your local Siemens office.

Turning and Milling

4 Commissioning Manual, 03/2013, 6FC5397-3DP40-3BA1
Table of contents

Preface ...................................................................................................................................................... 3
1 Scope of delivery and requirements ........................................................................................................ 11
1.1 System overview ..........................................................................................................................11
1.2 Commissioning and service tools ................................................................................................13
1.3 Commissioning process...............................................................................................................15
1.3.1 Guide to the documentation.........................................................................................................15
1.4 Starting up the control..................................................................................................................18
1.5 Communication with the control...................................................................................................21
1.5.1 Communicating with the control via X130....................................................................................21
1.5.2 How to communicate with the control using the Programming Tool............................................23
1.5.3 How to communicate with the control via Access MyMachine ....................................................26
1.5.4 Example: How to communicate with the control using the NCU Connection Wizard..................29
2 Introduction and use of data classes........................................................................................................ 33
2.1 Data classes in the NCK ..............................................................................................................34
2.2 Data classes in the PLC...............................................................................................................37
2.3 Data classes in the operating software........................................................................................38
3 Operating software settings ..................................................................................................................... 41
3.1 Access levels ...............................................................................................................................41
3.2 How to set and change the password..........................................................................................43
3.3 How to set the date and time .......................................................................................................44
3.4 Setting the operating software languages ...................................................................................45
3.4.1 Available system languages and language extensions ...............................................................45
3.4.2 Entering Asian characters using the Input Method Editor ...........................................................45
3.4.3 This is how you enter the Chinese character...............................................................................47
3.4.4 This is how you enter Korean characters ....................................................................................48
3.5 Checking and entering licenses ...................................................................................................50
3.5.1 How to enter a license key...........................................................................................................50
3.5.2 This is how you determine missing licenses/options ...................................................................52
3.5.3 Definitions for license management.............................................................................................53
3.6 Configuring PLC user alarms.......................................................................................................55
3.6.1 Structure of user PLC alarms.......................................................................................................56
3.6.2 How to create user PLC alarms ...................................................................................................57
3.6.3 Configuring the alarm log.............................................................................................................59
3.6.4 How to configure the log ..............................................................................................................60
3.7 Creating OEM-specific online help ..............................................................................................63
3.7.1 Structure and syntax of the configuration file...............................................................................64
3.7.2 Structure and syntax of the help book .........................................................................................65

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Table of contents

3.7.3 Description of the syntax for the online help ............................................................................... 67

3.7.4 Example: This is how you generate an OEM-specific online help book ..................................... 70
3.7.5 Example: How to create an online help for user PLC alarms ..................................................... 73
3.7.6 Example: This is how you generate an online help for NC/PLC variables ................................. 76
3.7.7 Example: This is how you generate a programming online help ................................................ 78
4 Commissioning the I/O ............................................................................................................................ 81
4.1 Connecting the I/O modules........................................................................................................ 81
4.1.1 Activating I/O modules ................................................................................................................ 81
4.1.2 Addressing the I/O modules........................................................................................................ 83
5 Parameterizing machine data .................................................................................................................. 85
5.1 Classification of machine data .................................................................................................... 85
5.2 Processing part programs from external CNC systems.............................................................. 88
5.3 Machining free form surfaces using Advanced Surface ............................................................. 89
5.4 Machine data for Advanced Surface........................................................................................... 91
5.5 Machine data for an analog spindle ............................................................................................ 94
5.6 Managing data ............................................................................................................................ 97
5.6.1 How to transfer data within the controller.................................................................................... 98
5.6.2 To save and load data................................................................................................................. 99
5.6.3 How to compare data ................................................................................................................ 100
6 Commissioning the drive........................................................................................................................ 101
6.1 Configuring the drive ................................................................................................................. 101
6.1.1 Example: Configuration with SINAMICS S120 Combi.............................................................. 101
6.1.2 Example: This is how you configure a spindle with SMC encoder ........................................... 106
6.1.3 Example: This is how you configure an axis with SMI encoder ................................................ 112
6.1.4 Example: Configuration with SINAMICS S120 Booksize.......................................................... 117
6.1.5 Example: This is how you configure a drive system ................................................................. 119
6.1.6 Example: How to configure the infeed ...................................................................................... 124
6.1.7 Example: This is how you configure a drive object................................................................... 129
6.1.8 Example: How to configure the external encoder ..................................................................... 136
6.1.9 Replacing a drive component after the initial commissioning ................................................... 139
6.1.10 Example: Parallel connection with TM120 ................................................................................ 140
6.1.11 Exchanging process data.......................................................................................................... 142
6.1.12 Parameters for the axis / spindle test run ................................................................................. 143
6.2 Assigning axes .......................................................................................................................... 145
6.2.1 Example: How to assign the axes............................................................................................. 145
6.2.2 Example: Setting machine data for an axis/spindle .................................................................. 151
6.3 Configuring data sets ................................................................................................................ 153
6.3.1 Data sets - overview.................................................................................................................. 153
6.3.2 Adding a data set ...................................................................................................................... 154
6.3.3 Remove data set ....................................................................................................................... 160
6.3.4 Modify data set.......................................................................................................................... 162
6.4 Topology rules for DRIVE-CLiQ................................................................................................ 164
6.4.1 Topology rules for S120 Combi ................................................................................................ 164
6.4.2 Topology rules for S120 Booksize ............................................................................................ 166
6.4.3 Topology rules for SMC40 ........................................................................................................ 170

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 Table of contents

6.5 Terminal assignments................................................................................................................171

6.5.1 Terminal assignment at X122 and X132....................................................................................171
6.5.2 Terminal assignment at X242 and X252....................................................................................172
6.5.3 Example: Circuitry for a CU with line contactor .........................................................................174
6.5.4 Connecting the probes...............................................................................................................176
7 Optimizing a drive .................................................................................................................................. 179
7.1 Introduction ................................................................................................................................179
7.2 Automatic servo optimization .....................................................................................................181
7.2.1 Objective ....................................................................................................................................181
7.2.2 Setting optimization strategy......................................................................................................184
7.2.3 How to start the automatic servo optimization ...........................................................................188
7.2.4 How to optimize the interpolation paths.....................................................................................191
7.3 Optimizing the axis jerk..............................................................................................................194
7.3.1 Checking the axis jerk................................................................................................................194
7.3.2 Parts program for axis jerk.........................................................................................................195
7.3.3 Selecting trace signals ...............................................................................................................196
7.3.4 Optimizing the jerk setting..........................................................................................................199
7.4 Torque load ................................................................................................................................202
7.5 Circularity test ............................................................................................................................206
7.5.1 Circularity test: Function ............................................................................................................206
7.5.2 Circularity test: Performing the measurement ...........................................................................207
7.5.3 Circularity test: Examples ..........................................................................................................209
7.5.4 Circularity test: Saving data .......................................................................................................212
7.6 Optimize the spindle ..................................................................................................................215
7.6.1 Set the machine data for the spindle .........................................................................................215
7.6.2 Spindle: Checking the speed controller .....................................................................................216
7.6.3 Spindle: Checking the position controller...................................................................................222
8 Service Planner ..................................................................................................................................... 225
8.1 Interfaces in the PLC user program...........................................................................................227
8.2 Interfaces to the operating software ..........................................................................................232
8.3 This is how you import and export maintenance tasks ..............................................................235
8.4 Acknowledging maintenance tasks............................................................................................238
9 Easy Extend .......................................................................................................................................... 239
9.1 Function of Easy Extend ............................................................................................................239
9.2 Configuration in the PLC user program .....................................................................................241
9.3 Option bits for machine manufacturers and dealers ..................................................................243
9.4 Display on the user interface .....................................................................................................246
9.5 Generating language-dependent text ........................................................................................247
9.6 Examples ...................................................................................................................................249
9.6.1 Example with control elements ..................................................................................................249
9.6.2 Example with parameters to support the commissioning ..........................................................250
9.6.3 User example for a power unit ...................................................................................................252

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Table of contents

9.7 Description of the script language............................................................................................. 255

9.7.1 Special characters and operators ............................................................................................. 256
9.7.2 Structure of the XML script........................................................................................................ 257
9.7.3 CONTROL_RESET................................................................................................................... 258
9.7.4 DATA......................................................................................................................................... 259
9.7.5 DATA_ACCESS ........................................................................................................................ 259
9.7.6 DATA_LIST ............................................................................................................................... 260
9.7.7 DRIVE_VERSION ..................................................................................................................... 261
9.7.8 FILE........................................................................................................................................... 261
9.7.9 FUNCTION................................................................................................................................ 263
9.7.10 FUNCTION_BODY.................................................................................................................... 264
9.7.11 INCLUDE................................................................................................................................... 265
9.7.12 LET............................................................................................................................................ 266
9.7.13 MSGBOX................................................................................................................................... 267
9.7.14 OP ............................................................................................................................................. 268
9.7.15 OPTION_MD ............................................................................................................................. 269
9.7.16 PASSWORD ............................................................................................................................. 270
9.7.17 PLC_INTERFACE ..................................................................................................................... 270
9.7.18 POWER_OFF............................................................................................................................ 271
9.7.19 PRINT........................................................................................................................................ 271
9.7.20 WAITING ................................................................................................................................... 272
9.7.21 ?up ............................................................................................................................................ 273
9.7.22 XML identifiers for the dialog .................................................................................................... 273
9.7.23 BOX........................................................................................................................................... 275
9.7.24 CONTROL................................................................................................................................. 275
9.7.25 IMG............................................................................................................................................ 277
9.7.26 PROPERTY .............................................................................................................................. 278
9.7.27 REQUEST ................................................................................................................................. 279
9.7.28 SOFTKEY_OK, SOFTKEY_CANCEL ....................................................................................... 279
9.7.29 TEXT ......................................................................................................................................... 280
9.7.30 TYPE_CAST ............................................................................................................................. 280
9.7.31 UPDATE_CONTROLS.............................................................................................................. 281
9.7.32 Addressing the parameters ....................................................................................................... 282
9.7.33 Addressing the drive objects ..................................................................................................... 285
9.7.34 XML identifiers for statements................................................................................................... 287
9.8 String functions ......................................................................................................................... 290
9.8.1 string.cmp.................................................................................................................................. 290
9.8.2 string.icmp ................................................................................................................................. 291
9.8.3 string.left.................................................................................................................................... 292
9.8.4 string.right.................................................................................................................................. 293
9.8.5 string.middle.............................................................................................................................. 293
9.8.6 string.length............................................................................................................................... 294
9.8.7 string.replace............................................................................................................................. 295
9.8.8 string.remove ............................................................................................................................ 295
9.8.9 string.delete............................................................................................................................... 296
9.8.10 string.insert................................................................................................................................ 297
9.8.11 string.find................................................................................................................................... 298
9.8.12 string.reversefind....................................................................................................................... 298
9.8.13 string.trimleft.............................................................................................................................. 300
9.8.14 string.trimright ........................................................................................................................... 301
9.9 Trigonometric functions............................................................................................................. 302

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8 Commissioning Manual, 03/2013, 6FC5397-3DP40-3BA1
 Table of contents

10 Tool management.................................................................................................................................. 305

10.1 Fundamentals ............................................................................................................................305
10.1.1 Structure of the tool management .............................................................................................306
10.1.2 Components of the tool management........................................................................................307
10.1.3 Loading and unloading tools manually ......................................................................................310
10.2 NC - PLC user interface.............................................................................................................311
10.2.1 Relocating, unloading, loading tool, positioning magazine........................................................312
10.2.2 Tool change ...............................................................................................................................318
10.2.3 Transfer-step and acknowledgment-step tables........................................................................326
10.3 Machine data for the tool management .....................................................................................328
10.3.1 Settings for the tool management..............................................................................................328
10.3.2 Dependency between MD20360 and SD54215 ........................................................................332
10.3.3 Tool measuring in JOG ..............................................................................................................335
10.4 PLC Program Blocks..................................................................................................................337
10.4.1 Acknowledgment process ..........................................................................................................337
10.4.2 Types of acknowledgment .........................................................................................................338
10.4.3 Acknowledgment states .............................................................................................................339
10.4.4 Configuring step tables ..............................................................................................................344
10.4.5 Configuring acknowledgment steps...........................................................................................347
10.4.6 Adjust the PLC user program.....................................................................................................349
10.4.7 Information on magazine location ..............................................................................................350
10.4.8 PI service: TMMVTL ..................................................................................................................352
10.5 Example: Loading/unloading......................................................................................................354
10.6 Example: Change manual tools .................................................................................................356
10.7 Application example for turning machine...................................................................................360
10.7.1 Example: Turning machine with revolver magazine (MAGKONF_MPF) ...................................360
10.7.2 Example: Acknowledgment steps (turning machine).................................................................365
10.7.3 Example: Tool change cycle for turning machine ......................................................................366
10.7.4 Example: Turning machine with counterspindle ........................................................................368
10.7.5 Example: Test for empty buffer..................................................................................................368
10.7.6 Example: Transporting a tool from a buffer into the magazine..................................................369
10.7.7 Example: Repeat "Prepare tool change" order..........................................................................370
10.8 Application example for milling machine....................................................................................371
10.8.1 Example: Milling machine with chain magazine and dual gripper
(MAGKONF_EXAMPLE_MPF) ..................................................................................................371
10.8.2 Flow chart: Tool change.............................................................................................................376
10.8.3 Example: Acknowledgment steps (milling machine)..................................................................386
10.8.4 Example: Tool change cycle for milling machine.......................................................................388
11 Easy Archive.......................................................................................................................................... 389
11.1 Backing up and archiving data...................................................................................................389
11.2 Saving data in archives..............................................................................................................390
11.3 This is how you create a commissioning archive.......................................................................393
11.4 This is how you import a commissioning archive.......................................................................395
11.5 This is how you back up just the machine data that have changed ..........................................396
11.6 Example: Data archiving "Easy Archive" (use case) .................................................................397
11.7 Parameterizing the serial interface ............................................................................................399

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Commissioning Manual, 03/2013, 6FC5397-3DP40-3BA1 9
Table of contents

A Appendix................................................................................................................................................ 401
A.1 Table: Language code in file names ......................................................................................... 401
A.2 List of abbreviations .................................................................................................................. 402
A.3 Documentation overview SINUMERIK 828D ............................................................................ 405
Glossary ................................................................................................................................................ 407
Index...................................................................................................................................................... 415

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10 Commissioning Manual, 03/2013, 6FC5397-3DP40-3BA1
Scope of delivery and requirements 1
1.1 System overview

Configuration with SINAMICS S120 Booksize

The following configuration shows a typical example with SINAMICS S120 booksize:

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6,180(5,.'

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Figure 1-1 Configuration example 1: Basic configuration with 4 axes

Turning and Milling

Commissioning Manual, 03/2013, 6FC5397-3DP40-3BA1 11
Scope of delivery and requirements
1.1 System overview

Configuration with SINAMICS S120 Combi

The following configuration shows an example with SINAMICS S120 Combi:

SINUMERIK 828D
BASIC T
BASIC M DMC20/DME20

Up to 5 linear scales
DRIVE-CLiQ

SINAMICS S120
TTL spindle encoder SINAMICS S120
Combi
Motor Module
Booksize Compact format
Optional line Line
filter reactor

3-ph.
380 ... 480 V AC

Spindle motor Feed motor 1FK7 Feed motor 1FK7 Feed motor 1FK7 Feed motor 1FK7
1PH8 auxiliary spindle 1PH8

Figure 1-2 Configuration example 2: SINUMERIK 828D BASIC T/M with S120 Combi

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12 Commissioning Manual, 03/2013, 6FC5397-3DP40-3BA1
 Scope of delivery and requirements
1.2 Commissioning and service tools

1.2 Commissioning and service tools

Toolbox CD
The Toolbox CD for SINUMERIK 828D has the following content:
● PLC Programming Tool for Integrated PLC
● Commissioning software for SINAMICS S120
● PLC Library (example)

PLC Programming Tool for Integrated PLC

The following tool is available for programming the PLC: PLC Programming Tool for
Integrated PLC. The designation "Programming Tool" is used in the rest of this manual.

Commissioning software for SINAMICS S120

Until the SINAMICS S120 commissioning functionality is completely available via the user
interface, drive configuration and optimization is performed using the commissioning
software for SINAMICS S120. The PC is connected using the Ethernet interface on the front
of the SINUMERIK 828D.

Note
Ordering data
The ordering data for the following tools can be found in Catalogs NC 82 and NC 62.

SINUMERIK Integrate Access MyMachine /P2P

Access MyMachine /P2P (previously: RCS Commander) is a tool that allows the
commissioning engineer to exchange files between the PC and the control very easily using
drag and drop.
For data transmission, the PC is connected directly to the Ethernet interface on the front of
the control. For a point-to-point connection, time-consuming parameterization of the Ethernet
interface is not necessary. All settings are made automatically by Access MyMachine /P2P.
Several NCUs can be accessed in sequence via a company network with
Access MyMachine /P2P.
The designation "Access MyMachine" is used in the rest of this manual.

Turning and Milling

Commissioning Manual, 03/2013, 6FC5397-3DP40-3BA1 13
Scope of delivery and requirements
1.2 Commissioning and service tools

STARTER drive/commissioning software

Drive commissioning for the SINUMERIK 828D can be performed using the STARTER
drive/commissioning software. Simple commissioning procedures which are usually
performed by field service staff (such as activating direct measuring systems) can be
executed directly via the SINUMERIK 828D user interface. Advanced commissioning
procedures which are usually performed when the machine is being manufactured (such as
drive optimization) can be executed offline via the commissioning software used for
SINAMICS S120.

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14 Commissioning Manual, 03/2013, 6FC5397-3DP40-3BA1
 Scope of delivery and requirements
1.3 Commissioning process

1.3 Commissioning process

1.3.1 Guide to the documentation

The commissioning process described in the following table represents an efficient
suggestion that is also discussed in the SINUMERIK training. The tasks shown in square
brackets apply to the numbers of the steps described in the training documents. The
sections contained in the manual that provide supplementary information to the training
documents are specified as references in the right-hand column.
Overview:

<B060> System overview

"Turning and Milling" (Page 11)
Commissioning Manual
<B002> Commissioning and service tools
"Turning and Milling" (Page 13)
Commissioning Manual
Basics:

<B061> Menu structure Measuring Cycles Programming

Manual
<B021> Access levels
"Turning and Milling" (Page 41)
Commissioning Manual
<B021> Date and time
"Turning and Milling" (Page 44)
Commissioning Manual
<B041> Parameterizing machine data
"Turning and Milling" (Page 85)
Commissioning Manual
<B032> SINUMERIK Integrate Access MyMachine online help
<B044> Checking and entering licenses
"Turning and Milling" (Page 50)
Commissioning Manual
<B045> Network configuration → define drives Turning Operating Manual
Milling Operating Manual
<B007> Electronic logbook "SINUMERIK Operate"
Commissioning Manual
<B017> Data management "Turning and Milling"
Commissioning Manual
 Introduction and use of data classes
(Page 33)
 Easy Archive (Page 389)
<B006> Electrocabinet structure "EMC Guidelines"
Configuration Manual

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Commissioning Manual, 03/2013, 6FC5397-3DP40-3BA1 15
Scope of delivery and requirements
1.3 Commissioning process

Configuration and diagnosis:

<B010> PPU connections diagnosis "PPU" Device Manual

 System overview
 Digital inputs/outputs
<B030> Digital inputs/outputs → terminal
assignment "Turning and Milling" (Page 171)
Handwheels and measuring inputs Commissioning Manual
<B051> Line Modules, Motor Modules SINAMICS S120 Device Manual
<B053> Diagnosis "SINUMERIK Operate"
 Drive system diagnostics Commissioning Manual
 Diagnosis and service → axes
<B008> PROFINET connections diagnosis: "PPU" Device Manual
 MCP 310C PN / MCP 483C PN
 PP 72/48D PN/PP 72 / 48D 2/2A PN

PLC:

<B026> Creating a PLC program "PLC Programming Tool"

online help
<B019> S7-200 PLC instructions "PLC Programming Tool"
online help
<B033> PLC functions "Fundamentals" Function Manual (P4)
<B031> PLC alarms and messages → function "Fundamentals" Function Manual (P4)
interface: PLC user alarms
<B058> PLC onboard diagnosis Turning Operating Manual
Milling Operating Manual
"Fundamentals" Function Manual (P4)
<B000> PLC interface structure "NC Variables and Interface Signals"
List Manual, Section: "Interface signals
– overview"
Commissioning process:

<B068> Commissioning process → placing a drive

into operation "Turning and Milling" (Page 101)
Commissioning Manual
<B084> Homing encoder adjustment "Fundamentals" Function Manual (R1)
<B101> Drive optimization "Turning and Milling" (Page 179)
Commissioning Manual
<B102> Tool optimization "Turning and Milling" (Page 305)
Commissioning Manual
<B009> Easy Extend "Turning and Milling" (Page 239)
Commissioning Manual

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16 Commissioning Manual, 03/2013, 6FC5397-3DP40-3BA1
 Scope of delivery and requirements
1.3 Commissioning process

<B011> SINUMERIK Integrate Run MyScreens "SINUMERIK Integrate

Run MyScreens" (BE2)
Programming manual
<B020> Service Planner "Turning and Milling" (Page 225)
Commissioning Manual
<B018> Easy Message Turning Operating Manual
Milling Operating Manual
<B016> Installation of an additional axis ---

<B029> Analog spindle "Turning and Milling" (Page 94)

Commissioning Manual

General conditions
This manual assumes the following general conditions:
● The mechanical and electrical installation of the system must have been completed.
● Check the system visually for:
– Correct mechanical installation with secure electrical connections
– Connection of the power supply
– Connection of shielding and grounding
● Switching on the control and startup in "Normal startup":
The control has finished booting when the main screen of the operating software is
displayed.

References
Detailed information on cycle startup under SINUMERIK Operate can be found in the
Commissioning Manual Operating Software and Basic Software, SINUMERIK Operate (IM9),
Section "Configuring cycles".

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Scope of delivery and requirements
1.4 Starting up the control

1.4 Starting up the control

Control startup
Procedure:
1. Switch the control on. The following display then appears during startup:

2. Press the <SELECT> key within three seconds.

3. Then press the following keys in succession:
Menu reset key, HSK2 (horizontal SK2), VSK2 (vertical SK2)
4. The "Setup menu" is displayed, "Normal startup" is the default setting.

Operating modes for startup

Selection Function
Normal startup The system carries out a normal startup.
Reload saved user data The system loads the stored user data ("Save data" softkey)
from the system CompactFlash card.
Install software update/backup An update is installed on the system CompactFlash card from
the user CompactFlash card or USB FlashDrive.
Create software backup A backup of the system CompactFlash card is saved to the user
CompactFlash card or USB FlashDrive.

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1.4 Starting up the control

Selection Function
NCK default data The system loads the Siemens NCK data default settings and
deletes the retentive data on the PLC.
Drive default data The SINAMICS user data is deleted.
PLC default data PLC general reset and load default NOP PLC program.
HMI default data User data in the directory /user is deleted.
Factory settings Choice between two cases: No [case 1]/ Yes [case 2]
 Case 1:

The SINAMICS user data is deleted.

Siemens standard NCK data is loaded.

PLC general reset and load default NOP PLC program.

User data in the directory /user is saved.

 Case 2:

As case 1 and additionally:

Deletion of the data in the /oem and /addon directories.

Delete OEM files All the data under /oem and /addon is deleted: OEM archives;
OEM alarm texts; Easy Screen application.
Delete user files
PLC stop The PLC is stopped.

Note
Replacement of the system CompactFlash card between different PPUs
Because of the system-related dependency between the CompactFlash card and SRAM for
the data storage in the SINUMERIK 828D, the system CompactFlash card should be
considered as a permanently installed EEPROM and should not be replaced!
If this has to be performed for imperative reasons, the replacement of the system
CompactFlash card is detected during startup because of the stored serial number.
The reaction of the control is the loading of saved during startup (backup was performed
previously with "Save data" softkey). If no stored data is found, a startup is performed
automatically with the "NCK default data".

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Scope of delivery and requirements
1.4 Starting up the control

Checking the hardware

For the PPU 24x.2 hardware a distinction is made between the turning version BASIC T and
the milling version BASIC M:
This distinction is made when booting using the MLFB found in the hardware information
block, which is then compared with the existing NCK scaling. The following message is
output if software that is not suitable for this hardware is found:

Empty RTC capacitor

If the RTC capacitor is discharged, the following message is issued during startup:

You can then reset the date and time:

The capacitor is then charged again when the control is switched on during startup.

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1.5 Communication with the control

1.5 Communication with the control

Creating the connection

An Ethernet cable is needed to connect the control and PG/PC. The following Ethernet
interfaces are available on the control:
● Connection via X127 (behind the flap on the front):
Cable type: Crossed Ethernet cable
At interface X127, the control is preset as a DHCP server, delivering the IP
address192.168.215.1 for a direct connection (peer-to-peer connection).
● Connection via X130 (at the back):
Cable type: Uncrossed Ethernet cable
The interface X130 is the connection to the company network. The IP address that the
PG/PC receives here as a DHCP client is determined by the DHCP server from the
company network or fixed IP address is entered manually.

1.5.1 Communicating with the control via X130

Connection to the company network

The NCU is connected to the company network via the Ethernet interface X130. The
company network is used, for example, to access the network drives.
In the "Diagnostics" operating area select the "Bus TCP/IP " → "TCP/IP Diagnostics" →
"Details" softkey with the menu forward key in order to set the parameters for the
communication via X130.

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Scope of delivery and requirements
1.5 Communication with the control

Figure 1-3 Network settings

Company network X130

white Network cable inserted

red Network cable not inserted

Availability
The availability describes the percentage of faulty data compared to the entire data volume.
Problems in the company network (e.g. logical drives that cannot be reached, double IP
address, etc.) as well as settling time during power up can result in fluctuations in availability:
green Greater than 95%

yellow 50 - 95 %

red Less than 50%

Note
All information that is not available is marked in the relevant table line with a hyphen "-".

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1.5 Communication with the control

1.5.2 How to communicate with the control using the Programming Tool

Setting up the communications interface in the PLC Programming Tool

Proceed as follows to set up the network connection in the PLC Programming Tool:
1. Start the PLC Programming Tool via the following link or via the "Start" menu:

2. In the navigation bar, click the "Communication" icon or select "View" → "Communication"
from the menu.
3. In the left column, under "Communications parameters" enter 192.168.215.1as the IP
address for X127.
4. Double-click the "TCP/IP" icon at the top right.
5. In the dialog "PG/PC interface" select the TCP/IP protocol of the PG/PC. Normally this is
the network card of the PC.

Figure 1-4 TCP/IP communications settings

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1.5 Communication with the control

6. Confirm with "OK".

7. Connect by double-clicking the "Double-click to update" icon. If the connection is made
successfully, the icon will be displayed with a green border:

Figure 1-5 Online connection

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1.5 Communication with the control

8. If the connection is unsuccessful, the following setting may have to be deactivated:

Select "Control Panel" → "Network Connections"→ "Local Area Connection" "Properties"→
"Advanced"→ "Windows Firewall" → "Settings"→ "Advanced": Deactivate the option "Local
Area Connection".

Figure 1-6 Deactivate option

Confirm with "OK" and repeat Step 7.

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Scope of delivery and requirements
1.5 Communication with the control

1.5.3 How to communicate with the control via Access MyMachine

Connection options
The following options are available for "Access MyMachine" to establish a connection to the
control.
● Direct connection (peer-to-peer)
● Network connection
The current status of the connection is displayed at the bottom in the status bar of Access
MyMachine.

Meaning of the buttons:

Connect

Disconnect

Remote control

Note
Generally only one connection is permitted, i.e. several simultaneous connections to different
controls are not supported: Data exchange between two controls by means of "Access
MyMachine" is therefore not possible.

Direct connection
To create a direct connection:
1. The login data is entered in the dialog "Settings" → "Connection" → "Direct connection":

Figure 1-7 Dialog: Login data for direct connection

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 Scope of delivery and requirements
1.5 Communication with the control

2. In the menu, select "Connection" → "Connect" → "Direct connection" or click the "Connect"
button.
The following dialog box is displayed:

Figure 1-8 Dialog: Direct connection

3. The last selected direct connection is highlighted. Using the "Connect" button, a
connection to the IP address196.168.215.1 is created.
This dialog does not appear when the direct connection is selected using the menu.

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Scope of delivery and requirements
1.5 Communication with the control

Network connection
To create a network connection:
1. In the menu, select "Settings" → "Connection" → "Direct connection" or click the "Connect"
button.

Figure 1-9 Dialog: Network connection

2. In the menu, select "Connection" → "Connect" → "Network connection" or select – if

available – one of the previously selected connections.
3. Connection is made to the parameterized control.

Note
SSh key file
As an alternative to entering a password, the user may also use an SSh key for
authentication. Please refer to the Online Help for more information on this topic.

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1.5 Communication with the control

1.5.4 Example: How to communicate with the control using the NCU Connection
Wizard

Requirements
The commissioning software for SINAMICS S120 is installed on the PG/PC. The "NCU
Connection Wizard" is part of this software.
The connection to the control has already been set up via the PLC Programming Tool.

Create connection to control

Procedure for the PG/PC:
1. Start the "NCU Connection Wizard" via this link or via the "Start" menu.

2. In the "Select Control Model" dialog, select "840D solution line" for the NCU type
connection to the SINUMERIK 828D.

Figure 1-10 Select the NCU type

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1.5 Communication with the control

3. In the "Select Port" dialog, select the connection to the control that you have connected
via Ethernet.

Figure 1-11 Select connection

4. Confirm the cable connection for both devices in the"Cabling Help" dialog.

Figure 1-12 Cabling

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1.5 Communication with the control

5. Check the IP address and enter the name for these settings in the "Settings" dialog.

Figure 1-13 Network settings

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1.5 Communication with the control

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Introduction and use of data classes 2
Objective
The principle of data classes creates a clear demarcation between system data, (data that is
created when installing the software), OEM data (data that is created when commissioning a
prototype machine) and user data (data that is created by the user). OEM data is further
classified into data that is valid for a series of machines (standard data for all machines of a
series) and individual data, which only applies to a specific machine.
This data classification is realized when creating data class archives, i.e. archives that only
include a subset of data (manufacturer data, individual machine data or user data). This
simplifies commissioning and upgrading.

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Introduction and use of data classes
2.1 Data classes in the NCK

2.1 Data classes in the NCK

Classification
All control-relevant data is classified into data classes regarding its later use in
commissioning, software upgrade, software update and component replacement. Data is
classified according to four data classes: M (Manufacturer), I (Individual), U (User) and
S (System)

System (S) data class

This data class covers data in the Siemens and System directories on the CompactFlash
Card. For the rest of this document it will be referred to as "S".

Characteristics / properties of data class S

The data is automatically loaded the first time the system is switched on or during
initialization and activated as far as is necessary.
"S" class data cannot be backed up and are designated as "read only".

Data type Example

HMI: Siemens standard user interface and additional languages available
NCK: Standard cycles, measurement cycles and JobShop cycles, definitions such as
SGUD and SMAC and all NC active data with data class S
PLC: Hardware configurations
Drives: Code and data (data descriptions, alarm descriptions, macros)

Manufacturer (M) data class

This data class covers all data defined by the machine manufacturer (OEM) when a machine
in a model series is commissioned for the first time. For the rest of this document it will be
referred to as "M".

Characteristics / properties of data class M

Class M data is stored in a separate "Manufacturer" archive.

Data type Example

HMI: OEM dialogs (Easy Screen) and cycle support, alarm and message texts.
NCK: Manufacturer cycles, MGUD and MMAC definitions and all NC active data with
data class M (no memory normalizing machine data)
PLC: PLC program, contents of the data blocks in this data class
Drives: all

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 Introduction and use of data classes
2.1 Data classes in the NCK

Individual (I) data class

This data class covers data concerning a particular machine and is also created during
commissioning by the OEM, or later by the dealer. This data class will be referred to as "I" in
the rest of this document.

Characteristics / properties of data class I

Class I data is stored in a separate INDIVIDUAL archive.

Data type Example

HMI: Easy Extend and Service Planner
NCK: Reference point dimensions, backlash compensation, compensation data, tool
carrier data, all NC active data with data class I
PLC: Contents of the data blocks in this data class
Drives: No data available at this time.

User (U) data class

This data class covers all user data as well as data that is created during the machine
runtime, for example the maintenance interval timer. This data class will be referred to as "U"
in the rest of this document.

Characteristics / properties of data class U

Class U data is stored in a separate "User" archive.

Data type Example

HMI: ---
NCK: Tool data, setting data, part programs, subprograms and user cycles, UGUD and
UMAC definitions, but no program code (e.g. PLC)
PLC: Contents of the data blocks in this data class
Drives: No data available at this time.

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Introduction and use of data classes
2.1 Data classes in the NCK

GUD and macros

The following table shows how the definition files (GUD, macros) are assigned to a data
class:

Definition file Data class

GUD4 Individual (I)
MGUD Manufacturer (M)
MMAC Manufacturer (M)
UGUD User (U)
UMAC User (U)

Data class attribute

The data class attribute is set implicitly. The default setting of the data class attribute can be
explicitly changed.
● In general, data from the active file system is assigned to a data class as it belongs to a
certain file.
Example: Compensation data (data from CEC, EEC or QEC) is assigned to the
"Individual" data class. If data are generated as a result of a definition (GUDs and
macros) then this data also inherits the data class in which the definition file is located.
GUD from UGUD.DEF are assigned the "User" data class.
● However, if the data definition and data content are in different data classes, then this
must be specified in the data definition.
Example: The definition of the GUD, which defines a probe, should be located in the
"Manufacturer" data class, as it is required to run the manufacturer cycles.
However, the value of the data should belong to the "Individual" data class as the probe
type can differ from machine to machine. This is the reason that the additional variable
attribute "DC" (DataClass) has been introduced:
MGUD.DEF ("Manufacturer" data class)

DEF CHAN DCI INT CALIPER

The definition of the data class of the data content can only be "less than or equal to" the
data class of the definition. Any other configurations are rejected with an alarm.
For this purpose, the following weighting of the data classes is assumed: M > I > U

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 Introduction and use of data classes
2.2 Data classes in the PLC

2.2 Data classes in the PLC

Data classes in the PLC

Assigning program blocks in data classes is used to efficiently upgrade or commission a
SINUMERIK control. Here, a distinction is made between three data classes:
● Manufacturer (M) is allocated by the machine manufacturer during construction.
● Individual (I) is allocated by the machine manufacturer during the first commissioning
(values for this specific machine).
● User (U) is set by the end customer (values associated with the particular process). You
cannot assign a different data class to the main program or to subroutines.

Block Default setting Can be changed

Main program (OB1) MANUFACTURER No
Subroutine (SBR, INT, ...) MANUFACTURER No
Data block INDIVIDUAL Yes
MANUFACTURER
USER

Example
The data classes are assigned to the block in the dialog "Properties":
1. In the menu,"View" > "Data block", select a data block.
2. In the menu "View" → select "Properties" to change the data class.

Figure 2-1 Selecting the data class

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Introduction and use of data classes
2.3 Data classes in the operating software

2.3 Data classes in the operating software

Representing the data classes in the operating software

The arrangement in data classes is essentially already given by the directory structure of the
CompactFlash card:

Directory Data class

system SYSTEM
siemens
addon MANUFACTURER
oem MANUFACTURER, INDIVIDUAL
individual MANUFACTURER, INDIVIDUAL
user USER

The directories "System" and "Siemens" have no significance for archiving, since they are
set up with the installation of the SINUMERIK software and are not changed by installation,
configuration or in later use. An update or upgrade of the system will typically be carried out
in these directories. The archiving of these directories is for this reason only necessary as a
rollback backup in the background.
Further subdividing of these directories into SINUMERIK NCK / PLC / HMI and SINAMICS
covers the data areas described above and is echoed in all named directories (data classes).

CompactFlash card Data area

SINUMERIK NCK
PLC
HMI
SINAMICS Drives

Structure of the CompactFlash card

The file system comprises the uppermost level of the directories "addon", "individual", "oem",
"siemens" and "user": These directories have essentially an identical structure.
The section of the directory structure relevant for the configuration is shown below:

siemens directory
/siemens/sinumerik
/hmi
/appl Applications (operating areas)
/base Basic system components
/cfg All configuration files
/data Version data

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 Introduction and use of data classes
2.3 Data classes in the operating software

siemens directory
/hlp Online help files
/hlps Online help files, zipped and version files
/ico Icon files
/ico640 Icons with a resolution 640x480
/ico800 Icons with a resolution 800x600
/ico1024 Icons with a resolution 1024x768
/ico1280 Icons with a resolution 1280x1024
/ico1600 Icons with a resolution 1600x1240
/lng Text files
/lngs Text files zipped and versions files
/osal
/ace ACE/TAO
/qt Qt
/proj Easy Screen configurations
/template Various templates
/cfg Templates for configuration files
/ing Templates for text files
/tmpp Storage, temporary data

addon directory
/addon/sinumerik
/hmi
/appl Applications (operating areas)
/cfg Configuration files
/data Version data
/hlp Online help files, zipped and version files
/ico Icon files
/ico640 Icons with a resolution 640x480
/ico800 Icons with a resolution 800x600
/ico1024 Icons with a resolution 1024x768
/ico1280 Icons with a resolution 1280x1024
/ico1600 Icons with a resolution 1600x1240
/lng Text files
/lngs Text files zipped and versions files
/proj Easy Screen configurations
/template Various templates

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Introduction and use of data classes
2.3 Data classes in the operating software

oem directory
/oem/sinumerik
/data Version data
/archive Manufacturer archives
/hmi
/appl Applications (operating areas)
/cfg Configuration files
/data Version data
/hlp Online help files
/hlps Online help files, zipped and version files
/ico Icon files
/ico640 Icons with a resolution 640x480
/ico800 Icons with a resolution 800x600
/ico1024 Icons with a resolution 1024x768
/ico1280 Icons with a resolution 1280x1024
/ico1600 Icons with a resolution 1600x1240
/lng Text files
/lngs Text files zipped and versions files
/proj Easy Screen configurations
/template Various templates

user directory
/user/sinumerik
/data Version data
/archive User-specific archives
/prog User-specific programs
/hmi
/cfg Configuration files
/data Version data
/hlp Online help files
/ico Icon files
/ico640 Icons with a resolution 640x480
/ico800 Icons with a resolution 800x600
/ico1024 Icons with a resolution 1024x768
/ico1280 Icons with a resolution 1280x1024
/ico1600 Icons with a resolution 1600x1240
/lng Text files
/log Log files
/md Machine data views
/proj Easy Screen configurations

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Operating software settings 3
3.1 Access levels

Access to functions and machine data

The access concept controls access to functions and data areas. Access levels 0 to 7 are
available, where 0 represents the highest level and 7 the lowest level. Access levels 0 to 3
are locked using a password and 4 to 7 using the appropriate key-operated switch settings.

Access level Locked by Area Data class

0 --- (reserved) ---
1 Password: SUNRISE Manufacturer Manufacturer (M)
2 Password: EVENING Service Individual (I)
3 Password: CUSTOMER User User (U)
4 Key-operated switch setting 3 Programmer, machine setter User (U)
5 Key-operated switch setting 2 Qualified operator User (U)
6 Key-operated switch setting 1 Trained operator User (U)
7 Key-operated switch setting 0 Semi-skilled operator User (U)

The password remains valid until it is reset with the "Delete Password" softkey. The
passwords can be changed after activation.
If, for example, the passwords are no longer known, reinitialization (boot-up with
"NCK default data") must be carried out. This resets all passwords to the default (see table).
POWER ON does not reset the password.

Key-operated switch
Access levels 4 to 7 require a corresponding key-operated switch setting on the machine
control panel. Three keys of different colors are provided for this purpose. Each of these
keys provides access only to certain areas.

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Operating software settings
3.1 Access levels

Meaning of the key-operated switch settings:

Access level Switch position Key color

4-7 0 to 3 red
5-7 0 to 2 green
6-7 0 and 1 black
7 0 = Key removal position No key inserted

The key-operated switch setting must always be edited from the PLC user program and applied to the
interface accordingly.

See also
The password can also be deleted via the PLC (PI services: PI LOGOUT).
Function Manual Basic Functions, Section "PLC for SINUMERIK 828D" (P4)

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 Operating software settings
3.2 How to set and change the password

3.2 How to set and change the password

Set password
To change the access level, select the "Start-up" operating area:
1. Press the "Password" softkey.
2. Press the "Set password" softkey to open the following dialog:

Figure 3-1 Set password

3. Enter a password and confirm this with "OK" or with the <Input> key.
A valid password is acknowledged as set and the currently applicable access level is
displayed. Invalid passwords will be rejected.
4. You must delete the old password before activating a password for a lower access level
than the one activated.
The last valid password is deleted by pressing the "Delete password" softkey. Then the
current key-operated switch setting is valid.

Change password
To change the password:
1. Press the "Change password" softkey to open the following dialog:

Figure 3-2 Change password

2. Enter the new password in both fields and then confirm with the "OK" softkey. If both
passwords match, the new password becomes valid and is adopted by the system.

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Operating software settings
3.3 How to set the date and time

3.3 How to set the date and time

Precondition
Changes can only be made with the appropriate access authorization (as of "User" and
higher).

Setting the date and time

Procedure:
1. Select the "Startup" operating area.
2. Press the "HMI" softkey.
3. Press the "Date/Time" softkey.
The "Date/Time" window opens.
4. Select the required formats for the date and time in the "Format" field.
5. Confirm the entry with the "OK" softkey.
The new date and time details are accepted and output on the first line in the "current"
fields.

Note
Synchronization of time
The SINAMICS drives have no real-time clock. The time of day and date of the SINAMICS
clock are synchronized in a 10-second cycle with the SINUMERIK real-time clock.
The result is that after a change of the date and/or the clock of the SINUMERIK real-time
clock up to 10 seconds expire until this change has been synchronized with the SINAMICS
drives.
If, in this up period of up to 10 seconds, SINAMICS alarms occur (alarm numbers 200000 -
299999), this SINAMICS alarms still receive the outdated date / time stamp. The
SINUMERIK alarms (alarm numbers < 200000 and > 300000) triggered as a result of the
SINAMICS alarms, on the other hand, already receive the new date/ time stamp.

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 Operating software settings
3.4 Setting the operating software languages

3.4 Setting the operating software languages

3.4.1 Available system languages and language extensions

System languages
In the basic configuration, the SINUMERIK 828D is delivered with the following system
languages:
● English
● French
● German
● Italian
● Korean
● Portuguese (Brazil)
● Chinese (simplified)
● Spanish
● Chinese (traditional)
All system languages are installed in the SINUMERIK 828D as delivered, so that a change of
language can be carried out directly via the user interface, without having to download
system language data.

Additional languages
Additional system languages are available on the language extensions DVD. Installation
instructions are provided on the DVD.

3.4.2 Entering Asian characters using the Input Method Editor

Input Method Editor (IME)

The program editor and PLC alarm text editor both allow you to edit Asian characters. The
Input Method Editor is available as support for the following Asian languages:
● Simplified Chinese
● Traditional Chinese (Taiwanese)
● Korean
The editor is started using the shortcut key <Alt>+<S>.

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Operating software settings
3.4 Setting the operating software languages

Editor with active learning function

For Chinese simplified and Chinese traditional, the system offers the option of working with
dictionaries:
● Using a dictionary at the control
● Importing a dictionary into the control

The editor opens a learning function if a phonetic spelling is entered, for which there is no
match in the control system. This function allows syllables or words to be combined, which
are then permanently available after saving. The editor displays the combination of Chinese
characters next to the pinyin phonetic spelling. After being completely compiled, the word
should then be saved by pressing the <Input> key. It is simultaneously inserted in the
associated text box.

Editing the dictionary

When this function is activated, another line showing the combined characters and sounds
will appear. The editor will then offer various characters for this sound, from which you can
choose the desired one by entering the appropriate digit (1 ... 9). You can toggle the input
cursor between the compound phonetic notations field and the phonetic input field by
pressing the <TAB> key.

When the cursor is positioned in the upper field, you can undo the combination by
pressing the <backspace> key.

Press <Select> to save the characters currently being displayed.

Press the <Delete> key if you want to delete the currently displayed group of
characters from the dictionary.

Importing a dictionary
A dictionary can now be generated using any Unicode editor by attaching the corresponding
Chinese characters using the pinyin phonetic spelling. If the phonetic spelling contains
several Chinese characters, then the line must not contain any additional match. If there are
several matches for one phonetic spelling, then these must be specified in the dictionary line
by line. Otherwise, several characters can be specified for each line.
The generated file should be saved in the UTF8 format under the name chs_user.txt
(simplified Chinese) or cht_user.txt (traditional Chinese).
Line structure:
Pinyin phonetic spelling <TAB> Chinese character <LF>
OR

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 Operating software settings
3.4 Setting the operating software languages

Pinyin phonetic spelling <TAB> Chinese character1<TAB> Chinese character2 <TAB> …

<LF>
<TAB> - tab key
<LF> - line break
Store the created dictionary in one of the following paths:
../user/sinumerik/hmi/ime/

../oem/sinumerik/hmi/ime/

When the Chinese editor is called the next time, this enters the content of the dictionary into
the system dictionary.
Example:

Note
The dictionaries are also stored in the commissioning archive when "HMI data" is selected
(see also: Saving data in archives (Page 390))

3.4.3 This is how you enter the Chinese character

Entering Chinese characters

A character is selected using a phonetic spelling ("pinyin method"): whose sound can be
formed by combining Latin letters.
1. Enter the sound by combining Latin letters.
The editor lists a selection of characters that correspond to that particular sound.
2. Select the desired character using the cursor keys:

Figure 3-3 Example: Chinese simplified

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Operating software settings
3.4 Setting the operating software languages

If you switch over the option button to enter a Latin letters using the <SELECT> key, then the
entries are directly transferred into the text box that had the focus before the Chinese editor
was opened.

Zhuin input for Chinese traditional

For traditional Chinese, the following input options are available:
1. Use the numerical block of the keyboard to form the individual syllables.
Each number is assigned a certain number of letters, that can be selected by pressing
the numeric key one or several times.
2. In order to accept the selection made, which is displayed in the Zhuyin text box, confirm
the selection using the <INPUT> key or enter an additional number.

Figure 3-4 Example: Zhuin method

3.4.4 This is how you enter Korean characters

Enter characters using a matrix

If only the keyboard is available at the control, then a matrix technique is used, which only
requires the numerical block:
1. Using the first number, select the line: the line is then highlighted in color.
2. Using the second number, select the column: the character will be briefly highlighted in
color and then transferred to the "Character" field.
You can toggle between Korean and Latin using the <SELECT> key.

Figure 3-5 Example: Program editor

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 Operating software settings
3.4 Setting the operating software languages

Using the Korean keyboard

To enter Korean characters, you will need a keyboard with the keyboard assignment shown
below. In terms of key layout, this keyboard is the equivalent of an English QWERTY
keyboard and individual characters must be grouped together to form syllables.

Example: Korean keyboard

The Korean alphabet (Hangeul) consists of 24 letters: 14 consonants and 10 vowels.
Syllables are formed by combining consonants and vowels.

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Operating software settings
3.5 Checking and entering licenses

3.5 Checking and entering licenses

Use
The use of the installed system software and the options activated on a SINUMERIK control
system require that the licenses purchased for this purpose are assigned to the hardware. In
the course of this assignment, a license key is generated from the license numbers of the
system software, the options, as well as the hardware serial number. Here, a license
database administered by Siemens is accessed via the Internet. Finally, the license
information including the license key is transferred to the hardware.
The license database can be accessed using the Web License Manager.

Web License Manager

By using the Web License Manager, you can assign licenses to hardware in a standard Web
browser. To conclude the assignment, the license key must be entered manually on the
control via the user interface.
Internet address: Web License Manager (http://www.siemens.com/automation/license)

Note
SINUMERIK software products
If a license key has not been activated or does not exist for a SINUMERIK software product,
alarm 8081 is output by the control and NC START cannot be executed.

See also
Definitions for license management (Page 53)

3.5.1 How to enter a license key

Requirement
The appropriate licenses are required for the activated options. After licensing the options in
the Web License Manager, you receive a "license key" containing all options requiring a
license and which is only valid for your system CompactFlash card.
To set or reset options, "Manufacturer" access rights are required.

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 Operating software settings
3.5 Checking and entering licenses

Reading in or entering a license key

Procedure:
1. Select the "Start-up" operating area.
2. Press the menu forward key.
3. Press the "Licenses" softkey.
4. The "Licensing" window opens
5. Select the input line in order to enter a new license key.

Figure 3-6 Licensing

Other actions include:

● Softkey "All options": All options are displayed.
● Softkey "Missing licenses/options": Missing licenses and options are displayed: This is
how you determine missing licenses/options (Page 52)
● Softkey: "Export license requirement": The missing licenses are exported in a file and can
be saved on a storage medium.
● Softkey: "Read in the license key": The license key is read in from the license file.
This file is supplied or can be sourced from the Web License Manager
(http://www.siemens.com/automation/license).

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Operating software settings
3.5 Checking and entering licenses

3.5.2 This is how you determine missing licenses/options

Determining the license requirement

Procedure:
1. Press the "All options" softkey to list all the options that can be selected for this control.
2. Activate or deactivate the required options in the "Set" column:
– Mark the checkbox
– Enter the number of options
3. Press the "Missing lic./opt." softkey in order to display all options that are licensed. In the
"Set" column, you can deselect the options that you do not require.

Figure 3-7 Licensing (example)

4. Press the softkey "Set option according to license", to activate all of the options contained
in the license key. Confirm the following confirmation prompt with "OK".
5. To activate new selected options, press the "Reset (po)" softkey. A safety prompt
appears.
6. Press the "OK" softkey to trigger a warm restart.
- OR -
7. Press the "Cancel" softkey to cancel the process.

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 Operating software settings
3.5 Checking and entering licenses

3.5.3 Definitions for license management

Product
A product is marked by the data below within the license management of SINUMERIK
→ software products:
● Product designation
● Order number
● → License number

Software product
The term software product is generally used to describe a product that is installed on a piece
of → hardware to process data. Within the license management of SINUMERIK software
products, a corresponding → license is required to use each software product.

Certificate of License (CoL)

The CoL is the proof of the → license. The product may only be used by the holder of the
→ license or authorized persons. The CoL includes the following data relevant for the license
management:
● Product name
● → License number
● Delivery note number
● → Hardware serial number

Hardware
In the context of license management of SINUMERIK → software products, hardware refers
to the component of a SINUMERIK control system to which → licenses are assigned on the
basis of its unique identifier. The license information is also saved to non-volatile memory on
this component, e.g. on a → CompactFlash card.

CompactFlash card
As the carrier of all non-volatile data in a SINUMERIK solution line control system, the
CompactFlash card represents the identity of this control system. The CompactFlash card is
a memory card that can be plugged into the → control unit from outside. The CompactFlash
card also contains the following data relevant for the license management:
● → Hardware serial number
● License information including the → license key

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Operating software settings
3.5 Checking and entering licenses

Hardware serial number

The hardware serial number is a permanent part of the → CompactFlash card. It is used to
identify a control system uniquely. The hardware serial number can be determined by:
● → Certificate of License
● User interface
● Label on the CompactFlash card

License
A license gives the user the legal right to use a → software product. Evidence of this right is
provided by the following:
● → Certificate of License (CoL)
● → License key

License number
The license number is the feature of a → license used for its unique identification.

License key
The License Key is the "technical representative" of the sum of all the → licenses that are
assigned to one particular piece of → hardware, which is uniquely marked by its → hardware
serial number.

Option
One option is a SINUMERIK → software product that is not contained in the basic version
and which requires the purchase of a → license for its use.

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 Operating software settings
3.6 Configuring PLC user alarms

3.6 Configuring PLC user alarms

Creating user PLC alarms

The PLC alarms in the area from 700 000 - 700 247 are configured by the machine
manufacturer. The access level "Manufacturer" is required with the appropriate password.
To enter the user PLC alarms via the user interface, select → "HMI"→ "Alarm texts" in the
"Startup" operating area.
Then you receive the following selection:

Alarm texts for Name of the xml file

User cycle alarms oem_alarms_cycles
User PLC alarms oem_alarms_plc
User part program message texts oem_partprogram_messages

Loading user PLC alarms

The alarm text files are only loaded during startup.
● "Alarm" attribute: red, is shown in the "alarm list".
● "Message" attribute: black, is shown under "Messages".
To load the alarm texts, restart the system.

References
Description of the alarms with system responses and cancel criteria in: SINUMERIK 828D
Diagnostics Manual

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Operating software settings
3.6 Configuring PLC user alarms

3.6.1 Structure of user PLC alarms

Structure of a user PLC alarm

The user PLC alarms have the following structure:

 2LOSUHVVXUHWRRORZ
 $[LV G DWUHVWSRVLWLRQ



$ODUPQXPEHU 9DULDEOH $ODUPWH[W

Figure 3-8 Alarm structure

The table below shows the mode of operation of the PLC alarms:
1. The alarm is triggered with the appropriate number and output via the PLC signal.
2. If a variable has been configured to this alarm, the value of this variable is in the specified
data word of the PLC variable.
3. The NCK response when the alarm is triggered is defined in the MD14516[x] index (see
table below).
4. The alarm text can be freely selected and may be up to 255 characters long.

Alarm number PLC signal PLC variable Alarm response Alarm text
(MD)
700000 DB1600.DBX0.0 DB1600.DBD1000 14516[0] Alarm 1
700001 DB1600.DBX0.1 DB1600.DBD1004 14516[1] Alarm 2
700002 DB1600.DBX0.2 DB1600.DBD1008 14516[2] Alarm 3
700003 DB1600.DBX0.3 DB1600.DBD1012 14516[3] Alarm 4
700004 DB1600.DBX0.4 DB1600.DBD1016 14516[4] Alarm 5
700005 DB1600.DBX0.5 DB1600.DBD1020 14516[5] Alarm 6
700006 DB1600.DBX0.6 DB1600.DBD1024 14516[6] Alarm 7

Continuation:
700247 DB1600.DBX30.7 DB1600.DBD1988 14516[247] Alarm 248

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3.6 Configuring PLC user alarms

Defining the NCK response

The following NCK responses are possible:

MD14516[x] Meaning
Bit 0 NC start disabled
Bit 1 Read-in disable
Bit 2 Feed hold for all axes
Bit 3 EMERGENCY STOP
Bit 4 PLC in stop
Bit 5 Reserved
Bit 6 Definition for alarm or message
Bit 6=1: → alarm, Bit 6=0: → message
Bit 7 POWER ON

Configuring alarm texts with variables

The following data types are permitted for variables in the alarm text:

Variable Meaning
%b Binary representation of a 32-bit value
%d Integer decimal number
%f 4 byte floating point number
%i Integer decimal number with sign
%o Integer octal number
%u Unsigned decimal number
%x Integer hexadecimal number

3.6.2 How to create user PLC alarms

Notes for processing

The following points should be observed when processing the files:
● The files should be edited externally on a PG/PC with a text editor (e.g. notepad) or with
an XML editor. The structure must not be altered.
● The created alarm text files are copied to the the following directory on the
CompactFlash card: oem/sinumerik/hmi/lng
● To enable the system to recognize the alarm text file, the file name must be written in
lower case letters.
● The alarm text file is converted during system startup: The system must be restarted to
activate the alarms.

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Operating software settings
3.6 Configuring PLC user alarms

Procedure
To edit a larger number of alarms, first create 2 or 3 alarms directly on the control. Then the
file oem_alarms_plc_xxx.ts is created and you have a "document template" with the correct
structure, which you can then extend with further alarms. The abbreviation "xxx" stands for
the language in which the file has been created.
1. Select the "Start-up" operating area.
2. Press the "HMI" softkey.
3. Press the "Alarm texts" softkey. The "Select file" window appears.
4. Select "oem_alarms_plc" to create user PLC alarm texts.
5. Enter the alarm number in the "Number" field and the desired alarm text in the "Text"
field. The alarm numbers and their alarm texts do not have to be consecutive. If an alarm
is triggered without a configured text, only the alarm number is specified.

Searching within the alarm texts

To search for a text or a series of characters:
1. Press the "Find >" softkey. The "Find" window opens; and a new menu is displayed on
the vertical softkey bar.
2. Enter the search term in the "Text" field.
3. Place the cursor in the "Direction" field and choose the search direction (forward,
backward) with the "SELECT" key.
4. Activate the "Case-sensitive" checkbox when a distinction is to be made between upper
and lower case in the entered text.
5. Press the "Find + replace" softkey. The "Find and replace" window appears.
6. Press the "OK" softkey to start the search.
7. Press the "Cancel" softkey to cancel the search.
Other navigation options are:
● Softkey "Go to start":
The cursor jumps to the first entry of the selected alarm text file
● Softkey "Go to end":
The cursor jumps to the last entry of the selected alarm text file.

See also
Table: Language code in file names (Page 401)
Example: How to create an online help for user PLC alarms (Page 73)

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3.6 Configuring PLC user alarms

3.6.3 Configuring the alarm log

Logging
Configure the alarm log in the "Diagnostics" operating area.
All alarms and messages are logged in chronological order with their raised and cleared time
stamps. The exception are messages of the type "msg" from the NC part program. All alarms
and messages that are no longer active when the log is displayed are also retained
(historical alarm events).
The alarm log is organized as a ring buffer (default setting). The oldest entries are
overwritten with new events in the following cases:
● When the maximum size is exceeded (permissible range: 0 - 32000).
● When the events happened before the last time the system was switched on.

Permanent backup
To save the alarm log permanently, the alarm log is written to the CompactFlash card.

Note
Saving the alarm log
For permanent storage, the alarm log is written to the CompactFlash card which only allows
a limited number of write cycles.
 Therefore, ensure that the backup is only performed when there is a justifiable need!
 Make sure you undo the setting "on every event" if you no longer require storage of the
alarm log.
Default setting: The alarm log is not backed up.

Filtering alarms
Set up a filter to limit the number of events in the alarm log. Select the range for the following
filters:
● Time interval
● Alarm number range

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3.6 Configuring PLC user alarms

3.6.4 How to configure the log

Configuring the log

Procedure:
1. Select the "Diagnostics" operating area.
2. Press the "Alarm log" softkey.
3. Press the "Settings" softkey.
4. Enter the desired number in the "Number of entries" field to change the maximum number
of raised and cleared events.
Default is 500 events; permissible value range 0 - 32000.
5. Select the type of logging under "File write mode":
– "Off" if the events are not to be written to a file.
– "On every event" if every event is to be written to a file.
– "Time controlled" if the file is to be overwritten after a particular time interval. An
additional "Time interval" input field appears in which you can specify the time in
seconds.
6. Press the "Save log" softkey to save the alarm log.
The settings become effective only after restarting the system.

Editing the configuration file

Procedure:
1. Copy the configuration file "oem_alarmprot_slaesvcconf.xml" from the
/siemens/sinumerik/hmi/template/cfg directory.

2. Insert the file into the directory /oem/sinumerik/hmi/cfg or /user/sinumerik/hmi/cfg

3. Name the file "slaesvcconf.xml".
4. Open the user-specific file "slaesvcconf.xml" in the editor.
5. Enter the number of events to be output in the <Records type .../> identifier.
The default value is 500. The permissible number is in the range from 0 ... 32000.
OR:

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3.6 Configuring PLC user alarms

The number of events to be output and the type of logging can also be entered directly via
the user interface:
1. Press the "Alarm log" → "Settings >" softkey in the "Diagnostics" operating area.
As soon as changes are made to the default settings, the "slaesvcconf.xml" file is
automatically created in the /user/sinumerik/hmi/cfg directory.
2. Enter the mode of the permanent storage in the <DiskCare type="int" value="-1"/>
identifier. The following values are possible:
-1: There is no saving of the alarm log (default setting).
0: Each alarm event triggers an immediate saving of the alarm log.
>0: Time for saving the log in seconds:
When there is a change, the log is saved every n > 0 seconds.
3. You adapt the filter for the entry type in the <Filter> identifier.
Here the following applies:
– An alarm event is only entered in the log when it satisfies the filter criteria.
– When several filters are defined, these should be linked using the logical operators
OR or AND.
The settings become effective only after restarting the system.

Note
Number of events
Each incoming or outgoing event of an alarm or message requires a separate entry, even
when they belong to the same alarm or message.
Acknowledgement events are also contained in the alarm log. They also require an entry
even when they are not recognizable in the alarm log.

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3.6 Configuring PLC user alarms

Examples
All alarms that fulfill the following conditions are logged:
● CLEARINFO ≠ 15, therefore without part program messages:

<CONFIGURATION>
<Protocol>
<Filters>
<Siemens_Filter_01 type="QString" value="CLEARINFO NOT 15" />
</Filters>
</Protocol>
</CONFIGURATION>

● "SEVERITY larger than 10" and "smaller than 500":

<CONFIGURATION>
<Protocol>
<Filters>
<Filter_01 type="QString" value= "SEVERITY HIGHER 10
AND SEVERTY LOWER 500" />
</Filters>
</Protocol>
</CONFIGURATION>

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3.7 Creating OEM-specific online help

3.7 Creating OEM-specific online help

Overview
In addition to the existing system online help, you also have the option of creating a
manufacturer-specific online help and adding this to the operator software.
This online help is generated in the HTML format, i.e. it comprises HTML documents that are
linked with one another. The subject being searched for is called in a separate window from
a contents or index directory. Similar to a document browser (e.g. Windows Explorer), a list
of possible selections is displayed in the left-hand half of the window and when you click the
required subject, the explanation is displayed in the right-hand half of the window.
Context-sensitive selection of online help pages is not possible.
General sequence:
1. Generating HTML files
2. Generating a help book
3. Integrating the online help in the operator software
4. Saving help files in the target system

Other application cases

Online help for the following OEM-specific expansions can be generated and used to
supplement the SINUMERIK Operate online help system:
● Online help for cycles and/or M functions of the machine manufacturer, which extend the
programming options for SINUMERIK control systems. This online help is called in just
the same way as the SINUMERIK Operate online help "Programming".
See also: Example: This is how you generate a programming online help (Page 78)
● Online help for OEM-specific variables of the machine manufacturer. This online help is
called from the variable view of SINUMERIK Operate.
See also: Example: This is how you generate an online help for NC/PLC variables
(Page 76)

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3.7 Creating OEM-specific online help

3.7.1 Structure and syntax of the configuration file

Syntax description of the "slhlp.xml"

You require the configuration file "slhlp.xml" to integrate the help book in the existing online
help system of the user interface:

Tag Number Meaning

CONFIGURATION 1 Root element of the XML document: Indicates that this
involves a configuration file.
OnlineHelpFiles 1 Introduces the section of the help books.
<help_book> * Introduces the section of a help book.
EntriesFile File name of the help book with the list of contents and subject
(keyword) entries.
1 Attributes:
value Name of the XML file
type Data type of the value (QString)
III-Technology Specifies the technology for which the help book applies.
"All" applies for all technologies.
If the help book applies to several technologies, then the
0,1 technologies are listed separated by comma.
Possible values:
All, Universal, Milling, Turning, Grinding, Stroking, Punching
Attributes:
value Technology data
type Data type of the value (QString)
DisableSearch Disable the subject (keyword) search for the help book.
Attributes:
0,1 value true, false
type type, data type of the value (bool)
DisableFullTextSearch Disable the full text search for the help book.
Attributes:
0,1 value true, false
type type, data type of the value (bool)
DisableIndex Disable the subject index for the help book.
Attributes:
0,1 value true, false
type type, data type of the value (bool)
DisableContent Disable the table of contents for the help book.
0,1 Attributes:
value true, false
type type, data type of the value (bool)

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Tag Number Meaning

DefaultLanguage Abbreviation for the language that should be displayed if the
actual country language is available for the help book.
0,1 Attributes:
value chs, cht, deu, eng, esp, fra, ita, kor, ptb ...
type Data type of the value (QString)

The following applies to the "Number" column: * means 0 or several

Example of a "slhlp.xml" file

The help book "hmi_myhelp.xml" is configured in the following example; the subject index is
not activated:

<?xml version="1.0" encoding="UTF-8" standalone="yes"?>

<!DOCTYPE CONFIGURATION>
<CONFIGURATION>
<OnlineHelpFiles>
<hmi_myhelp>
<EntriesFile value="hmi_myhelp.xml" type="QString"/>
<DisableIndex value="true" type="bool"/>
</hmi_myhelp>
</OnlineHelpFiles>
</CONFIGURATION>

3.7.2 Structure and syntax of the help book

Syntax for the help book

The help book is an XML file in which the structure of the online help is defined. The name of
the file can be freely selected, e.g. "hmi_myhelp". In this file, you define:
● HTML documents
● Contents and subject index

Tag Number Meaning

HMI_SL_HELP 1 Root element of the XML document
BOOK Identifies a help book. The name can be freely selected under the
constraint that no name predefined by the system is used (such as
sinumerik_alarm_plc_pmc).
Attributes:

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3.7 Creating OEM-specific online help

Tag Number Meaning

ref Identifies the HTML document that is displayed as the
+ entry page for the help book.
titel Title of the help book that is displayed in the table of
contents.
helpdir Directory that contains the online help of the help book.
ENTRY Chapter of the online help
Attributes:
ref Identifies the HTML document that is displayed as entry
* page for the chapter.
titel Title of the chapter that is displayed in the table of
contents.
INDEX_ENTRY Subject (keyword) to be displayed
Attributes:
ref Identifies the HTML document that is jumped to for this
* subject index entry.
titel Title of the subject that is displayed in the subject index.

The following applies to the "Number" column:

* means 0 or several
+ means 1 or several

Formatting the index

You have the following options to format the subject index:
● Single entry: <INDEX_ENTRY ...title="index"/>

● Two two-stage entry, whereby each title has a main and a subentry.
Separate the entries with a comma.
<INDEX_ENTRY ...title="mainIndex_1,subIndex_1 with mainIndex_1"/>

● Two-stage entry, whereby the first title is the main entry and the second title is the
subentry.
Separate the entries with a semicolon.
<INDEX_ENTRY ...title="mainIndex_2;subIndex_2

without mainIndex_1"/>

Figure 3-9 Example: Two-stage index

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3.7.3 Description of the syntax for the online help

Rules for creating the HTML files

Generating help files in the HTML format. It is possible to save all information in a single
HTML file or to distribute the information over several HTML files.
The file names are assigned taking into account the following rules:
● References within HTML files should always be specified with relative paths. Only then
can it be ensured that the references function in precisely the same way on both the
development computer as well as on the target system.
● If jumps are to be made to certain points within an HTML file per link, then so-called
anchors must be defined for this purpose.
Example of an HTML anchor:
<a name="myAnchor">This is an anchor</a>

See also: Example: How to create an online help for user PLC alarms (Page 73)
● The contents of HTML documents must be saved with the UTF-8 coding. This guarantees
that the HTML documents are correctly displayed in all of the supported country
languages.

HTML tags
The following sub-set of the HTML functional scope is supported:

Tag Description Comment

a Anchor or link Supported attributes: href and name
address Address
b Bold
big Larger font
blockquote Indented paragraph
body Document body Supported attributes: bgcolor (#RRGGBB)
br Line break
center Centered paragraph
cite Inline citation Same effect as tag i
code Code Same effect as tag tt
dd Definition data
dfn Definition Same effect as tag i
div Document division The standard block attributes are supported
dl Definition list The standard block attributes are supported
dt Definition term The standard block attributes are supported
em Emphasized Same effect as tag i
font Font size, family, color Supported attributes: size, face, and color (#RRGGBB)
h1 Level 1 heading The standard block attributes are supported
h2 Level 2 heading The standard block attributes are supported

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Tag Description Comment

h3 Level 3 heading The standard block attributes are supported
h4 Level 4 heading The standard block attributes are supported
h5 Level 5 heading The standard block attributes are supported
h6 Level 6 heading The standard block attributes are supported
head Document header
hr Horizontal line Supported attributes: width (can be specified as absolute or
relative value)
html HTML document
i Italic
img Image Supported attributes: src, width, height
kbd User-entered text
meta Meta-information
li List item
nobr Non-breakable text
ol Ordered list The standard attributes for lists are supported
p Paragraph The standard block attributes are supported (default setting:
left-aligned)
pre Preformated text
s Strikethrough
samp Sample code Same effect as tag tt
small Small font
span Grouped elements
strong Strong Same effect as tag b
sub Subscript
sup Superscript
table Table Supported attributes: border, bgcolor (#RRGGBB),
cellspacing, cellpadding, width (absolute or relative), height
tbody Table body No effect
td Table data cell The standard attributes for table cells are supported
tfoot Table footer No effect
th Table header cell The standard attributes for table cells are supported
thead Table header This is used to print tables that extend over several pages
title Document title
tr Table row Supported attributes: bgcolor (#RRGGBB)
tt Typewrite font
u Underlined
ul Unordered list The standard attributes for lists are supported
var Variable Same effect as tag tt

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Block attributes
The following attributes are supported by the tags div, dl, dt, h1, h2, h3, h4, h5, h6, p:
● align (left, right, center, justify)
● dir (ltr, rtl)

Standard attributes for lists

The following attributes are supported by tags ol and ul:
● type (1, a, A, square, disc, circle)

Standard attributes for tables

The following attributes are supported by tags td and th:
● width (absolute, relative, no-value)
● bgcolor (#RRGGBB)
● colspan
● rowspan
● align (left, right, center, justify)
● valign (top, middle, bottom)

CSS properties
The following table includes the supported CSS functional scope:

Property Values Description

background-color <color> Background color for elements
background-image <uri> Background image for elements
color <color> Foreground color for text
text-indent <length>px Indent the first line of a paragraph in pixels
white-space normal | pre | nowrap | pre- Defines how whitespace characters are handled
wrap in HTML documents
margin-top <length>px Width of the upper edge of the paragraph in
pixels
margin-bottom <length>px Width of the lower edge of the paragraph in
pixels
margin-left <length>px Length of the left hand edge of the paragraph in
pixels
margin-right <length>px Width of the righthand edge of the paragraph in
pixels
vertical-align baseline | sub | super | Vertical alignment for text (in tables, only the
middle | top | bottom values middle, top and bottom are supported)
border-color <color> Border color for text tables

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Property Values Description

border-style none | dotted | dashed | dot- Border style for text tables
dash | dot-dot-dash | solid |
double | groove | ridge |
inset | outset
background [ <'background-color'> || Short notation for background property
<'background-image'> ]
page-break-before [ auto | always ] Page break before a paragraph/table
page-break-after [ auto | always ] Page break after a paragraph/table
background-image <uri> Background image for elements

Supported CSS selectors

All CSS 2.1 selector classes are supported with the exception of so-called pseudo selector
classes such as :first-child, :visited and :hover.

3.7.4 Example: This is how you generate an OEM-specific online help book

Requirements
Generate the following files:
● Configuration file: "slhlp.xml"

<?xml version="1.0" encoding="UTF-8" standalone="yes"?>

<!DOCTYPE CONFIGURATION>
<CONFIGURATION>
<OnlineHelpFiles>
<hmi_myhelp>
<EntriesFile value="hmi_myhelp.xml" type="QString"/>
<DisableIndex value="false" type="bool"/>
</hmi_myhelp>
</OnlineHelpFiles>
</CONFIGURATION>

● Definition of the help book: "hmi_myhelp.xml"

<?xml version="1.0" encoding="UTF-8"?>

<HMI_SL_HELP language="en-US">
<BOOK ref="index.html" title="Easy Help" helpdir="hmi_myhelp">
<ENTRY ref="chapter_1.html" title="Chapter 1">

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<INDEX_ENTRY ref="chapter_1.html" title="Keyword 1"/>

<INDEX_ENTRY ref="chapter_1.html" title="Keyword 2"/>
</ENTRY>
<ENTRY ref="chapter_2.html" title="Chapter 2">
<INDEX_ENTRY ref="chapter_2.html" title="Keyword 2"/>
</ENTRY>
<ENTRY ref="chapter_3.html" title="Chapter 3">
<INDEX_ENTRY ref="chapter_3.html" title="Keyword 3"/>
<ENTRY ref="chapter_31.html" title="Chapter 3.1">
<INDEX_ENTRY ref="chapter_31.html" title="test;Chapter 3.1"/>
</ENTRY>
<ENTRY ref="chapter_32.html" title="Chapter 3.2">
<INDEX_ENTRY ref="chapter_32.html" title="test;Chapter 3.2"/>
</ENTRY>
</ENTRY>
</BOOK>
</HMI_SL_HELP>

Saving help files in the target system

In the following example, the structure of a help book with the name "Easy Help" with table of
contents and subject index is described.
Procedure:
1. Copy the configuration file "slhlp.xml" to the following directory:
/oem/sinumerik/hmi/cfg

2. Create a directory for the desired language of the online help under the following
path: /oem/sinumerik/him/hlp
Use the specified language code from Chapter Table: Language code in file names
(Page 401).

Note
Notation
The directory names must be written in lower case.
For example, if you are integrating a help in English, create an "eng" folder.

3. Place the help book, e.g. "hmi_myhelp.xml" in the "eng" folder.

/oem/sinumerik/him/hlp/eng/hmi_myhelp.xml

4. Copy the help files to the following directory:

/oem/sinumerik/him/hlp/eng/hmi_myhelp/

The settings become effective only after restarting the system.

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3.7 Creating OEM-specific online help

Note
Updates or changes
When displaying the table of contents and index of a help book, for quicker processing, the
help files are saved in the binary format in the /siemens/sinumerik/sys_cache/hmi/hlp
directory: slhlp_<Hilfebuch>_*_<lng>.hmi .
In the example: slhlp_hmi_myhelp_*_eng.hmi
These files must first be deleted so that the changes can take effect and be displayed in the
online help.

Result
The book consists of three chapters with sections:

Figure 3-10 Example: OEM online help

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Entries in the subject index:

Figure 3-11 Example: Index

3.7.5 Example: How to create an online help for user PLC alarms

Overview
If a user PLC alarm is triggered, a context-sensitive online help can be created for the
respective alarm, e.g. with explanation and remedy. The online help texts for the user PLC
alarms are managed in the following file: "sinumerik_alarm_oem_plc_pmc.html"

Figure 3-12 Example: Online help of user PLC alarms

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Operating software settings
3.7 Creating OEM-specific online help

Structure of the help file

The following entries are permitted in the help file:

Entry Meaning
<a name="AlarmNo">AlarmNo</a> Hyperlink to the alarm number
<b> .....</b> Help text for the corresponding alarm
<td width="85%">......</td> Text that is displayed after the "Explanation" or "Remedy"
field.

Creating a help file

The file name is language-neutral and must be:

sinumerik_alarm_oem_plc_pmc.html
<?xml version="1.0" encoding="UTF-8" standalone="yes"?>
<!DOCTYPE html PUBLIC>

<html>
<head><title></title></head>
<body>
<table>
...
<tr>
<td width="15%">
<b><a name="700004">700004</a></b></td>
<td width="85%"><b>Help for user PLC alarm 700004 </b></td></tr>
<tr><td valign="top" width="15%"><b>Reaction: </b></td>
<td width="85%">Reaction for user PLC alarm 700004 </td></tr>
<tr><td valign="top" width="15%"><b>Remedy:</b></td>
<td width="85%">Restart control. </td>
</tr>
<br>

<tr>
<td width="15%">
<b><a name="700005">700005</a></b></td>
<td width="85%"><b>Help for user PLC alarm 700005 </b></td></tr>
<tr><td valign="top" width="15%"><b>Reaction: </b></td>
<td width="85%">Reaction for user PLC alarm 700005 </td></tr>
<tr><td valign="top" width="15%"><b>Remedy:</b></td>
<td width="85%">Clear alarm with Reset key. </td>
</tr>
<br>

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sinumerik_alarm_oem_plc_pmc.html
...
</table>
<p></p>
</body>
</html>

Procedure:
1. Copy the file to one of the following directories:
/oem/sinumerik/hmi/hlp/<lng>/sinumerik_alarm_plc_pmc/

/user/sinumerik/hmi/hlp/<lng>/sinumerik_alarm_plc_pmc/

<lng> stands for the language code.

2. Delete all files in the directory:

/siemens/sinumerik/sys_cache/hmi//hlp

The settings become effective only after restarting the system.

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Operating software settings
3.7 Creating OEM-specific online help

3.7.6 Example: This is how you generate an online help for NC/PLC variables

Overview
In order to generate context-sensitive online help for NC/PLC variables or system variables
as shown in the following example, the descriptive texts are managed in language-
dependent html files.

Figure 3-13 Example: Online help for user variables

Structure of the online help

The following files are required for the online help:

File Meaning
sldgvarviewhelp.ini Configuration file to manage an html file or several html
files
<lng>/<name>1.html The contents of all html files of the online help are
<lng>/<name>2.html
language-dependent and are saved in the relevant
. . .
<lng>/<name>n.html
language directory <lng>.

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Structure of the configuration file

The file is language-neutral and must be called:

sldgvarviewhelp.ini
[HelpBindings]
/BAG/STATE/OPMODE = var1_help.html#var1
$AA_IM[X1] = var1_help.html
$R[1] = var1_help.html#var2
/Channel/Parameter/R[u1,1] = var2_help.html#var2
DB1600.DBB0 = var2_help.html#var1
GUD/MyVar[2] = var2_help.html

Note
The html files can be generated with any html editor. A definition is provided in the
configuration file as to which html files belong to the online help.
The description can comprise one or several html files: For example, one html file for each
variable or several identical variables in one file.

Procedure:
1. Copy the configuration file to the following directory:
/oem/sinumerik/hmi/cfg/sldgvarviewhelp.ini

2. Copy the html files to one of the following directories:

/oem/sinumerik/hmi/hlp/<lng>/

/user/sinumerik/hmi/hlp/<lng>/

<lng> stands for the language code.

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3.7 Creating OEM-specific online help

3. Delete all files in the directory:

/siemens/sinumerik/sys_cache/hmi//hlp

The settings become effective only after restarting the system.

3.7.7 Example: This is how you generate a programming online help

Requirements
Generate the following files:
● Configuration file "prog_help.ini"

[milling]
CYCLE1=cycle1_help.html
CYCLE2=cycle2_help.html#TextAnchor1
CYCLE3=cycle3_help.html
CYCLE4=cycle4_help.html

[turning]
CYCLE3=cycle2_help.html
CYCLE4=cycle3_help.html

● Configuration file for the help book "slhlp.xml" (optional)

<?xml version="1.0" encoding="UTF-8" standalone="yes"?>

<!DOCTYPE CONFIGURATION>
<CONFIGURATION>
<OnlineHelpFiles>
<hmi_prog_help>
<EntriesFile value="hmi_prog_help.xml" type="QString"/>
<DisableIndex value="true" type="bool"/>
</hmi_prog_help>
</OnlineHelpFiles>
</CONFIGURATION>

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● Configuration file for the help book "hmi_prog_help.xml" (optional)

<?xml version="1.0" encoding="UTF-8"?>

<HMI_SL_HELP language="en-US">
<BOOK ref="index.html" title="OEM_CYCLES" helpdir="hmi_prog_help">
<ENTRY ref="cycle1_help.html" title="Cycle1"></ENTRY>
<ENTRY ref="cycle2_help.html" title="Cycle2"></ENTRY>
<ENTRY ref="cycle3_help.html" title="Cycle3"></ENTRY>
<ENTRY ref="cycle4_help.html" title="Cycle4"></ENTRY>
<ENTRY ref="cycle_help.html" title="OEM_Cycles"></ENTRY>
</BOOK>
</HMI_SL_HELP>

● Language-dependent file "<prog_help_eng>.ts": this filename is permanently specified.

<?xml version="1.0" encoding="utf-8" standalone="yes"?>

<!DOCTYPE TS>
<TS>
<context>
<name>oem_cycles</name>
<message>
<source>CYCLE1</source>
<translation>short description for cycle 1</translation>
<chars>*</chars>
</message>
<message>
<source>CYCLE2</source>
<translation>short description for cycle 2</translation>
<chars>*</chars>
</message>
<message>
<source>CYCLE3</source>
<translation>short description for cycle 3</translation>
<chars>*</chars>
</message>
</context>
</TS>

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Operating software settings
3.7 Creating OEM-specific online help

Saving help files in the target system

Procedure:
1. Copy the configuration file "prog.ini" to the following directory:
/oem/sinumerik/hmi/cfg

2. Copy the file "slhlp.xml" to the help book in the following directory:
/oem/sinumerik/hmi/cfg

3. Create a directory for the desired language of the online help under the following
path: /oem/sinumerik/hmi/hlp/<lng> and copy the hmi_prog_help.xml file there
Use the specified language code from the list of language codes for file names. The
directory names must be written in lower case.
4. Copy the language-dependent prog_help_<lng>.ts file for the brief description to the
following path: /oem/sinumerik/hmi/<lng>/prog_help_<lng>.ts
5. Copy the html files with the description of the OEM cycles to the following directory:
/oem/sinumerik/him/hlp/<lng>/hmi_prog_help/cycle<n>_help.html

The settings become effective only after restarting the system.

See also
Example: This is how you generate an OEM-specific online help book (Page 70)

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Commissioning the I/O 4
4.1 Connecting the I/O modules

4.1.1 Activating I/O modules

Machine data for the PLC I/O

The following components are assigned fixed addresses for the input and output image of
the PLC: I/O modules, machine control panel, SENTRON PAC3200, SENTRON PAC4200
and PN bus coupler.
The machine data contains two fields to deactivate the update of the input and output image
of the PLC:

Machine data Value range

12986[i] $MN_PLC_DEACT_IMAGE_LADDR_IN 0≤i≤7 Input addresses
12987[i] $MN_PLC_DEACT_IMAGE_LADDR_OUT 0≤i≤7 Output addresses

The SINUMERIK 828D works with a fixed maximum configuration of the I/O modules. As
delivered, the data transfer to the input and output image of the PLC is deactivated for all I/O
modules.
Field with logical input addresses:

MD Logical input address Data transfer to the PLC deactivated

12986[0] 0 1st PP module inactive
12986[1] 9 2nd PP module inactive
12986[2] 18 3rd PP module inactive
12986[3] 27 4th PP module inactive
12986[4] 36 5th PP module inactive
12986[5] 96 PN bus coupler inactive
12986[6] 112 Machine control panel inactive
12986[7] 132 SENTRON PAC4200 inactive
12986[8] 144 SENTRON PAC3200 inactive

The field of output addresses is empty (default setting): MD12987[i] = -1

If an I/O module is to be activated, its address must not be entered in either MD12986[i] or in
MD12987[i]. Instead, the value -1 ("empty") must be entered.

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Commissioning the I/O
4.1 Connecting the I/O modules

Example
There are two PP modules, the machine control panel and the SENTRON PAC4200
activated:

MD Logical input Data transfer to the PLC deactivated

address
12986[0] -1 1st PP module active
12986[1] -1 2nd PP module active
12986[2] 18 3rd PP module inactive
12986[3] 27 4th PP module inactive
12986[4] 36 5th PP module inactive
12986[5] 96 PN bus coupler inactive
12986[6] -1 Machine control panel active
12986[7] -1 SENTRON PAC4200 active
12986[8] 144 SENTRON PAC3200

Note
The use of an input/output address of a deactivated module in the PLC user program does
not trigger an alarm. The PLC user program always works with the image memory. Whether
there is a connection to the physical input/outputs is configured via MD12986[i] and
MD12987[i].
Active modules are then monitored cyclically for failure.

3/&XVHU ,QSXWV 31PRGXOH

SURJUDP ,%

2XWSXWV
4%

0'>L@
RU
0'>L@

Figure 4-1 I/O switch

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 Commissioning the I/O
4.1 Connecting the I/O modules

4.1.2 Addressing the I/O modules

IP addresses of the I/O modules

You can find the DIP switch S1 for the IP address of the appropriate I/O module in the
following table. In this case, the maximum configuration with I/O modules, bus coupler and
machine control panel via the PLC I/O Interface based on PROFINET is taken into
consideration.

I/O module Bus Device name IP address Input addresses Output addresses
192.168.214. (active with MD12986[x] = -1)
Index n:
1st digital PP module PN pp72x48pn9 9 0…8 0…5
2nd digital PP module PN pp72x48pn8 8 9 … 17 6 … 11
3rd digital PP module PN pp72x48pn7 7 18 … 26 12 … 17
4th PP module digital PN pp72x48pn6 6 27… 35 18 … 23
5th digital PP module PN pp72x48pn5 5 36 … 44 24 … 29
Unassigned 45 30 … 55
Index d:
1st PP module diagnostics PN pp72x48pn9 9 46 … 47 --
2nd PP module diagnostics PN pp72x48pn8 8 48 … 49 --
3rd PP module diagnostics PN pp72x48pn7 7 50 … 51 --
4th PP module diagnostics PN pp72x48pn6 6 52 … 53 --
5th PP module diagnostics PN pp72x48pn5 5 54 … 55 --
Index m:
1st analog PP module PN pp72x48pn9 9 56 … 63 56 … 63
2nd analog PP module PN pp72x48pn8 8 64 … 71 64 … 71
3rd analog PP module PN pp72x48pn7 7 72 … 79 72 … 79
4th analog PP module PN pp72x48pn6 6 80 ... 87 80 ... 87
5th analog PP module PN pp72x48pn5 5 88 … 95 88 … 95

PN/PN coupler * PN pn-pn-coupler20 20 96 … 111 96 … 111

External machine control panel PN mcp-pn64 64 112 … 125 112 … 121
Reserved -- -- 126 … 131 122 ... 123
Sentron PAC 4200 * PN pac4200-pn21 21 132 ... 143 132 ... 143
Sentron PAC 3200 * PN pac3200-pn22 22 144 ... 155 144 ... 155

The Index n, m, d is always the start address of the address range.

*) The IP address of these components is not set using a switch but rather configured appropriately.

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Commissioning the I/O
4.1 Connecting the I/O modules

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Parameterizing machine data 5
5.1 Classification of machine data

Authorization for machine data

At least the Manufacturer password is necessary to enter or change machine data.

WARNING
Lethal danger and danger for machines
Changes in the machine data have a considerable influence on the machine.
Incorrect configuration of the parameters can endanger human life and cause damage to
the machine.

Classification of machine data

The machine data is divided into the following areas:
● General machine data ($MN )
● Channel-specific machine data ($MC )
● Axis-specific machine data ($MA )
● Display machine data ($MM )
● General setting data ($SN )
● Channel-specific setting data ($SC )
● Axis-specific setting data ($SA )
● SINAMICS machine data (Control Unit and drive machine data):
r0001 ... r9999 (read-only)
r0001 ... r9999 (read/write)

Note
Machine data for turning and milling technologies is already set up in such a way that an
adjustment of machine data is only necessary in exceptional cases.

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Parameterizing machine data
5.1 Classification of machine data

A separate list image is provided for each of these areas in which you can view and edit
machine data:

Figure 5-1 Softkey bar

The following properties of the machine data are displayed from left to right:
● Number of the machine data, if applicable with array index in square brackets
● Name of the machine data
● Value of the machine data
● Unit of the machine data
● Effectiveness of the machine data
● Data class

Physical units of the machine data

The physical units of machine data are displayed on the right-hand side of the input field:

Display Unit Measured quantity

m/s**2 m/s² Acceleration
rev/s**3 rev/s³ Acceleration change for the
rotating axis
kg/m**2 kgm² Moment of inertia
mH mH (millihenry): Inductance
Nm Nm (Newton meters): Torque
us µs (microseconds): Time
µA µA (microamperes): Electric current
µVs µVs (microvolt-seconds): Magnetic flux
userdef user-defined: The unit is defined by the user.

If the machine data does not use units, no units are displayed.
If the data is not available, the "#" symbol is displayed instead of the value. If the value ends
in an "H", it is a hexadecimal value.

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 Parameterizing machine data
5.1 Classification of machine data

Effectiveness of the machine data

The right-hand column indicates when the changed machine data takes effect:

cf The changed machine data must be activated by pressing the "Apply MD"
softkey.
po The changed machine data requires an "NCK Power On-Reset" to take effect.
re The changed machine data must be activated by pressing the <RESET> key.
so The changed machine data becomes active immediately.

User views
User views are user-specific groups of machine data. They are used to call all relevant
machine data in a certain operating state from various areas for processing.
The user views are stored on the CompactFlash card with the following path:
user/sinumerik/hmi/template/user_views

The following user views are already available as template:

● Electrical_Startup
● Mechanical_Startup
● Optimizing_Axis

See also
Description of the data classes: Function Manual Basic Functions (P4)
A detailed description of the machine data is given in the list manual with cross-references to
the appropriate section in the function manual.

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Parameterizing machine data
5.2 Processing part programs from external CNC systems

5.2 Processing part programs from external CNC systems

Note
Default setting
For SINUMERIK 828D, the following machine data are already suitably preset for the
particular technology – either turning or milling. These machine data cannot be changed and
are not displayed.

Activate the ISO Dialect function

The MD18800 $MN_EXTERN_LANGUAGE machine data is used to activate the external
language. The ISO dialect M or T language types can be selected using MD10880
$MN_EXTERN_CNC_SYSTEM.
The two G commands of group 47 are used to switch from Siemens mode to ISO dialect
mode:
● G290: Siemens NC programming language active
● G291: ISO dialect NC programming language active
The active tool, tool offsets and work offsets are retained. G290 and G291 must be the only
components of an NC program block.
The switchover to an external programming language is contained in the scope of delivery
for SINUMERIK 828D. MD10712 $MN_NC_USER_CODE_CONF_NAME_TAB is only valid
for NC language commands in the Siemens mode.

References
Function Manual ISO Dialects

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 Parameterizing machine data
5.3 Machining free form surfaces using Advanced Surface

5.3 Machining free form surfaces using Advanced Surface

Machining with Advanced Surface

When executing CAM programs in the high-speed cutting (HSC) range, the control has to
process high feedrates with the shortest NC blocks. The result should be a good surface
quality of the workpiece with high precision in the µm range at extremely high machining
feedrates of > 10 m/min.
Using CYCLE832, the NC program is very precisely harmonized across the various
machining strategies:
● When roughing, using smoothing of the contour the emphasis is on speed.
● When finishing, the emphasis is on accuracy.
In both cases, specifying a tolerance ensures that the machining contour is maintained in
order to achieve the desired surface quality.

6XUIDFHTXDOLW\

$FFXUDF\ 9HORFLW\

Figure 5-2 Machining a workpiece surface

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Parameterizing machine data
5.3 Machining free form surfaces using Advanced Surface

Checking the settings for Advanced Surface

After installation of the 828D Toolbox, the following test programs are contained in the
\Examples\AS_checkprograms directory:
● MDC3AXV3B_SW2_6.SPF
● MDC3AXV3A_SW2_7__SW4_4.SPF
● MDC3AXV3B_SW4_5.SPF
The readme.txt file also contains further information in order to test the recommended
machine data settings for Advanced Surface with the programs. When the program is
started, a MDADVS.SPF file will be created in the SPF.DIR directory in which the test results
are output as a list.
Example:
(extract from the complete file)
Machine Data setting different to required Advanced Surface Setting
Machine Data setting different to recommended Advanced Surface Setting
N20470 $MC_CPREC_WITH_FFW=1, recommended: 3
N20485 $MC_COMPRESS_SMOOTH_FACTOR[2]=0, recommended: 0.0001
N20485 $MC_COMPRESS_SMOOTH_FACTOR[3]=0, recommended: 0.0001
N20485 $MC_COMPRESS_SMOOTH_FACTOR[4]=0, recommended: 0.0001
N20486 $MC_COMPRESS_SPLINE_DEGREE[2]=3, recommended: 5
N20486 $MC_COMPRESS_SPLINE_DEGREE[3]=3, recommended: 5
N20486 $MC_COMPRESS_SPLINE_DEGREE[4]=3, recommended: 5
N20487 $MC_COMPRESS_SMOOTH_FACTOR_2[2]=0, recommended: 0.5
N20487 $MC_COMPRESS_SMOOTH_FACTOR_2[3]=0, recommended: 0.5
N20487 $MC_COMPRESS_SMOOTH_FACTOR_2[4]=0, recommended: 0.5

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5.4 Machine data for Advanced Surface

5.4 Machine data for Advanced Surface

Machine data for Advanced Surface

The following setpoints are recommended for the listed machine data in order to achieve the
optimum workpiece surface when machining mold workpieces:
General machine data:

MD number Designation Default Recom- Data Parameter

setting mendation class
10200 $MN_INT_INCR_PER_MM 100000 100000 M --
10210 $MN_INT_INCR_PER_DEG 100000 100000 M --
10682 $MN_CONTOUR_SAMPLING_FACTOR 1 1 M --

Channel-specific machine data:

MD number Designation Default Recom- Data Parameter

setting mendation class
20150[3] $MC_GCODE_RESET_VALUES 3 3 M FIFOCTRL
20150[44] $MC_GCODE_RESET_VALUES 2 2 M UPATH
20170 $MC_COMPRESS_BLOCK_PATH_LIMIT 20 20 M --
20172 $MC_COMPRESS_VELO_TOL 60000 1000 M --
20443[0] $MC_LOOKAH_FFORM 0 0 M DYNNORM
20443[1] $MC_LOOKAH_FFORM 0 0 M DYNPOS
20443[2] $MC_LOOKAH_FFORM 0 1 M DYNROUGH
20443[3] $MC_LOOKAH_FFORM 0 1 M DYNSEMIFIN
20443[4] $MC_LOOKAH_FFORM 0 1 M DYNFINISH
20455 $MC_LOOKAH_FUNCTION_MASK 0 0 M --
20480 $MC_SMOOTHING_MODE 0 0 M --
20482 $MC_COMPRESSOR_MODE 100 100 M --
20485 $MC_COMPRESS_SMOOTH_FACTOR[0-4] 0 0 M --
20486 $MC_COMPRESS_SPLINE_DEGREE[0-4] 3 3 M --
20490 $MC_IGNORE_OVL_FACTOR_FOR_ADIS 1 1 M --
20550 $MC_EXACT_POS_MODE 3 3 M --
20600[0] $MC_MAX_PATH_JERK 10000 10000 M DYNNORM
20600[1] $MC_MAX_PATH_JERK 10000 10000 M DYNPOS
20600[2] $MC_MAX_PATH_JERK 10000 10000 M DYNROUGH
20600[3] $MC_MAX_PATH_JERK 10000 10000 M DYNSEMIFIN
20600[4] $MC_MAX_PATH_JERK 10000 10000 M DYNFINISH
20602[0] $MC_CURV_EFFECT_ON_PATH_ACCEL 0 0 M --
20602[1] $MC_CURV_EFFECT_ON_PATH_ACCEL 0 0 M --
20602[2] $MC_CURV_EFFECT_ON_PATH_ACCEL 0.6 0.65 M --

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Parameterizing machine data
5.4 Machine data for Advanced Surface

MD number Designation Default Recom- Data Parameter

setting mendation class
20602[3] $MC_CURV_EFFECT_ON_PATH_ACCEL 0.6 0.6 M --
20602[4] $MC_CURV_EFFECT_ON_PATH_ACCEL 0.6 0.5 M --
20603[0] $MC_CURV_EFFECT_ON_PATH_JERK 0 0 M --
20603[1] $MC_CURV_EFFECT_ON_PATH_JERK 0 0 M --
20603[2] $MC_CURV_EFFECT_ON_PATH_JERK 0 0 M --
20603[3] $MC_CURV_EFFECT_ON_PATH_JERK 0 0 M --
20603[4] $MC_CURV_EFFECT_ON_PATH_JERK 0 0 M --
20605[0] $MC_PREPDYN_SMOOTHING_FACTOR 0 1 M --
20605[1] $MC_PREPDYN_SMOOTHING_FACTOR 0 1 M --
20605[2] $MC_PREPDYN_SMOOTHING_FACTOR 0 1 M --
20605[3] $MC_PREPDYN_SMOOTHING_FACTOR 0 1 M --
20605[4] $MC_PREPDYN_SMOOTHING_FACTOR 0 1 M --
20606[0] $MC_PREPDYN_SMOOTHING_ON 0 0 M DYNNORM
20606[1] $MC_PREPDYN_SMOOTHING_ON 0 0 M DYNPOS
20606[2] $MC_PREPDYN_SMOOTHING_ON 0 1 M DYNROUGH
20606[3] $MC_PREPDYN_SMOOTHING_ON 0 1 M DYNSEMIFIN
20606[4] $MC_PREPDYN_SMOOTHING_ON 0 1 M DYNFINISH
28060 $MC_MM_IPO_BUFFER_SIZE 150 150 M --
28070 $MC_MM_NUM_BLOCKS_IN_PREP 80 80 M --
28302[0] $MC_MM_PROTOC_NUM_ETP_STD_TYP 28 28 M --
28520 $MC_MM_MAX_AXISPOLY_PER_BLOCK 3 5 M --
28530 $MC_MM_PATH_VELO_SEGMENTS 5 5 M --
28533 $MC_MM_LOOKAH_FFORM_UNITS 18 18 M --
28540 $MC_MM_ARCLENGTH_SEGMENTS 10 10 M --

Axis machine data:

MD number Designation Default Recom- Data Parameter

setting mendation class
32300 $MA_MAX_ACCEL[0-3] 1 1 M --
32300 $MA_MAX_ACCEL[4] 1 1 M --
32310[0] $MA_MAX_ACCEL_OVL_FACTOR 1.2 1.2 M --
32310[1] $MA_MAX_ACCEL_OVL_FACTOR 1.2 1.2 M --
32310[2] $MA_MAX_ACCEL_OVL_FACTOR 1.2 1.2 M --
32310[3] $MA_MAX_ACCEL_OVL_FACTOR 1.2 1.2 M --
32310[4] $MA_MAX_ACCEL_OVL_FACTOR 1.2 1.2 M --
32400 $MA_AX_JERK_ENABLE 0 0 M --
32402 $MA_AX_JERK_MODE 2 2 M --
32410 $MA_AX_JERK_TIME 0.001 0.001 M --
32431[0] $MA_MAX_AX_JERK 1000000 1000000 I DYNNORM

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5.4 Machine data for Advanced Surface

MD number Designation Default Recom- Data Parameter

setting mendation class
32431[1] $MA_MAX_AX_JERK 1000000 1000000 I DYNPOS
32431[2] $MA_MAX_AX_JERK 1000000 1000000 I DYNROUGH
32431[3] $MA_MAX_AX_JERK 20 20 I DYNSEMIFIN
32431[4] $MA_MAX_AX_JERK 20 20 I DYNFINISH
32432[0] $MA_PATH_TRANS_JERK_LIM 1000000 1000000 I DYNNORM
32432[1] $MA_PATH_TRANS_JERK_LIM 1000000 1000000 I DYNPOS
32432[2] $MA_PATH_TRANS_JERK_LIM 1000000 1000000 I DYNROUGH
32432[3] $MA_PATH_TRANS_JERK_LIM 20 20 I DYNSEMIFIN
32432[4] $MA_PATH_TRANS_JERK_LIM 20 20 I DYNFINISH
32620 $MA_FFW_MODE 3 3 M DYNNORM
32640 $MA_STIFFNESS_CONTROL_ENABLE 1 1 M DSC
33120 $MA_PATH_TRANS_POS_TOL 0.005 0.005 U --

Setting data:

MD number Designation Default Recom- Data Parameter

setting mendation class
42470 $SC_CRIT_SPLINE_ANGLE 36° 36° U --
42471 $SC_MIN_CURV_RADIUS 1 1 M --
42500 $SC_SD_MAX_PATH_ACCEL 10000 10000 U --
42502 $SC_IS_SD_MAX_PATH_ACCEL 0 0 U --
42510 $SC_SD_MAX_PATH_JERK 10000 10000 U --
42512 $SC_IS_SD_MAX_PATH_JERK 0 0 U --

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Parameterizing machine data
5.5 Machine data for an analog spindle

5.5 Machine data for an analog spindle

Connection for encoder actual values

Precondition for connecting a spindle actual value encoder is an axis with digital drive
(SINAMICS axis), which only has one encoder. A Sensor Module, e.g. SMC30, is connected
as 2nd encoder at the axis module, which is connected with the directly mounted spindle
actual value encoder. The PROFIdrive message frame the SINAMICS axis must be
designed for two encoder actual values. Depending on MD11240
$MN_PROFIBUS_SDB_NUMBER, the standard SDB of SINUMERIK 828D supports
Siemens message frame 116 or Siemens message frame 136.
Functional restrictions:
● There is no setpoint message frame for the analog spindle; this means that the
functionality based on the setpoint message frame is not available, e.g. DSC, torque
feedforward control.
● The driver software simulates the "Drive ready" signal as being set.
● As drive parameters cannot be accessed, the associated functionality is restricted (e.g.
spindle utilization display, automatic speed and position controller optimization). The
missing values are shown in gray in the "Service Overview" dialog in the analog spindle
column: "This axis is not affected."

Connection for spindle setpoints

The analog spindle is connected to interface X252. Depending on the operating mode of the
analog spindle, the following signals are output:

Spindle type Signal name Meaning

Bipolar spindle AOUT Analog output +/-10 V
AGND Analog output 0 V reference signal
DOUT11 Controller enable
Unipolar spindle with separate AOUT Analog output +10 V
enable and direction signals
AGND Analog output 0 V reference signal
DOUT12 Negative direction of travel (remains set even if
there is no controller enable)
Unipolar spindle with direction- AOUT Analog output +10 V
dependent enable
AGND Analog output 0 V reference signal
DOUT11 Controller enable and positive direction of travel
DOUT12 Controller enable and negative direction of travel

The D/A conversion of the spindle setpoint is realized with a 14 bit resolution.

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 Parameterizing machine data
5.5 Machine data for an analog spindle

Relevant machine data

The following machine data must be set for the analog spindle:
● Activation of the analog spindle:
MD30100:$MA_CTRLOUT_SEGMENT_NR = 0
The analog spindle for the setpoint output is activated by setting the local bus as bus
segment.
● Selecting the analog spindle mode:

MD30134:$MA_IS_UNIPOLAR_OUTPUT
=0 bipolar output (+/-10 V)
=1 unipolar spindle with separate enable and direction signals
=2 unipolar spindle with direction-dependent enable

● The rated output voltage must be adapted to the rated speed of the analog drive:
MD32250: $MA_RATED_OUTVAL
MD32260: $MA_RATED_VELO
● If the analog spindle is to be operated without an actual value encoder, then the value 0
must be entered as number of encoders:
MD30200: $MA_NUM_ENCS = 0
● When using a directly mounted spindle actual value encoder, PROFIBUS should be
selected as the actual value sensing type:
MD30240: $MA_ENC_TYPE = 1 or 4
● The spindle actual value encoder must then be configured as 2nd encoder of a
SINAMICS axis. To do this, the drive assignment of the actual value should be set the
same as for the axis, where the SMC30 is to be connected at its axis module:
MD30220[0]: $MA_ENC_MODULE_NR[0] = MD30220[0] of the SINAMICS axis
● The input assignment of the actual value should be set to the input for the 2nd encoder at
the SINAMICS axis module:
MD30230[0]: $MA_ENC_INPUT_NR[0] = 2
● Automatic drift compensation can be activated for a connected spindle actual value
encoder:
MD36700:$MA_DRIFT_ENABLE
MD36710: $MA_DRIFT_LIMIT
● A basic drift value is continuously entered as additional speed setpoint independent of
whether there is a spindle actual value encoder:
MD36720:$MA_DRIFT_VALUE

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Parameterizing machine data
5.5 Machine data for an analog spindle

Example
Example of three axes and analog spindle with actual value encoder (SMC30 as 2nd
encoder connected to the Y axis).

MD identifier X Y Z SP Meaning
MD30100 CTRLOUT_SEGMENT_NR 5 5 5 0 Bus segment
MD30110 CTRLOUT_MODULE_NR 1 2 3 1 Module assignment
MD30120 CTRLOUT_NR 1 1 1 1 Output assignment
MD30130 CTRLOUT_TYPE 1 1 1 1 Output type
MD30134 IS_UNIPOLAR_OUTPUT 0 0 0 0 "0" means bipolar
MD30200 NUM_ENCS 1 1 1 1 Number of encoders
MD30220[0] ENC_MODULE_NR[0] 1 2 3 2 SMC30 on the Y axis
MD30230[0] ENC_INPUT_NR[0] 1 1 1 2 Input for second encoder
MD30240 ENC_TYPE 1/4 1/4 1/4 1/4 Encoder type

MD identifier SP Meaning
MD32250 RATED_OUTVAL 80 (80% of 10V) Rated output voltage
MD32260 RATED_VELO 3000 (at 8V) Rated motor speed
MD36700 DRIFT_ENABLE 0 Automatic drift compensation is
deactivated.
MD36710 DRIFT_LIMIT 0 Limit for automatic drift compensation
MD36720 DRIFT_VALUE 0 Drift basic value

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5.6 Managing data

5.6 Managing data

Application
The "Manage data" function is used to support and simplify the commissioning and provides
functions for backing up, loading and comparing the following data:
● Machine data
● Setting data
● Drive data
● Compensation data
In contrast to a commissioning archive, only a single control object (axis, channel, servo,
infeed, etc.) is saved in ASCII format (*.tea). This file can be edited and transferred to other
control objects of the same type. The "Manage data" function is also used to transfer drive
objects for SINAMICS drives.

Managing data
The "Manage data" function offers the following options:
● Transfer data within the control
● Save data to a file
● Load data in a file
● Compare data
The following data can be saved and stored under the following absolute path on the
CompactFlash card:
● user/sinumerik/hmi/data/backup/ec for compensation data
● user/sinumerik/hmi/data/backup/md for machine data
● user/sinumerik/hmi/data/backup/sd for setting data
● user/sinumerik/hmi/data/backup/snx for SINAMICS parameters
The function is called from "Commissioning" → "Machine data" → "Manage data".

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Parameterizing machine data
5.6 Managing data

Example of "transferring data within the control"

Figure 5-3 Managing data

5.6.1 How to transfer data within the controller

Transfer data within the control

Note
Protection of the machine
For safety reasons, the machine and setting data should only be transferred when the
enable is locked.

Procedure:
1. Select the "Transfer data within the control" option.
2. Select the source data in the data structure and confirm with "OK".
3. In the drop-down list, select an object, e.g. a different axis or a different drive object, to
which you want to transfer the data and confirm with "OK".

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5.6 Managing data

4. Observe the safety instructions and check the enable signals at the machine and the
drive.
5. For drive data, the "Load" softkey is used to transfer the data to the target object.

5.6.2 To save and load data

Save data to a file

Procedure:
1. Select the "Save data to a file" option.
2. In the data structure, select the data that you want to save to a file and confirm with "OK".
3. Select as the storage location, a directory or a USB storage medium and enter a name.

Note
SINAMICS parameters
An ASCII file (*.TEA) is always generated when saving.
Three files of the following type are generated when saving the drive data:
 A binary file (*.ACX) that cannot be read.
 An ASCII file (*.TEA) that can be read or edited in the ASCII editor.
 A log file (*.log) that contains message texts (error situation) or is empty (successful
storage).

Loading data from a file

Note
Protection of the machine
For safety reasons, the machine and setting data should only be transferred when the
enable is locked.

Procedure:
1. Select the "Load data from a file" option.
2. In the data structure, select the saved file and confirm with "OK".
3. In the drop-down list, select an object, e.g. a different axis or a different drive object, to
which you want to transfer the data and confirm with "OK".
4. Observe the safety instructions and check the enable signals at the machine and the
drive.
5. For drive data, the "Load" softkey is used to transfer the data to the target object.

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Parameterizing machine data
5.6 Managing data

5.6.3 How to compare data

Compare data
You can select different data sources for the data comparison: Store the current data in files
on the controller or data.
Procedure:
1. Select the "Compare data" option.
2. In the data structure, select the data that you want to compare.
3. Press the "Add to list" softkey to transfer the data to the list in the lower area of the
display.
4. Press the "Delete from list" softkey to remove the data again.
5. If the list contains more than two data objects, you can activate the checkbox to compare
two or more data objects from the list.
6. Press the "Compare" softkey to start the comparison. The display of the comparison
results can take some time for extensive parameter lists.
7. Press the "Legend" softkey to display or hide the legend. The following display is the
default:
– Different parameters are displayed.
– The same parameters are not displayed.
– Parameters not available everywhere are displayed.

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Commissioning the drive 6
6.1 Configuring the drive

6.1.1 Example: Configuration with SINAMICS S120 Combi

Overview
The SINAMICS S120 commissioning software is available on the Toolbox CD, free of
charge. Until the SINAMICS S120 commissioning functionality is completely available in the
user interface, commissioning the drive in two steps is described here.
● The topology is automatically identified and provided using the functionality in the user
interface.
● The encoder is configured and parameterized using the commissioning software for
SINAMICS S120. The PG/PC is connected via the Ethernet interface on the front of the
SINUMERIK 828D.

Configuring the drive

Example 2 with the SINAMICS S120 Combi from Section "System overview (Page 11)" is
selected for the configuration of the drive. The DRIVE-CLiQ connections must correspond to
the topology rules in Section "Topology rules for S120 Combi (Page 164)".
The sequence of the DRIVE-CLiQ connections corresponds to the sequence of the
SINAMICS drive object numbers (= default setting):

SINAMICS drive object

Axes Number Name
--- 1 Control Unit
--- 2 Line Module
MSP1 3 SERVO 1
MX1 4 SERVO 2
MY1 5 SERVO 3
MZ1 6 SERVO 4
MA1 7 SERVO 5
--- 11 HUB module
--- 9 TM54F master

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Commissioning the drive
6.1 Configuring the drive

Sequence
The sequence is divided into the following steps:
● Step 1: Configure the spindle.
● Step 2: Configure the axes.
● Step 3: Assign the axes and backup the data:
Procedure as described in Section "Example: How to assign the axes (Page 145)".
These steps are described in more detail in the following sections.

Initial state
Before you begin:
● Connect the PG/PC to the control: see Section "Communication with the control
(Page 21)"
● The control is powered-up with "Siemens default data".
● Display in the "Startup" operating area at the control:

Figure 6-1 Control after powering-up with "Siemens default data"

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6.1 Configuring the drive

Procedure
To configure the drive:
1. Start commissioning using the "Drive system" softkey.
2. Confirm the following question with "OK", in order to start the device configuration.

Figure 6-2 Start commissioning with SINUMERIK Operate

The system topology is then automatically read-out.

3. Confirm the following question with "OK", in order to configure the device.

Figure 6-3 Device configuration

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Commissioning the drive
6.1 Configuring the drive

4. Confirm the following question with "OK", in order to perform an NCK Power On Reset.
This can take several minutes.

Figure 6-4 Confirming the Power On Reset

5. After the system has been powered-up, you receive the following message:
6. Confirm with "OK".

Figure 6-5 Completing the automatic configuration

7. The configuration has been completed once the topology data has been determined.
The commissioning software for SINAMICS S120 (Page 13) is required on the PG/PC for
the next commissioning steps.

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 Commissioning the drive
6.1 Configuring the drive

8. Select the "Startup" operating area.

9. Set the password to "Manufacturer" access level.
10.Confirm the following question with "OK", in order to start the additional configuration.

Figure 6-6 Start commissioning

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Commissioning the drive
6.1 Configuring the drive

6.1.2 Example: This is how you configure a spindle with SMC encoder

Spindle configuration with SMC20

Procedure:
1. First, select the spindle using the "Drive +" or "Drive -" softkey.
2. Select "Change" to configure the spindle.

Figure 6-7 Drive\overview

The following spindle data is displayed:

Figure 6-8 Drives\configuration: Motor Module (spindle)

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6.1 Configuring the drive

3. Select "Continue >" to assign the associated motor: The motor can either be selected
using the "Motor type" or using "Search" to find the code number.

Figure 6-9 Drives\configuration: Motor

4. Select "Continue >" to configure the motor holding brake:

Please observe the note regarding the bearing design.

Figure 6-10 Drives\configuration: Motor holding brake

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Commissioning the drive
6.1 Configuring the drive

5. Select "Continue >" to assign the encoder: The two encoders (at the motor measuring
system and at the direct measuring system) were already correctly assigned when
automatically determining the topology.

Figure 6-11 Drives\configuration: Encoder assignment

6. Select "Continue >" to configure the motor encoder.

Figure 6-12 Drives\configuration - encoder 1

7. Select "Input data" to adapt the encoder properties to the value of 4096 revolutions.

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6.1 Configuring the drive

8. Confirm this setting with "OK", the encoder is displayed as "user-defined":

Figure 6-13 Drives\configuration - encoder 2: user-defined

9. Select "Continue >" to accept the default setting with telegram 116 (speed feedforward
control). This means that for the internal drive variables, additional process data (PZD) is
also transferred and saved in system variables.

Figure 6-14 Drives\configuration - control type

- OR -

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Commissioning the drive
6.1 Configuring the drive

10.Select the setting with telegram 136 (torque feedforward control), in order to transfer
additional process data (PZD) for the internal drive variables and save in system
variables.

Figure 6-15 Drives\configuration - control type

11.Select "Continue >" to save the selection. This operation can take several minutes.
12.Select "Continue >" to accept the BICO configuration.
The following summary is then displayed in order to check all of the spindle data:

Figure 6-16 Drives\configuration - summary

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6.1 Configuring the drive

13.Select "Ready >" to complete the spindle configuration.

Figure 6-17 Commissioning - query

14.Select "Yes" to save the configuration.

Result
This completes configuration of the spindle.

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Commissioning the drive
6.1 Configuring the drive

6.1.3 Example: This is how you configure an axis with SMI encoder

Configuring the axis with SMI encoder

Procedure:
1. First, select the axis using the "Drive +" or "Drive -" softkey.
2. Select "Change" to configure the axis.

Figure 6-18 Drive\overview

The following axis data is displayed:

Figure 6-19 Drives\configuration - Motor Module

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6.1 Configuring the drive

3. Select "Continue >" to configure the associated motor: The motor type was already
correctly identified when automatically determining the topology.

Figure 6-20 Drives\configuration - motor

4. Select "Continue >" to configure the motor holding brake.

Figure 6-21 Drives\configuration - motor holding brake

Please observe the note regarding overvoltage protection. The following can be selected:
– No measure
– VPM (Voltage Protection Mode)

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6.1 Configuring the drive

5. Select "Continue >" to assign the encoder: The two encoders (at the motor measuring
system and at the direct measuring system) were already correctly assigned when
automatically determining the topology.

Figure 6-22 Drives\configuration - encoder assignment

6. Select "Continue >" to configure the motor encoder.

Figure 6-23 Drives\configuration - encoder 1

7. Select "Input data" to adapt the encoder properties to "Invert position actual value".

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6.1 Configuring the drive

8. Confirm this setting with "OK", the encoder is displayed as "user-defined":

Figure 6-24 Drives\configuration - encoder 2

9. Select "Continue >" to accept the default setting with telegram 116 (speed feedforward
control). This means that for the internal drive variables, additional process data (PZD) is
also transferred and saved in system variables.

Figure 6-25 Drives\configuration - control type

- OR -

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Commissioning the drive
6.1 Configuring the drive

10.Select the setting with telegram 136 (torque feedforward control), in order to transfer
additional process data (PZD) for the internal drive variables and save in system
variables.

Figure 6-26 Drives\configuration - control type

11.Select "Continue >" to accept the BICO configuration.

The following summary is then displayed in order to check all of the axis data:

Figure 6-27 Drives\configuration - summary

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6.1 Configuring the drive

12.Select "Ready >" to complete the axis configuration.

13.Select "Yes" to save the configuration. This operation can take several minutes.

Figure 6-28 Commissioning - query

Result
This completes configuration of the axis.

6.1.4 Example: Configuration with SINAMICS S120 Booksize

Overview
The SINAMICS S120 commissioning software is available on the Toolbox CD, free of
charge.
Until the SINAMICS S120 commissioning functionality is completely available via the user
interface, drive commissioning is performed using the commissioning software for
SINAMICS S120. The PG/PC is connected via the Ethernet interface on the front of the
SINUMERIK 828D.

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Configuring the drive

To configure the drive, the example with four axes and SINAMICS S120 Booksize is
selected from Section "System overview (Page 11)". The DRIVE-CLiQ connections are
connected as in the following diagram:

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Figure 6-29 DRIVE-CLiQ connections

The following applies to the configuration of four axes:

The sequence of the DRIVE-CLiQ connections corresponds to the sequence of the
SINAMICS drive object numbers (= default). Adjustments are only necessary if this setting
does not match the sequence in the drive system.

Index Axes SINAMICS drive object

Number Name
1 CU_I_3.3:1
2 SLM_3.3:2
4 MSP1 3 SERVO_3.3:3
1 MX1 4 SERVO_3.3:4
2 MY1 5 SERVO_3.3:5
3 MZ1 6 SERVO_3.3:6

Sequence
The sequence is divided into the following steps:
● Create connection to control.
● Step 1: Configure the drive system.
● Step 2: Configure the infeed.
● Step 3: Configure the drive object.

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● Step 4: Assign the encoders.

● Step 5: Assign the axes.
● Finally: Save the data.
These steps are described in more detail in the following sections.

See also
Topology rules for S120 Booksize (Page 166)

6.1.5 Example: This is how you configure a drive system

Initial state
Before you begin:
● Connect the PG/PC to the control: See Section Example: How to communicate with the
control using the NCU Connection Wizard (Page 29)
● The control is powered-up with "Siemens default data".
● Display in the "Startup" operating area at the control:

Figure 6-30 Machine configuration after powering up

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Procedure
To configure the drive:
1. Start the commissioning software for SINAMICS S120 on PG/PC:

2. Select the "Startup" operating area.

3. Set the password to "Manufacturer" access level. Then you obtain the following display:

Figure 6-31 Machine configuration: Starting commissioning

Note
Updating firmware
When a drive is connected, the update of the firmware is started automatically.
 During loading, you will be informed of progress with a status display.
 While the firmware is loading, the "RDY" LED flashes alternately red - green on the
appropriate module. When the module is finished, this LED will show a steady green light.
The "DC LINK" LED will show a steady orange light.

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4. When the firmware has finished loading successfully, confirm this message with "OK":

Figure 6-32 Commissioning: Loading firmware

5. Carry out a POWER ON for the drive – as requested in the message: Switch off
completely and then on again.
The following selection depends on the configuration of the target system:
– Without NX expansion module: "Drive unit" softkey
– With NX expansion module: "Drive system" softkey
This example configuration is a topology without NX expansion module.

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6. Select the "Drive unit" softkey (vertical bar) and continue the configuration with "OK".

Figure 6-33 Drive units/configuration - topology comparison

7. Then you receive the message that the device configuration process may last several
minutes.

Figure 6-34 Message to carry out the configuration

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8. Then you obtain the following display:

Figure 6-35 Drive units\configuration: NCK Power On reset

9. Confirm with "Yes". The system carries out a warm restart. This operation can take
several minutes. After the warm restart you receive the following selection:

Figure 6-36 Drive units\configuration: Continue with commissioning

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10.To continue commissioning, press the "Drives" softkey.

Figure 6-37 Drive\overview

11.Option: To identify the individual Motor Modules, select "Identify via LED": The "RDY"
LED flashes alternately red - orange.
Select the next module with the vertical softkeys "Drive +" and "Drive -".

Result
Step 1 for commissioning the drives has now been completed.

6.1.6 Example: How to configure the infeed

Configuring the infeed

Note
If there are alarms that require acknowledgment after switching on, these must be
acknowledged first. Then commissioning can be continued.

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Procedure:
1. Then press the horizontal softkey "Infeed" to obtain the following overview:

Figure 6-38 Infeeds\overview

2. To configure the infeed, select the vertical softkey "Change". In the following dialog you
can assign a new name for the infeed or accept the default setting:

Figure 6-39 Infeeds\configuration - names

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3. In the following dialog "Configuration - Line Module", the automatically detected Line
Module and the connected line filter are displayed. Press "Continue >" to continue
commissioning – or select the option "External braking module" if a braking module is
being used.

Figure 6-40 Infeeds\configuration - Line Module

4. In the following dialog "Configuration - Additional data", the line/DC link identification was
determined and saved. Press "Continue >", to continue with commissioning or select a
device supply voltage and a message frame type.

Figure 6-41 Infeeds\configuration - additional data

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5. In the following dialog "Configuration - terminal wiring", select the internal SINAMICS line
contactor control or press "Continue >" to continue with commissioning.

Figure 6-42 Infeeds\configuration - terminal wiring

6. In the following dialog "Configuration - summary", the infeed data that was entered is
displayed. Press "Finish" to complete the configuration – or "Back" if you want to make
further settings.

Figure 6-43 Infeeds\configuration - summary

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7. Confirm the query with "Yes" if you want to save the data. This operation can take several
minutes.

Figure 6-44 Infeeds\configuration - summary: Query

8. In the following "Overview" dialog you obtain an overview of the configuration data of the
drive object:

Figure 6-45 Infeeds\overview

Result
Step 2 for commissioning the infeed has now been completed.

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6.1.7 Example: This is how you configure a drive object

Initial state
The following drive objects (DO) are displayed in the "Drive startup" overview:

Drive commissioning

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Procedure
To configure a drive object:
1. Use the cursor keys to select a drive object and then press the "Drives" softkey. Select
"Change" if the drive object has still not commissioned.

Figure 6-46 Drives\overview: Starting commissioning

2. In the following "Configuration - Motor Module" dialog, you can assign a new name for the
Motor Module or you can accept the default setting:

Figure 6-47 Drives\configuration - Motor Module

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3. In the following "Configuration - Motor" dialog, from the list of motors select the connected
motor type. Press "Continue >" to continue with commissioning.

Figure 6-48 Drives\configuration - motor

4. In the following "Configuration - motor holding brake" dialog, select the motor holding
brake if available and select the extended brake control. Press "Continue >" to continue
with commissioning.

Figure 6-49 Drives\configuration - motor holding brake

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5. In the following "Configuration - encoder assignment" dialog, select the encoder

connected at the motor from the list of encoders in the drive line up. Press "Continue >" to
continue with commissioning.

Figure 6-50 Drives\configuration - encoder assignment

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6. In the following "Configuration - encoder 1" dialog, under "Select motor encoder", select
the encoder type.
– In order to configure an encoder that is not in the selection list, select "Enter data".
– Select "Details" to enter the encoder configuration data.
Press "Continue >" to continue with commissioning.

Figure 6-51 Drives\configuration - encoder 1

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7. In the following "Configuration - control type" dialog, select the control type with or without
encoder as well as the associated PROFIBUS message frame. The control mode and the
PROFIBUS message frame are generally already correctly pre-assigned.
Here, you also select the number of drive data sets (DDS) for this motor data set (MDS).
The default setting is 1 DDS; a maximum of 8 DDS per MDS is permitted. Press
"Continue >" to continue with commissioning.

Figure 6-52 Drives\configuration - control type

8. In the following "Configuration - BICO Interconnections" dialog, select the BICO

interconnection for OFF2. The default setting is dependent on the selected message frame.
Press "Continue >" to continue with commissioning.

Figure 6-53 Drives \ Configuration - BICO Interconnections

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9. In the following "Configuration - summary" dialog, the data entered for the Motor Module
is displayed. Press "Finish >", in order to complete commissioning.

Figure 6-54 Drives\configuration - summary

10.In the following query, select whether you want to save the drive data: Confirm with
"Yes>" to save the drive configuration.

Figure 6-55 Commissioning - query

Result
Step 3 for commissioning a drive object has therefore been completed. Repeat this
procedure for all drive objects.

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6.1.8 Example: How to configure the external encoder

Connecting a direct measuring system

In addition, a direct measuring system is connected for the spindle (see chapter Example:
Configuration with SINAMICS S120 Booksize (Page 117)). The following section describes
the configuration.

Procedure
To change the configuration of the drive:
1. You pressed the vertical softkey "Change".

Figure 6-56 Change drive

2. Confirm the query with the "Change" softkey.

The dialog "Configuration - Motor" is opened and the drive object 3 = Spindle is selected.
Press "Next >".
3. The next dialog tells you which motor is assigned to the drive.
Press "Next >".

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4. The next dialog tells you about the motor assignment. Press "Next >".

Figure 6-57 Configuring the motor

5. This dialog tells you the exact data of the motor recognized.
Press "Next >".
6. The next dialog tells you about the configuration of the motor brake.
Press "Next >".

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7. The next dialog tells you which encoder has already been assigned to this drive object (=
spindle):

Figure 6-58 Assigning the encoder

8. Activate the "Encoder 2" option.

9. Select the encoder "SM_19.Encoder_20" from the selection list.
10.Confirm with the <INPUT> key.
11.Press "Next >".
12.Confirm the query with "OK".
This may take several minutes.
13.While the data is being saved, you receive the following status display:

Figure 6-59 Encoder 2: Saving data

14.The next dialog tells you about the configuration of the control mode.
15.Press "Next >".

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16.The next dialog tells you about the BICO connection.

17.Press "Next >".
18.At the end you receive a summary showing all the data.
19.If you press "Finish >" you receive the following information:

Figure 6-60 Confirm saving

20.Confirm the saving of the configuration data with "Yes".

Saving can take several minutes.

Result
Step 4 for commissioning the direct measuring system has therefore been completed.

6.1.9 Replacing a drive component after the initial commissioning

Component replacement
The replacement of components after the first commissioning, e.g. in order to use an ALM
with a higher power 16 kW → 50 kW, must be performed in such a way that the configuration
data is reimported and is up-to-date:

Note
Firmware update
The firmware of the configured drive components is updated correctly only when the
components were inserted in the switched-off state. The subsequent insertion of drive
components must ONLY be performed in the switched-off state.

If a drive component is replaced by a component with a different order number, e.g. a more
powerful module, after the first commissioning, observe the following sequence:

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Procedure:
1. Select "Drive unit" → "Topology" → "Change".
2. Select the module and select "Deactivate drive object".
3. Replace the module in the cabinet.
4. Select the module and select "Activate drive object".
5. The configuration data of the new module is read in.
6. Update the drive data in the commissioning archive with the new configuration data.

6.1.10 Example: Parallel connection with TM120

Application: Four motors connected in parallel

Sample topology:

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M1 ... M4 Motor 1 ... motor 4

One KTY and three PTC in series are connected for each motor.
SMx Sensor Module (motor encoder)
ALM Active Line Module
DMM Double Motor Module
SMM Single Motor Module
TM120 Terminal Module

The shown topology requires four KTY sensors and four PTC sensors:
● Each primary section has one KTY sensor (Temp-F) and three series-connected PTC
sensors (Temp-S).

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Two TM120s are required:

● A TM120 is interconnected automatically in series between the Motor Module and the
SMx sensor module.
● A TM120 is directly inserted into a Line Module: This requires a manual interconnection
by the commissioning engineer.
Measures for the TM120:
1. TM120 between the Motor Module and the SMx Sensor Module
This TM120 evaluates four KTYs => sensor types must be selected by Servo-p4610/TM-
p4100. The associated temperature is output by servo-r4620/TM120-r4105.
2. TM120 directly on the Line Module
This TM120 evaluates four PTCs => sensor types must be selected by TM-p4100. The
associated temperature is output by servo-r4105.
Setting the threshold values in the PTC context:
– TM120-p4102[x]=251 => evaluation Off
– TM120-p4102[x]=120 => evaluation On
Assignment of the TM120 response using fault propagation on the drive => setting of
the propagation by servo-p0609=BICO:<object number>TM120:4105.0

Assignment of the alarms to the motor

The occurring error messages are assigned to the motors as follows:
● Temperature channel on the TM120 in series connection with motor modules and
encoders:
Alarm 207015 <location>drive: Motor temperature sensor warning
Alarm 207016 <location>drive: Motor temperature sensor fault
Alarm 235920 <location>TM: Temperature sensor channel 0 error
In this case, the output message with reference to the motor and to the temperature
component shows the relevant motor.
● Temperature channel on the TM120 directly to the line module:
Alarm 235207 <location>TM: Temperature fault/alarm threshold channel 0 exceeded
Special feature with PTC:
TM120-r4105 = -50 temperature is below the nominal response temperature
TM120-r4105 = 250 temperature is above the nominal response temperature
In this case, a message is output only with reference to the temperature component.
The affected motor can be determined from the information concerning the TM120.

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6.1.11 Exchanging process data

Logical I/O address of drive

The I/O address informs the NC of the data area via which data is cyclically exchanged
between the drive and the Control Unit:
● I/O address of the drives
● I/O address of the Control Units
● Message frames
The I/O addresses parameterized in the PLC project are entered in the following machine
data:

Machine data without NX module

13120[0] $MN_CONTROL_UNIT_LOGIC_ADRESS = 6500
13120[1] $MN_CONTROL_UNIT_LOGIC_ADRESS =0

Machine data with NX module

13120[0] $MN_CONTROL_UNIT_LOGIC_ADRESS = 6500
13120[1] $MN_CONTROL_UNIT_LOGIC_ADRESS = 6516

PROFIBUS message frame type

The default setting of drive message frame to PROFIBUS message frame type 136
(Siemens message frame type like 116 plus torque feedforward control) is performed in the
preconfigured SDB. During commissioning, this message frame type is set in the numerical
control (MD13060) and SINAMICS S120 (p0922) components.
The set system data block is selected via MD11240[0...3]:

MD11240 $MN_PROFIBUS_SDB_NUMBER
Number of the used system data block (SDB) for the configuration of the
I/O.
MD11240[0] = 0...n PROFIBUS
MD11240[1] = -1 This default setting must be retained.
MD11240[2] = 0...n PROFIBUS integrated in SINAMICS S120
MD11240[3] = 0...n PROFINET

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You configure the following properties with the setting of MD11240[0..3] = n:

Feature PPU24x.2 PPU26x.2 PPU28x.2

Bus cycle clock (system 1.5 ms 1.5 ms 1.5 ms
clock)
SERVO cycle clock 3 ms 3 ms TE: 1.5 ms
ME: 3 ms
n=0,1 Axes CU-I 6x message frame 136 6x message frame 136 6x message frame 136
Axes NX10 3x message frame 136 3x message frame 136 3x message frame 136
n=3 Axes CU-I 6x message frame 116 6x message frame 116 6x message frame 116
Axes NX10 3x message frame 116 3x message frame 116 3x message frame 116

References
The description of the message frames can be found in the following references:
● SINAMICS S120 Function Manual /FH1/, Section "Communication"
● SINAMICS S120 List Manual /LH1/ in "Function diagrams"

6.1.12 Parameters for the axis / spindle test run

Relevant parameters and terminals

Drive:

Parameter/terminal Meaning
p0840 ON/OFF1
p0844 1. OFF2
p0845 2. OFF2
p0848 1. OFF3
p0849 2. OFF3
p0852 Enable operation
X21.3 (+24 V) and X21.4 (ground) EP terminals enable (pulse enable)
p0864 Infeed enable
p1140 Ramp-function generator enable
p1141 Ramp-function generator start
p1142 Setpoint enable

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Infeed:

Parameter/terminal Meaning
p0840 ON/OFF1
p0844 1. OFF2
p0845 2. OFF2
p0852 Enable operation
X21.3 (+24 V) and X21.4 (ground) EP terminals enable (pulse enable)

The drive parameters are set under: Operating area "Start-up" → Softkey "Drive units" →
"Inputs/outputs".

See also
Further references on the drive:
● SINAMICS S120 Commissioning Manual
● Manual Booksize power units

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6.2 Assigning axes

6.2.1 Example: How to assign the axes

Assigning axes
After the final save of the Encoder 2 configuration data, the following overview is shown:

Figure 6-61 Drive\overview

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1. To assign every logical drive a real axis, select the horizontal softkey "Assign axis". The
"Axis assignment" dialog is opened:

Figure 6-62 Axis assignment

Note
Both the following actions are each carried out twice so the softkeys "Change" and
"Accept" must be pressed repeatedly.

2. Press the "Change" softkey to assign an axis to DO number 2.

3. From the selection list choose "MSP1" and press the “Accept” softkey.
4. An NCK Power On Reset is needed to make the assignment effective in the system.

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5. Press the "Cancel" softkey to assign the other axes first.

Figure 6-63 Axis assignment: Spindle

6. Select the next module with the vertical softkeys "Drive +" and "Drive -".
7. Assign all axes one after another:

Axis Drive
MSP1 SERVO_3.3:3
MX1 SERVO_3.3:4
MY1 SERVO_3.3:5
MZ1 SERVO_3.3:6

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Accept settings
Finally, carry out the NCK Power On Reset and check the following settings:

Figure 6-64 Axis assignment: Power On reset

Confirm with "OK" and carry out a restart; not only for the drives and but also for the control.
The following assignment is shown on the PG/PC:

Figure 6-65 Machine configuration

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After the restart, the following machine configuration is displayed on the control:

Figure 6-66 Machine configuration: All axes commissioned

Result
Step 5 for commissioning a drive system has therefore been completed.

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Data backup
The configuration data is backed up after commissioning in the non-volatile memory with the
vertical softkey "Save data":

Figure 6-67 Message to carry out data backup

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6.2.2 Example: Setting machine data for an axis/spindle

Axis machine data

After the commissioning in the previous example, the following values are set for the axis
machine data:

Axis machine data X Y Z SP A

30200 $MA_NUM_ENCS 1 1 1 1 1
30230 $MA_ENC_INPUT_NR 1 1 1 2 1
30240 $MA_ENC_TYPE 1 1 1 1 4
31020 $MA_ENC_RESOL 2048 2048 2048 1024 512
34200 $MA_ENC_REFP_MODE 1 1 1 1 0

Spindle machine data

To operate the spindle in the previous example in JOG mode after commissioning the drive,
enter the new values for the following machine data:

Spindle machine data Default setting New value

32000 $MA_MAX_AX_VELO 10000 3000
32010 $MA_JOG_VELO_RAPID 10000 100
32020 $MA_JOG_VELO 2000 50
35100 $MA_SPIND_VELO_LIMIT 10000 3000
35110[0] $MA_GEAR_STEP_MAX_VELO[0] 500 3000
35110[1] $MA_GEAR_STEP_MAX_VELO[1] 500 3000
35130[0] $MA_GEAR_STEP_MAX_VELO_LIMIT[0] 500 3150
35130[1] $MA_GEAR_STEP_MAX_VELO_LIMIT[1] 500 3150
36200[0] $MA_AX_VELO_LIMIT[0] 11500 3300
36200[1] $MA_AX_VELO_LIMIT[1] 11500 3300

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Maximum speed drive parameter

After a DDS switchover, e.g. DDS0 → DDS1, the spindle can only be traversed with the
speed from p1082[0]. If a value less than that in p1082[1 ... n] is entered in p1082[0], the
spindle speed is limited to the value in p1082[0].

Note
The maximum speed must be entered in parameter p1082[0]:
 If the parameter is assigned a greater value than in the other parameters, the spindle can
be traversed with the maximum speed.
 If parameter p1082[0] is subsequently changed to a lower value and then an NCK reset
or Power OFF/ON performed, then the spindle only traverses with the lower value from
p1082[0] and all other values are ignored.

Diagnostics displays
Further information on the status of axes and spindle is available in the "Diagnostics"
operating area with the menu forward key:
● The "Axis diagnostics" softkey opens the "Service Overview" dialog.
● The "Service axis" softkey opens the "Service Axis/Spindle" dialog.

Note
DSC operation
Parameterization of the combination STIFFNESS_CONTROL_ENABLE=1 and
ENC_FEEDBACK_POL= -(encoder inversion) is not permitted.
Encoder inversion must be performed in the drive parameter p0410 bit 1 of the SINAMICS.
 DSC operation is preset for motor measuring systems.
 DSC operation must be explicitly activated for external measuring systems.
Requirement: Message frame ≥ 116
SINAMICS drive parameters:
p1192[0] encoder selection
p1193[0] encoder adaptation factor

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6.3 Configuring data sets

6.3.1 Data sets - overview

Requirement

Note
The particular drives must have been already commissioned.

Data sets
The data sets are configured in the "Commissioning" → Drive system" → "Drives" → "Data
sets" operating area. The following prompts lead you through the sequences:
● "Add data set"
● "Remove data set" if an additional data set has already been created
● "Modify data set"
Number of configurable data sets:
● Motor data set → MDS0...3 (max. 4)
● Drive data set → DDS0...31 (max. 8 per MDS)
● Encoder data sets → EDS0...2 (max. 3)

Note
Drive parameters that affect data sets
Default setting p2038 = 0 for Interface Mode: SINAMICS
When a message frame is selected via p0922, the p2038 parameter affects the device-
specific assignment of the bits in the control and status words.
p0922 = 100 ... 199 sets p2038 = 1 automatically and blocks the changing of p2038. This
sets permanently the "SIMODRIVE 611U" Interface Mode with eight DDS per MDS for
these message frames.

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6.3 Configuring data sets

Application
The Data Set Assistant (DSA) offers machine manufacturers (OEM) with a simple and
efficient solution for duplicating and modifying data in order to configure the behavior of
drives, motors and encoders. The reuse of the DSA data helps to minimize the configuration
effort required to generate the machine data for matching the various parts.
Motor Data Sets (MDS), Drive Data Sets (DDS) and Encoder Data Sets (EDS) are used to
configure the component characteristics of the drive system. The reuse of data reduces the
configuration levels required for matching the machine dynamics of the individual parts.

References
You can find additional information in:
SINUMERIK 840D sl/828D Basic Functions Function Manual, various NC/PLC interface
signals and functions (A2)

6.3.2 Adding a data set

Adding a data set operating sequence

The default factory setting specifies an MDS0 motor data set with a DDS0 drive data set and
an EDS0 encoder data set:

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6.3 Configuring data sets

1. Press "Add data set". In the example, the maximum number of four MDSes are created.

2. Press "Next step >".

In the first step, the DDS1 to DDS7 drive data sets are created in the MDS0.

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6.3 Configuring data sets

3. Press "Next step >". The MDS1 motor data set is created.

4. Press "Next step >". The MDS2 motor data set is created.

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6.3 Configuring data sets

5. Press "Next step >". The MDS3 motor data set is created.

6. Press "Next step >". You need to create a complete MDS as shown in the following
diagram, or as an option, enter the number of DDS for the MDSx:

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6.3 Configuring data sets

7. Press "Next step >" to check in the summary the changes to be performed.

8. Press "Finish >" to accept the changes.

9. Confirm with "OK" to save the data in non-volatile memory.

The saving/writing of the parameters can take several minutes.

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6.3 Configuring data sets

10.The "Drives" → "Overview" dialog of the drive object is displayed. The "Select MDS >"
softkey is now available. Press "Select MDS...".

In the direct selection, select the motor data set, e.g. in this case MDS1.
11.Press "OK" to display the new motor data set for the drive object.

The drive is now operational.

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6.3 Configuring data sets

6.3.3 Remove data set

Precondition
To remove data sets, the following conditions must be met:
● Number of DDS > 1 in the MDS ⇒ DDSes can be removed.
● Number of MDS > 1 ⇒ MDSes can be removed.

Operating sequence to remove a data set

1. Select "Remove data set":

In the first column, select the MDS to be removed by marking the row with a check mark.
Several data sets can also be selected.

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6.3 Configuring data sets

2. Press "Next step >".

As an option, you can remove the remaining DDSes from MDS2 by entering the number
of DDS drive data sets that should remain in the MDS: By entering 3 DDS in MDS, five
DDSes are removed.
3. Press "Next step >".

"Cancel" terminates this process and the data set overview with MDS0 ... MDS3 is
displayed.

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6.3 Configuring data sets

4. Press "Finish >" to accept the changes.

The data is written to the parameters. The results are then displayed:

When you exit this dialog, press "Yes" to confirm the prompt to save the data to the non-
volatile memory.

6.3.4 Modify data set

Precondition
If more than one encoder is assigned to the drive object (SERVO), additional encoder data
sets (EDS0 ... 2) will be created.

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6.3 Configuring data sets

Modify data set

To change the assignment of these encoder data sets for the associated encoder, select the
"Modify data sets" softkey:

This activates the edit function in order to subsequently modify the assignment of EDSes to
the encoders:

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6.4 Topology rules for DRIVE-CLiQ

6.4 Topology rules for DRIVE-CLiQ

6.4.1 Topology rules for S120 Combi

Topology rules for DRIVE-CLiQ

There are fixed DRIVE-CLiQ topology rules for the S120 Combi. These rules must be
observed. If these rules are violated, then a corresponding alarm is displayed.

Assigning the DRIVE-CLiQ interfaces

Table 6- 1 Assigning the DRIVE-CLiQ interfaces on the S120 Combi

DRIVE-CLiQ interface Connection with

X200 X100 of the PPU
X201 Motor encoder, spindle
X202 Motor encoder, feedrate 1
X203 Motor encoder, feedrate 2
X204 Motor encoder feed 3 → only for 4-axis S120 Combi
Remains empty for 3-axis S120 Combi
X205 Optional: 2. direct sin/cos encoder for spindle (via SMx20) 1)
Remains empty when connecting a direct TTL spindle encoder via X220
1) In this case, the TTL encoder interface X220 remains free

Table 6- 2 Assigning the DRIVE-CLiQ interfaces to the SINUMERIK 828D (PPU)

DRIVE-CLiQ interface Connection with

X100 X200 of the S120 Combi
X101 X200 of a Single Motor Module or Double Motor Module
X102 X500 of the Terminal Module TM54F
X500 of the Hub Modules (DMx20) 1)
1) When using a TM54F, the DMx20 is connected in series at the TM54F via the DRIVE-CLiQ interface X501

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6.4 Topology rules for DRIVE-CLiQ

Table 6- 3 Assigning the DRIVE-CLiQ interfaces of the expansion axes

DRIVE-CLiQ interface Connection with

First Single Motor Module
X200 X101 of the PPU
X201 1) X200 of the second Single Motor Module
X202 Motor encoder for feedrate 1st expansion axis (via Sensor Module)
Second Single Motor Module
X200 X201 of the first Single Motor Module
X201 Remains empty
X202 Motor encoder for feedrate 2nd expansion axis (via Sensor Module)
Double Motor Module
X200 X101 of the PPU
X201 Remains empty
X202 Motor encoder for feedrate 1st expansion axis
X203 Motor encoder for feedrate 2nd expansion axis
1) Remains empty if only one Single Motor Module is used

Table 6- 4 Assigning the DRIVE-CLiQ interfaces at the DMx20 to assign a direct measuring system to the feed axes.

DRIVE-CLiQ interface Feed axis

X500 X501 of the TM54F
X102 of the PPU (if a TM54F is not being used)
X501 Direct encoder, feedrate 1 at the S120 Combi
X502 Direct encoder, feedrate 2 at the S120 Combi
X503 Direct encoder, feedrate 3 at the S120 Combi → only for 4-axis S120 Combi
Remains empty for 3-axis S120 Combi
X504 Feedrate 1st expansion axis at the Motor Module
X505 Feedrate 2nd expansion axis at the Motor Module

Table 6- 5 Assigning the DRIVE-CLiQ interfaces at the TM54F

DRIVE-CLiQ interface
X500 X102 of the control (PPU)
X501 X500 of the DMx20
If a DMx20 is not being used, then this interface remains empty.

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6.4 Topology rules for DRIVE-CLiQ

6.4.2 Topology rules for S120 Booksize

Introduction
The following rules apply for wiring components with DRIVE-CLiQ. A distinction is made
between DRIVE-CLiQ rules, which must always be observed, and recommended rules,
which, when observed, do not require any subsequent changes to the topology when
expansions are made.
The maximum number of DRIVE-CLiQ components and the possible wiring form depend on
the following points:
● The binding DRIVE-CLiQ wiring rules
● The number and type of activated drives and functions on the respective Control Unit
● The computing power of the respective Control Unit
● The set processing and communication cycles
In addition to the binding wiring rules that must be observed, some additional
recommendations as well as topology examples for DRIVE-CLiQ wiring are provided in the
PPU manual.
The components used in these examples can be removed, replaced with others or
supplemented. If components are replaced by another type or additional components are
added, the SIZER tool should be used to check the topology.

Note
Every topology that SIZER permits can also run and is therefore correct (SINAMICS S120 D
Function Manual /FH1/).

DRIVE-CLiQ rules
The wiring rules below apply to standard cycle times (servo 125 µs). For cycle times that are
shorter than the corresponding standard cycle times, additional restrictions apply due to the
computing power of the Control Unit.
The rules below apply on a general basis, unless limited, as a function of the firmware
version.
● A maximum of eight DRIVE-CLiQ nodes can be connected in one row. A row is always
seen from the perspective of the Control Unit.
This number reduces to a maximum of four DRIVE-CLiQ nodes in one row when the
extended functions of drive-based Safety Integrated are configured.
● A maximum of 14 nodes can be connected to one DRIVE-CLiQ line on a Control Unit.

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6.4 Topology rules for DRIVE-CLiQ

● Ring wiring is not permitted.

● Components must not be double-wired.

338

;
;
;
       

     
1RULQJZLULQJ

1RGRXEOHZLULQJ

Figure 6-68 Example: DRIVE-CLiQ line at the X100 terminal (without Safety Integrated)

● The following applies to the booksize format:

– In the servo control and vector U/f control operating modes, only one Line Module may
be connected to the Control Unit. In the vector control operating mode, a maximum of
three further Line Modules may be connected in parallel (i.e. a total of four Line
Modules).
– It is permissible that one Line Module and Motor Modules are connected together to
one DRIVE-CLiQ line in the servo control mode.
– One Line Module and Motor Modules must be connected to separate DRIVE-CLiQ
lines in the vector control mode.
– For booksize format, a parallel connection of Infeed Modules or Motor Modules is not
possible.
● The following applies to the chassis format: Line Modules (Active Line, Basic Line, Smart
Line) and Motor Modules must be connected to separate DRIVE-CLiQ lines.
● The default sampling times may be changed.
● A maximum of 16 measuring systems can be connected to a PPU with NX10.3:
Example 1: PPU with six axes with six motor measuring systems and six direct
measuring systems as well as NX10.3 with two motor measuring systems and two direct
measuring systems.
Example 2: PPU with five axes with five motor measuring systems and five direct
measuring systems as well as NX10.3 with three motor measuring systems and three
direct measuring systems.
● Only one TM54F is permitted for each PPU and for each NX10.3.

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6.4 Topology rules for DRIVE-CLiQ

● The Active Line Module Booksize and the Motor Modules Booksize can be connected to
one DRIVE-CLiQ line.
● Chassis Line Module and Motor Module are connected in series.
● To allow the following modules to be assigned automatically during the commissioning
(device identification), they should be connected to a free DRIVE-CLiQ port on the
associated Active Line Module/Motor Module:
– Voltage Sensing Module (VSM)
– Terminal Module TM120

Note
If the TM120 is connected without observing this rule, the commissioning engineer
must use BICO technology to assign the temperature channels to the drive.

● The sampling times (p0115[0] and p4099) of all components that are connected to a
DRIVE-CLiQ line must be divisible by one another with an integer result. If the current
controller sampling time on a DO has to be changed to another pattern that does not
match the other DOs on the DRIVE-CLiQ line, the following options are available:
– Reconnect the DO to a separate DRIVE-CLiQ line.
– Also change the current controller sampling time and the sampling time of the
inputs/outputs of the DO not involved so that they again fit into the time grid.

Note
A Double Motor Module, a DMC20, and a TM54F each correspond to two DRIVE-
CLiQ nodes. This also applies to Double Motor Modules, of which just one drive is
configured.

To enable the function "Automatic configuration" to assign the encoders to the drives, the
recommended rules below must be observed.
Recommended rules
● The DRIVE-CLiQ cable from the Control Unit must be connected as follows:
– To X200 of the first booksize power unit
– To X400 of the first chassis power unit
● The DRIVE-CLiQ connections between the power units must each be connected from
interface X201 to X200 or from X401 to X400 on the follow-on component.

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6.4 Topology rules for DRIVE-CLiQ

338 6LQJOH 'RXEOH 6LQJOH

0RWRU 0RWRU 0RWRU
0RGXOH 0RGXOH 0RGXOH

; ;; ; ;;


; ;; ; ;;
; ;; ; ;;
;

Figure 6-69 Example: DRIVE-CLiQ line

● The motor encoder must be connected to the associated power unit.

Component Connecting the motor encoder via DRIVE-CLiQ

Single Motor Module booksize X202
Double Motor Module booksize  Motor connection X1: Encoder at X202
 Motor connection X2: Encoder at X203
Single Motor Module chassis X402
Power Module chassis X402

Note
If an additional encoder is connected to a Motor Module, it is assigned to this drive as
encoder 2 in the automatic configuration. At a Double Motor Module, an encoder at X201 is
assigned to the 2nd feedrate as 2nd measuring system.

338 $FWLYH 6LQJOH

/LQH 0RWRU
0RGXOH 0RGXOH

; ;; ; ;;


; ;; ;;
; ;; ;;
960

Figure 6-70 Example: Topology with VSM for booksize and chassis components

Component VSM connection

Active Line Module booksize X202
Active Line Module (chassis) X402
Power Modules The VSM is not supported.

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6.4 Topology rules for DRIVE-CLiQ

6.4.3 Topology rules for SMC40

Use of the SMC40

The SMC40 Sensor Module Cabinet-Mounted is used to convert encoder signals from
absolute encoders with EnDat 2.2 to DRIVE-CLiQ. Two encoder systems with EnDat 2.2 can
be connected to the SMC40. Their signals are converted independent of each other on two
DRIVE-CLiQ encoder signals.

Connection conditions
To ensure that the SMC40 Sensor Module Cabinet-Mounted is integrated into the topology
during the initial commissioning, you must absolutely observe the following rules:
● Connect at least one of the DRIVE-CLiQ interfaces X500/1 or X500/2 on the SMC40
using DRIVE-CLiQ.
● Connect one EnDat encoder to the corresponding encoder interface X520/1 (to X500/1)
or X520/2 (to X500/2).
● Operate the SMC40 only in a star topology. The DRIVE-CLiQ X500/1 and X500/2 sockets
cannot be used for a series connection.

NOTICE
Display in the "Topology" dialog
The SMC40 can be integrated in the actual topology only when the DRIVE-CLiQ X500/x
interfaces and the corresponding encoder interfaces X520/x are assigned.
Without a connected encoder, it is also not possible to subsequently integrate the SMC40
in the topology.

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6.5 Terminal assignments

6.5 Terminal assignments

6.5.1 Terminal assignment at X122 and X132

X122: Digital inputs/outputs of the PPU

Pin Signal name Status Meaning

1 DI0 DI0 r722.0 Digital input 0
2 DI1 DI1 r722.1 Digital input 1
3 DI2 DI2 r722.2 Digital input 2
4 DI3 DI3 r722.3 Digital input 3
5 DI16 DI16 r722.16 Digital input 16
6 DI17 DI17 r722.17 Digital input 17
7 M2 MEXT2 --- Ground for pins 1...6
8 P1 P24EXT1 --- +24 V power supply
9 IO8 DI/DO8 r722.8 / r747.8 Digital input/output 8
10 IO9 DI/DO9 r722.9 / r747.9 Digital input/output 9
11 M1 MEXT1 --- Ground for pins 9, 10, 12, 13
12 IO10 DI/DO10 r722.10 / r747.10 Digital input/output 10
13 IO11 DI/DO11 r722.11 / r747.11 Digital input/output 11
14 M1 MEXT1 --- Ground for pins 9, 10, 12, 13

X132: Digital inputs/outputs of the PPU

Pin Signal name Status Meaning

1 DI4 DI4 r722.4 Digital input 4
2 DI5 DI5 r722.5 Digital input 5
3 DI6 DI6 r722.6 Digital input 6
4 DI7 DI7 r722.7 Digital input 7
5 DI20 DI20 r722.20 Digital input 20
6 DI21 DI21 r722.21 Digital input 21
7 M2 MEXT2 --- Ground for pins 1...6
8 P1 P24EXT1 --- +24 V power supply
9 IO12 DI/DO12 r722.12 / r747.12 Digital input/output 12
10 IO13 DI/DO13 r722.13 / r747.12 Digital input/output 13
11 M1 MEXT1 --- Ground for pins 9, 10, 12, 13
12 IO14 DI/DO14 r722.14 / r747.14 Digital input/output 14
13 IO15 DI/DO15 r722.15 / r747.15 Digital input/output 15
14 M1 MEXT1 --- Ground for pins 9, 10, 12, 13

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6.5 Terminal assignments

6.5.2 Terminal assignment at X242 and X252

X242 pin assignment

Pin Signal name NC variable Meaning

1 Not connected
2 Not connected
3 IN1 DIN1 $A_IN[1] Digital NCK input 1
4 IN2 DIN2 $A_IN[2] Digital NCK input 2
5 IN3 DIN3 $A_IN[3] Digital NCK input 3
6 IN4 DIN4 $A_IN[4] Digital NCK input 4
7 M4 MEXT4 Ground for pins 3...6
8 P3 P24EXT3 +24 V power supply
9 O1 DOUT1 $A_OUT[1] Digital NCK output 1
10 O2 DOUT2 $A_OUT[2] Digital NCK output 2
11 M3 MEXT3 Ground for pins 9, 10, 12, 13
12 O3 DOUT3 $A_OUT[3] Digital NCK output 3
13 O4 DOUT4 $A_OUT[4] Digital NCK output 4
14 M3 MEXT3 Ground for pins 9, 10, 12, 13

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6.5 Terminal assignments

X252 pin assignment

Pin Signal name NC variable Meaning

1 AO AOUT Analog output (voltage for analog
spindle)
2 AM AGND Analog ground
3 IN9 DIN9 $A_IN[9] Digital NCK input 9
4 IN10 DIN10 $A_IN[10] Digital NCK input 10
5 IN11 DIN11 $A_IN[11] Digital NCK input 11
6 IN12 DIN12 $A_IN[12] Digital NCK input 12
7 M4 MEXT4 Ground for pins 3...6
8 P3 P24EXT3 +24 V power supply
9 O9 DOUT9 $A_OUT[9] Digital NCK output 9
10 O10 DOUT10 $A_OUT[10] Digital NCK output 10
11 M3 MEXT3 Ground for pins 9, 10, 12, 13
12 O11 DOUT11 --  Without analog spindle:

Digital NCK output 11

 With analog spindle:

Controller release for analog spindle

(in accordance with
MD30134 $MA_IS_UNIPOLAR_OUT
PUT)
13 O12 DOUT12 --  Without analog spindle:

Digital NCK output 12

 With analog spindle:

Travel direction of the analog spindle

(in accordance with
MD30134 $MA_IS_UNIPOLAR_OUT
PUT)
14 M3 MEXT3 Ground for pins 9, 10, 12, 13

See also
Machine data for an analog spindle (Page 94)

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6.5 Terminal assignments

6.5.3 Example: Circuitry for a CU with line contactor

Example
The circuitry shown refers to the assignment of the terminals in the previous chapters.

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2XWSXW ,QSXW
,QIHHGUHDG\WRVWDUW
U ;
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,QSXW 2XWSXW
2))
;

(QDEOHVLJQDOVYLDWKH3/&XVHUSURJUDP
2XWSXW

,QSXW (0(5*(1&<2))
2)) 6DIHW\UHOD\
; ,QSXW
RU
2XWSXW

RU

9
/LQHFRQWDFWRUFRQWURO 2XWSXW
U ;
1RWH /LQHFRQWDFWRU
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WKH/LQHFRQWDFWRUFRQWURO
DFFWRWHUPLQDOGLDJUDP
UHTXLUHG
,QSXW
/LQHFRQWDFWRU
IHHGEDFNVLJQDO ;

2XWSXW ,QSXW
,QIHHGRSHUDWLRQ
U ;

Figure 6-71 Circuitry for a Control Unit with line contactor

Smart Line Module connection

The connections for the digital in/outputs X122 and X132 are on the rear side of the control.

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6.5 Terminal assignments

/ /
H[W
/ /
/ /
9
3( 3(
 0

0DLQVZLWFK
 0

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 6PDUW/LQH0RGXOH '&3
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9
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 &8 '2:DUQLQJ, W
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;
 8 9:

① Early opening contact t > 10 ms, 24 VDC and ground must be applied for operation
② DI/DO controlled by the Control Unit
③ No additional load permitted downstream of line contactor
④ The current carrying capacity of the DO must be observed; an output interface must be used if
required.
⑤ DO high, feedback deactivated (a jumper can be inserted between X22 pin 1 and pin 2 for
permanent deactivation).
⑥ X22 pin 4 must be connected to ground (external 24 V).
⑦ Contacting via rear mounting panel or shielding buses in accordance with EMC installation
guideline
⑧ 5 kW and 10 kW line filters via shield connection
⑨ Signal output of the control, to avoid interference of the 24 VDC supply on the EP terminal.
⑩ Connect via BICO to parameter p0864 → X122.1

Figure 6-72 Example: SLM connection

ON/OFF1 enable: Connection of Smart Line Module pin X21.1 → X122.1 SINUMERIK 828D

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6.5 Terminal assignments

Connect further input and output signals to the PLC I/O:

● DI → PLC inputs
● DO → PLC outputs

See also
Additional information can be found in:
● SINUMERIK 828D Manual PPU
● SINAMICS S120 Manual Booksize Power Units

6.5.4 Connecting the probes

Connecting the probes

The probes are connected to both the SINUMERIK 828D CU and the NX:
1st probe at terminal X122 pin 13 / X122 pin 13 of the NX
2nd probe at terminal X132 pin 13 / X122 pin 12 of the NX

Note
A precondition for measuring with the SINUMERIK 828D is that the distributed (local)
measurement function has been parameterized.
Central measurement is not possible with SINUMERIK 828D.

Machine data
The following machine data should be checked and adjusted if necessary:
● General machine data:
MD13200[0] $MN_MEAS_PROBE_LOW_ACTIVE = 0 or 1
MD13200[1] $MN_MEAS_PROBE_LOW_ACTIVE = 0 or 1
Value 0 = deflected state 24 V (default)
Value 1 = deflected state 0 V
MD13210 $MN_MEAS_TYPE = 1 distributed measurement
● Axis-specific machine data:
MD30244[0] $MA_ENC_MEAS_TYPE = 1 for all axes
MD30244[1] $MA_ENC_MEAS_TYPE = 1 for all axes

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6.5 Terminal assignments

Note
The machine data MD13210 and MD30244 are preset to the value 1 and cannot be
changed! (Data class: SYSTEM)

● Control Unit parameters:

p0680[0] Central probe input terminal = 0
p0680[1] Central probe input terminal = 0
p0680[2] Central probe input terminal = 0

The 1st probe is connected to terminal X122 pin 13, the 2nd probe to terminal X132
pin 13 of the SINUMERIK 828D and - if present - on the NX10 module to terminal X122
pin 12.
A precondition is the switchover of pin X132.13 from output to input.
Set CU input or output = set p0728 bit 15 to 0 (DI/DO X132.13)
● Drive parameters:
p0488[0] Probe 1 input terminal: Encoder 1 = 3 → connector X 122.13
p0488[1] Probe 1 input terminal: Encoder 2 = 3 → connector X 122.13
p0488[2] Probe 1 input terminal: Encoder 3 = 0 → not used

p0489[0] Probe 2 input terminal: Encoder 1 = 6 → connector X 132.13

p0489[1] Probe 2 input terminal: Encoder 2 = 6 → connector X 132.13
p0489[2] Probe 2 input terminal: Encoder 3 = 0 → not used

The 2nd probe at terminal X122.12 must be parameterized for all axes that are
parameterized on the NX module:
p0489[0] Probe 2 input terminal: Encoder 1 = 6 → connector X 122.12
p0489[1] Probe 2 input terminal: Encoder 2 = 6 → connector X 122.12
p0489[2] Probe 2 input terminal: Encoder 3 = 0 → not used

Note
All drives must be parameterized.

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6.5 Terminal assignments

Probe status

DB2700 General signals from NCK [r]

NCK → PLC interface
Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
DBB0 -- -- -- -- -- -- EMERGENCY ---
STOP active
DBB1 Inch -- -- -- -- -- Probe actuated
dimension Probe 2 Probe 1
system

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Optimizing a drive 7
7.1 Introduction

Activating changed machine data

This procedure activates specific changes of machine data. The right-hand side of the
parameter value indicates how the associated change is activated:

po The changed machine data requires an "NCK Reset" to take effect.

re The changed machine data must be activated by pressing the <RESET> key.
cf The changed machine data must be activated by pressing the "Apply MD" softkey.
so The changed machine data becomes active immediately.

Backing up drive data

When the drive is switched on or a "Drive Reset" performed, the SINAMICS S120 data from
the saved file is loaded into the associated drive. To permanently accept changes made to
the drive data after the new power on/off or after a "Drive Reset", the data must be saved.

Note
An "NCK Reset" does not have any effect on the drive data.

Procedure:
1. Press the "Drive parameter" softkey and then the "Save/reset" softkey.
2. Press the "Save" softkey and finally the "Drive system" softkey.
Messages in the lower left-hand area of the screen indicate the status of the save action.
The following window is displayed when the save action completes: "All drive objects saved".

Control block diagram

The control and the drive contain three cascaded closed control loops:
● Current control loop
● Speed control loop
● Position control loop

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Optimizing a drive
7.1 Introduction

Each of the individual control loops is optimized successively starting with the current
controller, the speed controller and finally the position controller. The dynamic machine limits
for velocity, acceleration and jerk are set in the interpolator. Whereas the speed control loop
is always connected via the motor encoder, the position control loop can be connected via
the motor encoder or via the direct measuring system.

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See also
The following sections describe the individual steps for optimizing the control loops with
SINUMERIK Operate:
● Automatic servo optimization (Page 181)
● Axis jerk (Page 194)
● Torque load (Page 202)
● Circularity test (Page 206)
● Spindle optimization (Page 215)

References
You can find further details in the following manuals:
● SINUMERIK Operate (IM9) Commissioning Manual; "Trace" section
● Basic Functions Function Manual; Axis Monitoring, Protection Zones (A3)
● Basic Functions Function Manual; Velocities, Setpoint-Actual Value Systems, Closed-
Loop Control (G2)
● Extended Functions Function Manual; Compensations (K3)

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 Optimizing a drive
7.2 Automatic servo optimization

7.2 Automatic servo optimization

7.2.1 Objective

Introduction
Use the "Automatic servo optimization" function to optimize the current, speed and position
control loop with precontrol. The objective is the fine setting of an axis or spindle using
SINUMERIK Operate.
● Performing frequency response measurements
● Calculation of the speed control loop
● Setting of current setpoint filters
● Calculation of the position control loop
● Validation of the actual behavior of the planned control loops
● Precontrol mode: Equivalent speed control time
● Interpolation paths
Before the automatic optimization is performed, the dynamic stiffness control in
MD32640[0] $MA_STIFFNESS_CONTROL_ENABLE = 1 is set. This then permits a position
control with a faster cycle time. When dynamic stiffness control is used,
MD32110 $MA_ENC_FEEDBACK_POL = 1 must be set. If a polarity reversal is required, the
p0410 parameter "Actual encoder inversion value" must be set in the drive:
● p0410[0]=1 invert actual speed value
● p0410[1]=1 invert actual position value
If the "Automatic servo optimization" function is used for a main spindle, it is possible that no
PLC signal for the servo release is present. The machine manufacturer should provide a
method to activate this PLC signal for the optimization, for example, a special key
combination or the setting of a flag in the PLC status.

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Optimizing a drive
7.2 Automatic servo optimization

Automatic servo optimization

Start the "Automatic servo optimization" function in the "Commissioning" operating area →
"Optimization/Test" softkey.

Use the cursor keys to mark the axis and select with the <SELECT> softkey, for example,
the X1 axis:

The dialog indicates whether an axis has already been optimized. An optimized axis is
marked with the date and time of the optimization.

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 Optimizing a drive
7.2 Automatic servo optimization

Checking the options

Check whether all options for an automatic procedure are set: "Options" softkey. This
permits an optimization by pressing a single softkey. Follow the messages and instructions
shown on the screen.

The "Permit strategy selection during the optimization" option is recommended only for
experts.

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Optimizing a drive
7.2 Automatic servo optimization

7.2.2 Setting optimization strategy

Optimization strategy
For the speed controller and position controller axis strategies, the default settings
(strategies 102, 303, and 203; see figure) are recommended:

Figure 7-2 Selection of predefined strategy

The default optimization objective is "Moderate fault clearance". The option selected
depends on the mechanical properties of the machine/axis. The "Maximum fault clearance"
option should not be used for a "weak" axis.

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 Optimizing a drive
7.2 Automatic servo optimization

Optimization objective
Description of the optimization objective:
● Selection: "Maximum fault clearance"
The speed and position controller gain (servo gain factor) is optimized with maximum
values and minimum ruggedness.
– Application: High speed machining with maximum suppression of all disturbing forces
such as friction, teeth of the drive belt, strong cutting forces, when machining titanium,
for example.
Recommended for high-speed machining with linear motors.
– Precondition: The machine must have a rigid design; the dynamic masses do not
change significantly.
● Selection: "Moderate fault clearance"
The speed and position controllers are optimized with 80% of the maximum gain and a
good level of ruggedness.
– Application: There are many uses.
– Precondition: No high expectations for the machine design; recommended for general
use.
● Selection: "Optimal damping"
The speed controller is optimized so that it achieves maximum damping to prevent
vibrations and to achieve a good position control value.
– Application: Large machines with large dynamic masses.
– Precondition: A weak machine design due to large masses/inertia. The size of the
motor justifies a low dynamic response. Recommended, for example, for traversing
columns where the operator cabin moves with the column. Can be used if the "Optimal
damping" check produces a very low position controller gain.

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Optimizing a drive
7.2 Automatic servo optimization

User-defined settings
The optimization process is re-defined using the "User-defined" softkey.
Setting the speed controller:

The most important settings are: Optimization aggressiveness and Min integral time Tn.
● Optimization aggressiveness:
This parameter determines the setting of Kp and Tn based on stability limits.
– Default = 0.6
– Min = 0 [maximum stability]
– Max = 1 [maximum aggressiveness]
● Minimum integral time Tn:
This parameter prevents automatic servo optimization from setting the integrator time of
the speed control loop too low. Otherwise, if automatic servo optimization sets a value
lower than this parameter, the actual value used will be limited to the value set by the
minimum integral time Tn.
– Default setting = 5.0 ms
– Min = 0.5 ms
– Max = 100 ms

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 Optimizing a drive
7.2 Automatic servo optimization

Setting the position controller:

The most important setting is Kv (position controller) reduction factor

● Kv reduction factor:
This parameter acts in the same way as the aggressiveness of the position controller.
It causes a specific reduction of the maximum Kv calculated by automatic servo
optimization.
The maximum Kv is the largest Kv that would cause the zero position to be overshot
when the feedrate is deactivated.
– Default = 0.8
– Min = 0.1
– Max = 1 [no reduction]

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Optimizing a drive
7.2 Automatic servo optimization

7.2.3 How to start the automatic servo optimization

Starting automatic servo optimization

Procedure:
1. Ensure that the axis to be optimized is in a safe position. If this is not the case, move the
axis in JOG operation to the center of the travel path:

2. To confirm, press "OK". The prompt to press <CYCLE START> on the machine control
panel then appears:
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 Optimizing a drive
7.2 Automatic servo optimization

3. Further displays appear on the screen during the automatic optimization procedure.
Press the <CYCLE START> key several times to start the next measurement:

4. On completion of the optimization, the following display appears in which the new values
and the original values should be checked.
Example: Position controller

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Optimizing a drive
7.2 Automatic servo optimization

Example: Speed controller

The new values are accepted when the "Accept" softkey is pressed.
5. The following message indicates that more axes must be optimized to provide a regular
interpolation result:
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Optimization result
The date and time of the optimization are then output:

The other axes are also optimized in the same manner:

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 Optimizing a drive
7.2 Automatic servo optimization

7.2.4 How to optimize the interpolation paths

Introduction
Interpolation means that the axes to perform the contour must exhibit the same trailing error.
After the optimization of the individual axes, they have different control settings that are
optimum only for the associated axis. To ensure a consistent trailing error, the control
settings must be adapted so they correspond to the axis with the slowest response. This
includes the Kv factor and the precontrol mode.

Strategy selection for the interpolation

Procedure:
1. Specify the strategy for the interpolation path. The default setting is used:
• 1103 "Reduce independent optimum controller with partial adaptation".

Meaning of the strategies:

– Maximum adaptation: The Kp effective gain is adapted.
The Kp proportional gain can be reduced to 10% of its original value.
In order to use the lower effective value of the main spindle, the Kp gain of the feed
axis is not reduced. In order to use the lower Kp effective gain of the feed axis, the Kp
gain of the main spindle is not reduced.
– Moderate adaptation: The Kp effective gain is adapted.
The Kp proportional gain can be reduced to 50% of the original value.
In order to use the lower Kp effective gain of the main axis, the Kp gain of the feed
axis is not reduced.
In order to use the lower Kp effective gain of the feed axis, the Kp gain of the main
spindle is not reduced.
– Partial adaptation:
The Kp effective gain is not adapted.
– User-defined adaptation:
The strategy selection is made with user-defined settings. The checkboxes can be
activated.

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Optimizing a drive
7.2 Automatic servo optimization

General settings
Settings for "Optimum path":
● Dynamic Stiffness Control (DSC)
MD32640 $MA_STIFFNESS_CONTROL_ENABLE is either activated or deactivated for
all axes. If DSC is activated, higher KV factors are possible.
● Precontrol mode
– Once all axes with torque precontrol have been optimized, this setting is retained for
the interpolation path.
– If the precontrol for the axes is set differently to 3 or 4,
MD32620 $MA_FFW_MODE = 3 will then be set for all axes.
– If one axis without precontrol has been optimized, MD32620 $MA_FFW_MODE = 0
will be set for all axes.
Settings for "Optimum axis":
● The KV gain factor is calculated; the lowest setting is used for all axes: the KV factor is
always adapted!
● Kp proportional gain / moment of inertia for the later adaptation of the axes.
● The Tn delay time is adapted for all axes.
● The reference model (speed controller) is activated, i.e. it is adapted.
● Equivalent time constant for the speed control loop precontrol is calculated; the highest
setting is used for all axes:
MD32402 $MA_AX_JERK_MODE = 0 Filter type for axial jerk limitation is not activated.

Interpolation path
In the next step, the axes for optimization of the interpolations paths are selected.
Procedure:
1. Press the "Interpolation paths" softkey. The axes that interpolate together are assigned to
"Channel 1".
2. Press the "Edit & optimize" softkey.
3. Select only those axes that can interpolate together.
X, Y, Z and the spindle are selected for the following example:

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7.2 Automatic servo optimization

4. The new setting is calculated and displayed for validation:

5. Select "Accept" and confirm with OK.

This completes the automatic optimization.

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Optimizing a drive
7.3 Optimizing the axis jerk

7.3 Optimizing the axis jerk

7.3.1 Checking the axis jerk

Jerk limitation
The jerk-limited acceleration is optimized in the next step: The jerk is used to smooth the
acceleration and response behavior by applying a time for changing the acceleration.
The jerk is defined in units/s3, i.e. acceleration [units/s2] / time [s].
The time during which the acceleration change occurs is defined as: t [s] = acceleration
[units/s2] / jerk [units/s3].
Axes do not need to have the same jerk value. The result of a jerk limited acceleration is
rounded corners at the acceleration-phase start and end of the velocity profile and smoothed
movements.
● Jerk limitation is active when "SOFT" is programmed.
● Jerk limitation is deactivated when "BRISK" is programmed.

Machine data for jerk

It is recommended that the MD20150[20] = 2 default setting, i.e. "SOFT", is used.
● MD20150[20] = 1 then "BRISK" is active in the switch-on state (acceleration without jerk
limitation).
● MD20150[20] = 2 then "SOFT" is active the switch-on state (acceleration with jerk
limitation).
Example:

blue Acceleration without jerk limitation

red Acceleration with jerk limitation

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7.3 Optimizing the axis jerk

Positioning behavior of the axes

The Trace function over position setpoint steps using a part program with different feeds can
be used to check the positioning behavior.
● If a direct scale is used, the response behavior of the carriage can be seen easily.
● If a motor encoder is used to close the position control loop (indirect feedback), the
response behavior of the carriage for the closed position control loop with the Trace
function cannot be determined.
In general, jerk values between 20 and 100 are used for machines with SINUMERIK 828D.
The test program should move the axis over an adequate distance so that the programmed
feedrate velocity can be attained.
A delay time, for example 0.5 seconds, after the feedrate velocity and the position setpoint is
attained, should be used. The first programmed feedrate velocity should be 50% of the
maximum axis feedrate. This behavior should be checked for all increments of the feedrate
override up to the maximum feedrate velocity.

7.3.2 Parts program for axis jerk

Parts program for checking

The following NC program can be used in automatic or MDA operation depending on the
configuration of the deployed machine. The program contains commands for the
activation/deactivation of the trace trigger:
FFWON

SOFT

$AN_SLTRACE=0; Reset Start Servo-Trace-Trigger

LAB:

G01 Y210 F10000

G04 F0.5

$AN_SLTRACE=1; Start Servo-Trace-Trigger

Y260

G04 F0.5

GOTOB LAB

M30

View the trace results:

Select <MENU SELECT> → "Diagnosis" operating area, menu forward key → "Trace" softkey
and press <CYCLE START>:
The axis moves and the selected signals are monitored for five seconds. The result is then
displayed.

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Optimizing a drive
7.3 Optimizing the axis jerk

Machine data:
To check the positioning behavior without the effect of the position controller, the Kv position-
control gain factor should be set to 0. Specify positioning tolerances to prevent errors during
the test:
● MD32200 $MA_POSCTRL_GAIN = 0
● MD36012 $MA_STOP_LIMIT_FACTOR = 100
● MD36400 $MA_CONTOUR_TOL = 20

Initializing the trace

The "Start trace" softkey is used to start and initialize the tracing. This depends on the
selection defined in the "Settings" dialog. In this example, the trace is started with a parts-
program command. Press the "Start trace" softkey to initialize the trace.
The trace is now initialized and will be started when the trigger is set by the part program.

7.3.3 Selecting trace signals

Selecting trace signals

A trace of the position setpoints and actual position values is required.
Procedure:
1. Use the following key combination to invoke the Trace function:
<MENU SELECT> → "Diagnostics" operating area → Menu forward key → "Trace" softkey

2. The required variables are selected: "Select variable" softkey.

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7.3 Optimizing the axis jerk

3. Press the "Filter/search" softkey to limit the list of variables. The following filters are
available:
– System variables
– NC
– Axis
– Channel
– Mode groups (MGs)
– Servo
– Global user data (GUD)
– PLC
– PLC alarms
– All (no filter)
4. Set the filter to "Servo" and select the position setpoint and actual position-value
variables, e.g. for the Y axis:

Trace duration and start conditions

The trace can be started automatically or manually. The trace duration can also be set. In
the following example, the trace is started with a parts-program command. The "Quick list"
softkey can be used to select the variable.
Select the $AN_SLTRACE==1 option to start the trace with a variable:

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7.3 Optimizing the axis jerk

It is also possible to initiate the trace from a value of the previously selected signals or with a
system variable made available with the "Add variable" softkey:

Trace result
The axis moves and the selected signals are monitored for five seconds. The result is then
displayed:

Setting the trace scale

It is necessary to view that part of the trace in which the axis reaches the position setpoint.
To view this in detail, set the trace scale: "Display trace" softkey → "Scale" softkey
The following example shows the setting of the scale to view the axis positioning at -
110 mm. The entered values produce a 100-micrometer window around the target position of
-110 mm. Depending on the used machine/axis, a different scale may be necessary.

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7.3 Optimizing the axis jerk

If necessary, the X minimum/maximum values can also be adapted:

View in detail:

Position setpoint (yellow) and actual position (green) do not match because the position
controller is not active.

7.3.4 Optimizing the jerk setting

Optimization objective
The jerk must be set so that the actual position is not exceeded. This is done by setting a
jerk value that is too high.
A jerk value that is too low can also be disadvantageous for the machine because it affects
the time required for positioning an axis. Without the position controller, the axis is positioned
without overshooting.
The remaining positioning error results from the position controller being deactivated and the
axis moves only with feedrate signals. An overshooting on reaching the position that results
from the mechanical system can be prevented by using a jerk limitation.

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Optimizing a drive
7.3 Optimizing the axis jerk

The following machine data is first checked and set:

● MD32200 $MA_POSCTRL_GAIN = 0
● MD32610 $MA_VELO_FFW_WEIGHT = 1
● MD32620 $MA_FFW_MODE = 3
● MD32810 $MA_EQUIV_SPEEDCTRL_TIME = as optimized
The following examples show the effects of different jerk values on the positioning of an axis.

Examples
The MD32431 axis machine data is used to set the jerk.
Example 1: MD32431 $MA_MAX_AX_JERK = 600 ⇒ jerk too high
1. Restart the trace and then execute the part program.
2. Press the "Start trace" softkey and then the <RESET> and <CYCLE START> keys.
3. Correct the overshoot by increasing MAX_AX_JERK.
This diagram shows the jerk increase until an overshoot caused by the mechanical system.

Example 2: MD32431 $MA_MAX_AX_JERK = 2 ⇒ jerk too low

A jerk that is too low causes the positioning contour to be rounded.

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7.3 Optimizing the axis jerk

Example 3: MD32431 $MA_MAX_AX_JERK = 65 ⇒ jerk optimized

If the jerk is optimized, there is no overshoot or it is small and the positioning contour is
sharp.

Example: Positioning with precontrol and active position controller

If the jerk has been optimized, the position controller and the precontrol must be activated.
Set the machine data as required:
● MD20150[23] =2 The precontrol can then be released as default setting.
● MD32200 $MA_POSCTRL_GAIN = as optimized
● MD32610 $MA_VELO_FFW_WEIGHT = 1.0
● MD32620 $MA_FFW_MODE = 3
● MD32810 $MA_EQUIV_SPEEDCTRL_TIME = as optimized
● MD32431 $MA_MAX_AX_JERK = 65
● MD36012 $MA_STOP_LIMIT_FACTOR = original value
● MD36400 $MA_CONTOUR_TOL = original value
A good positioning without overshoot is achieved when the precontrol and jerk have been
optimized correctly:

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Optimizing a drive
7.4 Torque load

7.4 Torque load

Checking the maximum axis acceleration

To ensure that the torque limit is not reached, after optimizing the Kv factor and the feed
precontrol, check the torque loading under unfavorable conditions:
● At high velocity
● For high loading
The "Trace" function is used to measure the velocity setpoint of the active measuring
systems and the percentage torque load with the "Load (m_set / m_set_limit)" trace signal. If
the "Load (m_set / m_set_limit)" trace signal is set to 100%, the drive operates with current
limitation. Change the measurement parameters in the trace to display the torque loading.
MD32300 $MA_MAX_AX_ACCEL defines the maximum axis acceleration. The default
setting is [1 m/s2 (metric), 39.37 in/s2 (inch) and 2.77 rev/s2 (rotary)]. Each axis can have a
different setting for the acceleration.
If permitted by the machine manufacturer, MD32300 can be set so that the torque loading
during the acceleration phase in the worst case lies between 80% and 90% of the limit value,
depending on the size of the desired safety factor.

Note
The machine mechanical system limits the maximum axis acceleration. The machine
manufacturer must define the required setting value! If this value is not defined, use the
default setting unless the machine manufacturer permits an increased value.

Example: Test program

In this test program, the axes should be moved within an adequate distance so that the
programmed rapid-traverse velocity can be attained, e.g. 300 mm. To do this, change the
test program as follows:
SOFT

$AN_SLTRACE=0; Reset Start Servo-Trace-Trigger

LAB:

G0 X10

$AN_SLTRACE=1; Start Servo-Trace-Trigger

X310

GOTOB LAB

M30

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7.4 Torque load

Select one of the following signals for monitoring:

● Actual velocity measuring system 2
● Load (m_set/m_set_limit)
● Torque-generating actual current value i(q)

"Start trace" softkey → <RESET> → <CYCLE START>:

The three traces are displayed together; press the "Adapt all" softkey:

To recognize the maximum values of the three traces, press the "Cursors" softkey and
position it on the associated trace to mark the maximum values: "Cursors" softkey → "Cursor
A" softkey.

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Optimizing a drive
7.4 Torque load

To check the maximum values of the three traces, press the "Cursors" softkey and position
the cursor on the associated trace to read the maximum values of the following quantities:
● Velocity
The cursor positioned over the trace shows that the attained maximum velocity is
36 m/min:

● Load
The cursor positioned over the trace shows that the attained maximum load is 58.52
%/min:

● Current
The cursor positioned over the trace shows that the attained maximum current is 10.53 A:

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 Optimizing a drive
7.4 Torque load

Summary
The maximum velocity of 36 m/min is attained with a maximum load of 58.52%. The "Load
(m_set/m_set_limit)" signal selection shows the percentage load of the active current limit.
The active current limit is: p0640 = [A effective value]
p0640 is limited to p0338 motor current limit / Mot I Max [A effective value] or r0209 drive
current limit / PU I Max [A effective value] depending on which value is lower.
In this example, p0640 = 18 A
Consequently the load is 18 A x 58.52/100 = 10.53 A
The test was performed on the Y axis of a milling machine with a dividing unit on the table.
The load of 58% permits an additional weight to be added without problem. The load should
not exceed 85%. To affect the load, the acceleration can be changed.

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Optimizing a drive
7.5 Circularity test

7.5 Circularity test

7.5.1 Circularity test: Function

The circularity test serves to set and assess the dynamic response for interpolating axes and
to analyze the contour accuracy on the quadrant transitions (circular contours) achieved by
means of friction compensation (conventional quadrant error compensation).
The circularity test is used to check the interpolation of the axes which work together. This
function measures a circle with reference to the motor or to the direct measuring system.
Alignment of the machine-mechanical equipment is not taken into account in the result. This
gives the commissioning engineer the option of separating problems with the controller
optimization from mechanical problems.
The following axis machine data and parameters are checked with this procedure:
● MD32200, MD32400, MD32402, MD32410, MD32490, MD32500, MD32510, MD32520,
MD32540 MD32620, MD32640, MD32810, MD32900, MD32910, MD32930, MD32940
● p1421 to p1426, p1400, p1433, p1434

Note
MD32450 backlash must be adjusted via an external device, such as a circularity test or
gauge.

The following position error compensations should be disabled if this procedure is carried
out:
● MD32450 backlash compensation
● MD32500 friction compensation active
● MD32700 Encoder/lead error compensation
● MD32710 enable sag compensation
● MD32750 Temperature compensation type

Example
NC test program for the measurement of the X-Y axes:
FFWON

SOFT

G90 G01 F3000 X400 Y200 Z500

LAB:

G91 G64 G02 X0 Z0 I10

GOTOB LAB

M30

Position, feedrate and active plane must be adjusted to the machine!

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7.5 Circularity test

Specification and results

The best contour results are achieved when the circular form test results are in the correct
actual size, shape and minimum p/p deviation between a combined interpolation of the axes
(X-Y, X-Z, Y-Z).
An NC program in the MDA operating mode and the circularity test function are used to
measure and evaluate these results. The "worst case" of a circle radius and the path velocity
must lead to a realistic radial acceleration of which the machine is capable.
Machine manufacturers generally have specifications for the radius and feedrate test circuit.
Circularity tests of machine manufacturers usually use a radius of 100 mm or 150 mm with
feedrate speeds that are determined by the machine manufacturer. The machine
manufacturer determines the specifications for an acceptable result.
High-speed processes generally have higher requirements for testing circles with high-speed
milling machines and can range from circle radii of 10 - 25 mm and feedrates of 5 - 10
m/min. For high-speed milling machines, the results are generally acceptable if the P/P
deviation ≤ 0.010 mm and the actual size of the circle is equal to the programmed radius,
and in the worst-case scenario to the path velocity.

7.5.2 Circularity test: Performing the measurement

Setting parameters

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7.5 Circularity test

Enter the following parameters to carry out a measurement:

● "Measurement": Selection of the two axes that are meant to be measured and of the
measuring system.
● "Parameter": The parameter settings in the input fields "Radius" and "Feed" must
correspond to the values from the part program that controls the circular motion of the
axes, taking account of the feed override switch setting.
● "Representation": Parameters for displaying the graphics
– "Resolution" (scaling) of the diagram axes in [mm/scaled]
– "Display" via the mean radius or programmed radius

Perform measurement
Procedure:
1. In the "Commissioning" operating area select the "Optimization/Test" softkey →
"Circularity test" softkey.
2. Select the axes that are meant to be measured with the <SELECT> key or using the
"Axis+"/"Axis -" softkeys.
3. Set the "parameters" for the measurement: "Radius" and "Feed"
The "Measuring time" display field shows the measuring time calculated from the
"Radius" and "Feed" values for recording the actual position values during the circular
movement:
If the measuring time is not sufficient then only parts of the circle are portrayed. The
measuring time can be increased by reducing the feed value. This also applies if the
circularity test is started from the stationary condition.
4. Set the parameters for displaying the graphic:
If the measuring time calculated from this exceeds the time range that can be displayed
(maximum measuring time = position controller cycle frequency * 2048), a coarser
sampling rate is used for recording (n * position controller cycle frequency), so that a
complete circle can be displayed.

Further actions:
● To start the measurement, press the "Start" softkey.
● To stop the measurement, press the "Stop" softkey.
● To make further adjustments for optimization, press the "Optimization" softkey.
● On a new softkey bar, you can navigate directly to the following areas:
– "Service axis" in the "Diagnostics" operating area
– "Axis machine data"
– "Drive machine data"
– "User Views"

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● In order to save the parameters for a measurement, press the "Save parameter" softkey.
● In order, for example, to repeat a measurement with the same parameters, press the
"Load parameter" softkey.

Displaying a graphic
In order to display the measurement result as a graphic, press the "Graphic" softkey.

7.5.3 Circularity test: Examples

The MD32400 $MC_AX_JERK_ENABLE axial jerk limitation is set via a time constant and is
always active.
Machine data for setpoint filter:
● MD32402 $MC_AX_JERK_MODE = Type 2 is recommended, type 1 is preset for
compatibility reasons. Parameterizing a pure band-stop filter is expressly not
recommended.
● MD32402 $MA_AX_JERK_MODE (filter type) and MD32410 $MA_AX_JERK_TIME > 0 is
effective only if MD32400 $MA_AX_JERK_ENABLE = 1 is set.

Example 1 for optimization

Machine data after optimization of the axes:

Parameters / machine data X axis Z axis

MD32200 $MC_POSCTRL_GAIN 8.500 8.500
p1460 SPEEDCTRL_GAIN1 3.01 3.89
p1462 SPEEDCTRL_INTEGRATOR_TIME_1 6.18 6.18
p1463 SPEEDCTRL_REF_MODEL_FREQ 106.3 106.3
p1440 NUM_SPEED_FILTERS 0 0
MD32610 $MC_VELO_FFW_WEIGHT 1.0 1.0
MD32620 $MC_FFW_MODE 4 4
MD32810 $MC_EQUIV_SPEEDCTRL_TIME 0.0022 0.0022
MD32400 $MC_AX_JERK_ENABLE 0 0

The actual value of the radius is generally too large with optimized feed precontrol. This can
be corrected with the MD32410 $MC_AX_JERK_TIME time constant. Use a time constant in
all axes if required.

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7.5 Circularity test

This circle displays the results after the feed precontrol has been optimized. However, the
mean radius is 0.0019 mm too large:

X1: active measuring system Parameter

Z1: active measuring system Radius: 10.00000 mm

Feedrate: 3000.00000 mm/min

Measurement time: 1257 ms
X1: active measuring system
Z1: active measuring system
Representation
Resolution: 0.01000 mm
Display of mean radius
Radius: 10.00190 mm
Delta R: 4.02698 μm

Parameters / machine data X axis Z axis

MD32200 $MC_POSCTRL_GAIN 8.500 8.500
p1460 SPEEDCTRL_GAIN1 3.01 3.89
p1462 SPEEDCTRL_INTEGRATOR_TIME_1 6.18 6.18
p1463 SPEEDCTRL_REF_MODEL_FREQ 106.3 106.3
p1440 NUM_SPEED_FILTERS 0 0
MD32610 $MC_VELO_FFW_WEIGHT 1.0 1.0
MD32620 $MC_FFW_MODE 3 3
MD32810 $MC_EQUIV_SPEEDCTRL_TIME 0.0022 0.0022
MD32400 $MC_AX_JERK_ENABLE 1 1
MD32402 $MC_AX_JERK_MODE 2 2
MD32410 $MC_AX_JERK_TIME 0.012 0.012

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7.5 Circularity test

Example 2 for optimization

This circle shows the effect of a slightly different time constant for the axial jerk filter. The
time constant is adapted in order to correct this type of error:

Parameters / machine data X axis Z axis

MD32400 $MC_AX_JERK_ENABLE 1 1
MD32402 $MC_AX_JERK_MODE 2 2
MD32410 $MC_AX_JERK_TIME 0.012 0.0125

X1: active measuring system Parameter

Z1: active measuring system Radius: 10.00000 mm
Feedrate: 3000.00000 mm/min
Measurement time: 1257 ms
X1: active measuring system
Z1: active measuring system
Representation
Resolution: 0.01000 mm
Representation: mean radius
Radius: 10.00029 mm
Delta R: 25.47002 μm

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7.5 Circularity test

Example 3 for optimization

This circle shows the effect of a considerably different time constant for the axial jerk filter.
The time constant is adapted in order to correct this type of error:

Parameters / machine data X axis Z axis

MD32400 $MC_AX_JERK_ENABLE 1 1
MD32402 $MC_AX_JERK_MODE 2 2
MD32410 $MC_AX_JERK_TIME 0.015 0.012

X1: active measuring system Parameter

Z1: active measuring system Radius: 10.00000 mm
Feedrate: 3000.00000 mm/min
Measurement time: 1257 ms
X1: active measuring system
Z1: active measuring system
Representation
Resolution: 0.01000 mm
Representation: mean radius
Radius: 9.98971 mm
Delta R: 75.67665 μm

7.5.4 Circularity test: Saving data

The following data can be backed up with the circularity test:
● Save parameters: The parameters entered can be saved as a file.
The following path is the default path:
user/sinumerik/hmi/log/optimization/cicular/<name>.sup
● Save graphic: If the graphic has been saved correctly the message "Data was saved"
appears, otherwise an "Error in saving the file" error message is received.
The following path is the default path:
user/sinumerik/hmi/log/optimization/cicular/<name>.sud
● Print graphic: The graphic is saved as a pixel graphic in PNG format. Type in a name.
The name can be freely selected. The following path is the default path:
user/sinumerik/hmi/log/optimization/cicular/<name>.png

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Save parameters
The file format is structured as follows (with comments in brackets[ ])
H: CstPar [Identifier for circularity test parameters]

V: 5.0 [Version number of the file format]

@Measurement

P 1: 1 [Axis number first axis]

P 2: 2 [Axis number second axis]

P 3: 0 [Measuring system Axis 1 - 0: active; 1:first; 2: second]

P 4: 0 [Measuring system Axis 2 - 0: active; 1:first; 2: second]

@ parameters

P 10: 30 [Radius]

P 11: 3000 [Feed]

P 12: 3770 [Measuring time]

P 14: 1 [Multiplier]

@Representation

P 20: 10 [Resolution]

P 21: 8 [mean / prog. radius - 8 = mean R ; 9 = prog. Radius]

Save graphic
The file format is structured as follows (with comments in brackets[ ]):
H: CstPic [Identifier for circularity test graphic]

V: 5.0 [Version number of the file format]

@ parameters

P 1: 30 [Radius]

P 2: 3000 [Feed]

P 3: 3770 [Measuring time]

P 4: 0 [Measuring system Axis 1 - 0: active; 1:first; 2: second]

P 5: 0 [Measuring system Axis 2 - 0: active; 1:first; 2: second]

@Representation

P 10: 10 [Resolution]

P 11: 9 [mean / prog. radius - 8 = mean R ; 9 = prog. Radius]

P 12: X1 [Axis name 1]

P 13: Z1 [Axis name 2]

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7.5 Circularity test

@Intermediate values

P 20: 15.6632 [max. radius measured values]

P 21: 10.9326 [min. radius measured values]

P 22: 13.6694 [mean radius measured values]

P 23: 1886 [Number of measured values]

@Additional values

P 30: 1000 [Accuracy (1/P30))

@Physical units

P 40: 5370 [Text number radius unit]

P 41: 5381 [Text number feed unit]

P 42: 6165 [Text number Resolution unit]

P 43: 5346 [Text number DeltaRadius unit]

P 44: 0 [New: Operate: Basislengthunit]

@Abscissa

Ai: [Abscissa values i: 0..P23]

@Ordinate

Oi: [Ordinate values i: 0..P23]

@Radius

Ri: [Radius values i: 0..P23]

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7.6 Optimize the spindle

7.6 Optimize the spindle

7.6.1 Set the machine data for the spindle

Checking the machine data settings

Match the machine data default settings as well as all relevant parameters for spindle/axis
interpolation with the MD in the following table. The example is true for a spindle motor
without mechanical gearbox stages with 8000 rpm.
The machine data can be initialized with the suggested values shown in the table. The
values vary depending on the application.

Number Designation Value Meaning

MD30300 $MA_IS_ROT_AX 1 Rotary axis / spindle
MD30310 $MA_ROT_IS_MODULO 1 Modulo conversion for rotary axis /
spindle
MD30320 $MA_DISPLAY_IS_MODULO 1 360-degree modulo display for rotary axis
or spindle
MD32000 $MA_MAX_AX_VELO 8000 Maximum axis velocity
MD32010 $MA_JOG_VELO_RAPID 60 Rapid traverse in jog mode
MD32020 $MA_JOG_VELO 10 Jog axis velocity
MD32040 $MA_JOG_REV_VELO_RAPID 60 Revolutional feedrate in jog mode with
rapid traverse override
MD32050 $MA_JOG_REV_VELO 10 Revolutional feedrate for jog
MD32200[0] $MA_POSCTRL_GAIN x KV factor: as optimized
MD32200[1] $MA_POSCTRL_GAIN x
MD32620 $MA_FFW_MODE 3 Precontrol mode
MD32640 $MA_STIFFNESS_CONTROL_ENABLE 1 Dynamic stiffness control
MD32810[0] $MA_EQUIV_SPEEDCTRL_TIME x Equivalent time constant speed control
MD32810[1] $MA_EQUIV_SPEEDCTRL_TIME x loop for precontrol as optimized
MD33000 $MA_FIPO_TYPE 3 Fine interpolator type
MD34000 $MA_REFP_CAM_IS_ACTIVE 0 Axis with reference point cams
MD34020 $MA_REFP_VELO_SEARCH_CAM 30 Reference point approach velocity
MD34020 $MA_REFP_VELO_SEARCH_CAM 30
MD34040[0] $MA_REFP_VELO_SEARCH_MARKER 30 Creep velocity
MD34040[1] $MA_REFP_VELO_SEARCH_MARKER 30
MD34060[0] $MA_REFP_MAX_MARKER_DIST 370 Maximal distance to the reference mark
MD34060[1] $MA_REFP_MAX_MARKER_DIST 370
MD35000 $MA_SPIND_ASSIGN_TO_MACHAX 1 Assignment of spindle to the machine
axis
MD35100 $MA_SPIND_VELO_LIMIT 8000 Maximum spindle speed
MD35110[0] $MA_GEAR_STEP_MAX_VELO 8000 Maximum speed for gear stage change

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7.6 Optimize the spindle

Number Designation Value Meaning

MD35110[1] $MA_GEAR_STEP_MAX_VELO 8000
MD35130[0] $MA_GEAR_STEP_MAX_VELO_ 8000 Maximum speed of gear stage
LIMIT
MD35130[1] $MA_GEAR_STEP_MAX_VELO_ 8000
LIMIT
MD35200[0] $MA_GEAR_STEP_SPEEDCTRL_ x Acceleration in speed control mode: as
ACCEL optimized
MD35200[1] $MA_GEAR_STEP_SPEEDCTRL_ x
ACCEL
MD35210[0] $MA_GEAR_STEP_POSCTRL_ x Acceleration in position control mode: as
ACCEL optimized
MD35210[1] $MA_GEAR_STEP_POSCTRL_ x
ACCEL
MD35500 $MA_SPIND_ON_SPEED_AT_IPO_ 2 Feed enable with spindle in setpoint
START range
MD35550[0] $MA_DRILL_VELO_LIMIT 4000 Maximum speeds for tapping
MD35550[1] $MA_DRILL_VELO_LIMIT 4000
MD36000 $MA_STOP_LIMIT_COARSE 0.4 Coarse exact stop
MD36010 $MA_STOP_LIMIT_FINE 0.1 Fine exact stop
MD36030 $MA_STANDSTILL_POS_TOL 5 Standstill tolerance
MD36040 $MA_STANDSTILL_DELAY_TIME 1 Zero speed monitoring delay time
MD36050 $MA_STOP_ON_CLAMPING 1 Clamping tolerance
MD36060 $MA_STANDSTILL_VELO_TOL 2 Threshold velocity / speed
"Axis/spindle stationary"
MD36200 $MA_AX_VELO_LIMIT 8800 Threshold value for velocity monitoring
MD36200 $MA_AX_VELO_LIMIT 8800
MD36300[0] $MA_ENC_FREQ_LIMIT 1000000 Encoder limit frequency
MD36300[1] $MA_ENC_FREQ_LIMIT 1000000
MD36400 $MA_CONTOUR_TOL 30 Contour monitoring tolerance band
p1433 SPEED_CONTROLLER_REFERENCE_ x Speed controller reference model natural
MODEL_NATURAL_FREQUENCY frequency / n_reg RefMod fn: as
optimized

7.6.2 Spindle: Checking the speed controller

Checking the acceleration of the speed controller

The speed controller acceleration is checked. First, the acceleration time must be specified
without effects by the NC.
Set the following machine data:
● MD35200[0] $MA_GEAR_STEP_SPEEDCTRL_ACCEL = 9999
● MD35200[1] $MA_GEAR_STEP_SPEEDCTRL_ACCEL = 9999
( t=V/a t=9000/60s/9999 t=15 ms, consequently no effect).

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7.6 Optimize the spindle

Now glance at the motor datasheet, e.g. 1PH8089-1VM02-0MG1 asynchronous motor:

Figure 7-3 1PH8 asynchronous (induction) motor

Accelerating and decelerating with the original data of the motor corresponds to the S1 curve.

Number Designation Value

p0640 Current limit (p0305 motor rated current * 1.5) 17.7 A
p1520 CO: Torque limit upper/motorized M_max upper/mot 4.8 Nm
p1521 CO: Torque limit lower/regenerative / M_max lower/gen -4.8 Nm
p1530 Power limit motorized / P_max mot 1.5 kW
p1531 Power limit regenerative / P_max gen -1.5 kW

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Optimizing a drive
7.6 Optimize the spindle

Trace recording
Procedure:
1. Use the following key combination to invoke the Trace function:
<MENU SELECT> → "Diagnostics" operating area, menu forward key → "Trace" softkey

2. To select the required variables: "Select variable" softkey

– Actual motor speed/velocity
– Active power
– Torque-generating actual current value i(q)
– Torque/force setpoint (limited)
3. The required variables are selected: "Select variable" softkey.
4. Press the "Filter/search" softkey to limit the list of variables.
5. Ensure that the spindle is selected when you add the variables:

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7.6 Optimize the spindle

6. Press the "Settings" softkey.

7. Confirm with "OK".

8. Enter the following program in the MDA:
S8000 M03

G04 F5

M30

9. Initialize the trace and execute the program:

"Trace" softkey → "Display trace" softkey → "Start trace" softkey → <RESET> key →
<CYCLE START> key

Evaluation
● When the trace function completes, press the "Adapt all" softkey.

Use the cursor keys to set the acceleration time.

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Optimizing a drive
7.6 Optimize the spindle

Trace selection: Actual speed (Trace 1)

Time needed for acceleration to the speed setpoint = 2.5 seconds

The cursor is positioned at the trace start and at the point where the speed setpoint is
attained.
● The power used to accelerate the motor can be seen on Trace 2:
Trace selection: Actual speed

Maximum available power = 1.5 kW = S1 curve

● The torque setpoint can be seen on Trace 4:
Trace selection: Torque setpoint

Torque setpoint = 4.8 Nm = S1 curve

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7.6 Optimize the spindle

Checking the acceleration

The acceleration/deceleration can be changed using the motor datasheet through to the
maximum values, although this depends on the associated application. Enter appropriate
values for the application. In our example, a short acceleration/braking time is requested.

Number Designation Value

p0640 Current limit (p0305 motor rated current * 1.5) 32 A
p1520 CO: Torque limit upper/motorized M_max upper/mot 20.7 Nm
p1521 CO: Torque limit lower/regenerative / M_max lower/gen -20.7 Nm
p1530 Power limit motorized / P_max mot 13 kW
p1531 Power limit regenerative / P_max gen -13 kW

Enter the maximum values from the motor datasheet in the appropriate drive data: e.g.
1PH8089-1_M0, 1PH8089-1_M1 asynchronous motor

Figure 7-4 1PH8 asynchronous (induction) motor

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7.6 Optimize the spindle

Recording a new trace

Procedure:
1. Execute the Spindle and Trace function. The time required for acceleration to the speed
setpoint can now be checked.
Trace selection: Actual speed

2. Set MD35200so that it meets the machine manufacturer's requirements for the spindle
acceleration:
MD35200[0] $MA_GEAR_STEP_SPEEDCTRL_ACCEL
MD35200[1] $MA_GEAR_STEP_SPEEDCTRL_ACCEL

7.6.3 Spindle: Checking the position controller

Testing the position controller

A test can now also be performed to set the acceleration and jerk of the position control. This
test is performed by tapping without using a compensating chuck.
Procedure:
1. Check MD35550 [0] & [1] DRILL_VELO_LIMIT; this is the maximum tapping speed.
2. Check SD55484 $SCS_DRILL_TAPPING_SET_MC[0] = 1;, it holds the spindle in the
positioning mode during tapping.
The following program can be used to drill ten holes at the same position:
SUPA D0 G0 G90 Z-200

FFWON

M19

SOFT

LAB:

G331 Z-214 S4000 K1

G332 Z-200 S4000 K1

REPEAT LAB P=9

M30

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 Optimizing a drive
7.6 Optimize the spindle

3. Select the following variables:

– Position setpoint (64-bit)
– Measuring system actual position (64-bit)
– Contour deviation (64-bit)
– Load (m_set/m_set_limit) (64-bit)

Note
Ensure that the correct signal is selected for the monitoring of measuring systems, e.g.
measuring system 1 or 2.

4. Use the "Settings" softkey to select the trace trigger, etc. The example shows a trace that
is initiated when the actual position exceeds five degrees. The trace is recorded for ten
seconds.

5. Start the trace and press <CYCLE START> on the machine control panel.

Examples
Because the load reaches 64% in the following example, the position-control acceleration
can be increased. Because the spindle can operate above the S1 curve during the tapping, it
must be guaranteed that the load does not reach 100% and so no alarms for contour
monitoring are issued.
1. To achieve optimum results, optimize MD35210 $MA_GEAR_STEP_POSCTRL_ACCEL
and MD32431 $MA_MAX_AX_JERK.
2. Also check that adaptable p1464, p1465control range of the spindle.

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Optimizing a drive
7.6 Optimize the spindle

Spindle: Load 64%

The following example shows the effect of increasing the position-control acceleration from
120 to 160; the load then increases from 64% to 88%. If the application involves a pure
tapping machine, a test can be performed for which 100 holes are tapped. The trace
recording is then repeated to ensure that 100% load is never reached.
Spindle: Load 88%

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Service Planner 8
Overview
Using the service planner dialog at the user interface or programming tool, time intervals and
alarm sequences for the tasks to be processed (mainly machine maintenance tasks) can be
edited, started, deactivated or reactivated.
The numeric data of the tasks is organized in data blocks and provided in the user interface
for the HMI, PLC user program and programming tool. The designations of the particular
task are managed and edited by the operating software and displayed together with the
numerical data.
The PLC firmware accesses the user interface data blocks, processes the data and then
provides the results in the form of remaining times as well as warnings and alarms in data
blocks. The Service Planner is processed every minute in the PLC firmware. When the
control is switched off, the actual data of the maintenance tasks is frozen. When the control
is switched on, processing is continued with these retentively saved values.
The PLC user program evaluates the actual data and generates warning and alarm
messages in numeric form either with or without Power OFF status. The alarm handler
converts these messages with the appropriate PLC alarm text file oem_alarm_plc_<lng>.ts to
a message for the operator which is displayed on the user interface (<lng> currently set
language) and which can be logged, if required.

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Service Planner

Configuration in the system

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Figure 8-1 Service Planner: Configuration

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 Service Planner
8.1 Interfaces in the PLC user program

8.1 Interfaces in the PLC user program

PLC user program

The PLC user program operates the user interface. This includes, in particular, the bit
interfaces of the DB1800 and the evaluation of the remaining time in DB9904. You must
ensure that appropriate messages are displayed for the warnings and alarms.
During the configuration of these messages, so-called alarm responses can be selected, e.g.
the machine is "disabled" after a Power OFF message.
The alarm messages are configured in accordance with the specifications of the
SINUMERIK 828D PLC messages. The texts are entered with the alarm text editor. Then the
texts are available for the operating software:
● Evaluation of the alarm and actual data with the aim of generating PLC warning and
alarm messages. Additional signals can be included in the evaluation logic.
● Optional linking of the deactivation bits with bit memory or I/O signals.

Note
A sample program is supplied in the PLC function library. This can be adapted by
machine manufacturers to meet their requirements.

Interfaces to the PLC

The following data areas are available in the user interface:

Data block Meaning

DB9903 Initial data
DB9904 Actual data
DB1800.DBB2000 Deactivate tasks
DB1800.DBB3000 Alarms
DB1800.DBB4000 Acknowledgments
DB1800.DBB5000 Acknowledgment block

DB9903: Initial data

DB9903 Initial data table [r16]

Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
DBW0 Interval 1 [h]
DBW2 Time of first warning 1 [h]
DBW4 Number of warnings to be output 1
DBW6 Reserved 1
DBW8 Interval 2 [h]

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Service Planner
8.1 Interfaces in the PLC user program

DB9903 Initial data table [r16]

DBW10 Time of first warning 2 [h]
DBW12 Number of warnings to be output 2
DBW14 Reserved 2
... ...
DBW248 Interval 32 [h]
DBW250 Time of first warning 32 [h]
DBW252 Number of warnings to be output 32
DBW254 Reserved 32

Designation Meaning
Interval Number of hours after which the maintenance must be performed. When
this time expires, the warning or alarm bit belonging to the task is set for the
last time.
Time of the first Number of hours after which the first warning is output. This time must be
warning greater than or equal to the interval.
Number of warnings to Number of n warnings to be output before the alarm.
be output (The alarm bit is therefore set maximum (n+1)-times, i.e n-times as warning
and 1-time as alarm.)
Reserved Reserved for expansions.

Example:
Interval = 100
Time of the 1st warning = 80
Number of warnings to be output = 2
After the task is started, the warning/alarm bit is output for the first time after 80 hours, a
second time after a further 10 hours (i.e. after a total of 90 hours), and the warning/alarm bit
is set for the last time after 100 hours.

DB9904: Actual data

DB9904 Actual data table [r16]

Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
DBW0 Remaining time 1 [h]
DBW2 Number of warnings output 1
DBW4 Reserved_1 1
DBW6 reserved_2 1
DBW8 Remaining time 2 [h]
DBW10 Number of warnings output 2
DBW12 Reserved_1 2
DBW14 reserved_2 2

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DB9904 Actual data table [r16]

... ...
DBW248 Remaining time 32 [h]
DBW250 Number of warnings output 32
DBW252 Reserved_1 32
DBW254 reserved_2 32

Designation Meaning
Remaining time Number of hours remaining after the start of the task until it expires.
Remaining time ≠ 0 and associated alarm bit set: Warning
Remaining time = 0 and associated alarm bit set: Alarm
Number of warnings Number n of warnings that have already been output. If the interval has
output expired completely, the output value is (n+1):
n = "number of warnings to be output"
1 = alarm at the end of the interval
Reserved_1, ~_2 Reserved for expansions.

Example:
Interval = 100, time of the 1st warning = 80, number of warnings to be output = 2
After the task is started, the remaining time is decremented every hour.
● After 80 hours, the remaining time is 20 hours and the number of warnings that have
been output is increased from 0 to 1.
● After a further 10 hours (i.e. a total of 90 hours), the remaining time is 10 hours and the
number of warnings that have been output is increased from 1 to 2.
● After 100 hours, the remaining time is 0 and the number of warnings that have been
output is 3 (= 2 warnings plus 1 alarm).

DB1800: Acknowledgments

DB1800 Acknowledgments [r/w]

Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
DBB4000 Acknowl- Acknowl- Acknowl- Acknowl- Acknowl- Acknowl- Acknowl- Acknowl-
edgment 8 edgment 7 edgment 6 edgment 5 edgment 4 edgment 3 edgment 2 edgment 1
DBB4001 Acknowl- Acknowl- Acknowl- Acknowl- Acknowl- Acknowl- Acknowl- Acknowl-
edgment edgment edgment edgment edgment edgment edgment edgment 9
16 15 14 13 12 11 10
DBB4002 Acknowl- Acknowl- Acknowl- Acknowl- Acknowl- Acknowl- Acknowl- Acknowl-
edgment edgment edgment edgment edgment edgment edgment edgment
24 23 22 21 20 19 18 17
DBB4003 Acknowl- Acknowl- Acknowl- Acknowl- Acknowl- Acknowl- Acknowl- Acknowl-
edgment edgment edgment edgment edgment edgment edgment edgment
32 31 30 29 28 27 26 25

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8.1 Interfaces in the PLC user program

Designation Meaning
Acknowledgment n The acknowledgment bit assigned to task n:
Under the precondition that the corresponding acknowledgment blocking bit is
not set, the setting of the acknowledgment bit restarts the task and, in
particular, the actual data of the task is set:
 Remaining time = interval
 Number of warnings output = 0
The bit is automatically reset at the end of the PLC cycle.

Example:
Interval = 100, time of the 1st warning = 80, number of warnings to be output = 2
After the setting of the associated acknowledgment bit, the remaining time is set to the
interval time and the number of output warnings is zero - assuming the associated
acknowledgment blocking bit is not set.

DB1800: Alarms

DB1800 Warnings/Alarms [r]

Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
DBB3000 Alarm 8 Alarm 7 Alarm 6 Alarm 5 Alarm 4 Alarm 3 Alarm 2 Alarm 1
DBB3001 Alarm 16 Alarm 15 Alarm 14 Alarm 13 Alarm 12 Alarm 11 Alarm 10 Alarm 9
DBB3002 Alarm 24 Alarm 23 Alarm 22 Alarm 21 Alarm 20 Alarm 19 Alarm 18 Alarm 17
DBB3003 Alarm 32 Alarm 31 Alarm 30 Alarm 29 Alarm 28 Alarm 27 Alarm 26 Alarm 25

Designation Meaning
Alarm n The alarm bit assigned to task n.
The bit is set each time for one PLC cycle:
As warning (remaining time ≠ 0) and as alarm (remaining time = 0).

DB1800: Deactivate tasks

DB1800 Task deactivation [r/w]

Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
DBB2000 Deacti- Deacti- Deacti- Deacti- Deacti- Deacti- Deacti- Deacti-
vation 8 vation 7 vation 6 vation 5 vation 4 vation 3 vation 2 vation 1
DBB2001 Deacti- Deacti- Deacti- Deacti- Deacti- Deacti- Deacti- Deacti-
vation 16 vation 15 vation 14 vation 13 vation 12 vation 11 vation 10 vation 9

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8.1 Interfaces in the PLC user program

DB1800 Task deactivation [r/w]

DBB2002 Deacti- Deacti- Deacti- Deacti- Deacti- Deacti- Deacti- Deacti-
vation 24 vation 23 vation 22 vation 21 vation 20 vation 19 vation 18 vation 17
DBB2003 Deacti- Deacti- Deacti- Deacti- Deacti- Deacti- Deacti- Deacti-
vation 32 vation 31 vation 30 vation 29 vation 28 vation 27 vation 26 vation 25

Designation Meaning
Deactivation n The deactivation bit assigned to task n.
If the bit is set via the HMI or from the PLC user program, the current state
of task n is frozen and no longer processed.
TRUE: Task deactivated
FALSE: Task active
This means it is possible, for example, to adapt the maintenance interval
according to the actual runtime of the modules.

DB1800: Acknowledgment block

DB1800 Acknowledgment block [r/w]

Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
DBB5000 Acknowl- Acknowl- Acknowl- Acknowl- Acknowl- Acknowl- Acknowl- Acknowl-
edgment edgment edgment edgment edgment edgment edgment edgment
block 8 block 7 block 6 block 5 block 4 block 3 block 2 block 1
DBB5001 Acknowl- Acknowl- Acknowl- Acknowl- Acknowl- Acknowl- Acknowl- Acknowl-
edgment edgment edgment edgment edgment edgment edgment edgment
block 16 block 15 block 14 block 13 block 12 block 11 block 10 block 9
DBB5002 Acknowl- Acknowl- Acknowl- Acknowl- Acknowl- Acknowl- Acknowl- Acknowl-
edgment edgment edgment edgment edgment edgment edgment edgment
block 24 block 23 block 22 block 21 block 20 block 19 block 18 block 17
DBB5003 Acknowl- Acknowl- Acknowl- Acknowl- Acknowl- Acknowl- Acknowl- Acknowl-
edgment edgment edgment edgment edgment edgment edgment edgment
block 32 block 31 block 30 block 29 block 28 block 27 block 26 block 25

Designation Meaning
Acknowledgment The acknowledgment blocking bit assigned to task n.
block n If the bit is set via the HMI or from the PLC user program, the task is not
acknowledged even when the acknowledgment bit is set.
TRUE: Acknowledgment of the task blocked
FALSE: Acknowledgment of the task permitted
In this way, it is possible, for example, to incorporate a sensor in the PLC
user program, which signals that the maintenance task has been performed,
and, if required, block the acknowledgment.

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8.2 Interfaces to the operating software

8.2 Interfaces to the operating software

Overview
To process these service/maintenance tasks, you have the following options:
● Managing the data in the PLC user program using the programming tool.
● Maintenance tasks are created via an XML interface.
Using this segmentation, inconsistencies between the PLC block and the XML scripts are
avoided if the PLC block is changed in the PLC user program via the programming tool or as
a result of a commissioning archive.

Configuration
You can configure up to 32 maintenance tasks. The following columns are shown in the
configuring mode:

Designation of the column Meaning

Maintenance task Name of the maintenance task.
Interval [h] Maximum time until the next maintenance in hours; if this value ≠ 0,
this data set is accepted by the PLC as a valid maintenance task.
1st warning [h] Time in hours after which the first warning is displayed; this value
must be less than that of the interval.
Number of warnings Number of warnings that are output by the PLC before the PLC sets
the alarm bit for the last time after the interval has expired (remaining
time == 0).
Remaining time [h] Time until the interval expires in hours.
Status  A green check mark indicates that the time up to the next
maintenance is still running.
 A red clock symbol indicates that there is a maintenance task to
be performed.

The dialog is called with different contents depending on the access level.

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8.2 Interfaces to the operating software

Configuration mode
Access level 2: Service
Maintenance tasks can be created, changed and also deleted in this mode. The
maintenance tasks can also be acknowledged. All columns are visible. Navigation between
the columns is with <Tab> or <Key Left/Right>.

Note
Number assignment
A number is automatically assigned when a task is created. If this is not desirable, then the
tasks must be configured with the corresponding numbers.
This is recommended, for example, if task m is deleted by mistake and this has to be created
again under the same number because of the evaluation in the PLC user program.

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8.2 Interfaces to the operating software

Standard mode
Access level 3: User
In the standard mode, the actual status of the maintenance tasks is displayed. The following
columns are visible, but cannot be edited: "Maintenance task", "Interval", "Remaining time"
and "Status".

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8.3 This is how you import and export maintenance tasks

8.3 This is how you import and export maintenance tasks

Overview
In the dialog, there are two soft keys that can be used to read-in and read-out the
configuration files with the maintenance tasks:
● Importing maintenance tasks
● Exporting maintenance tasks

Configuring maintenance tasks

Procedure:
1. Generate a configuration file using the structure described below.
The filename in lower-case letters can be freely selected.
2. As a minimum, generate the oem_maintenance_<lng>.ts, file, which contains the
language-dependent designations for the maintenance tasks.
3. Copy the two files to a storage medium (CompactFlash card or USB FlashDrive).
4. Insert the storage medium into the appropriate slot at the front.
5. Press the "Import maintenance tasks" softkey.
6. Confirm with "OK".
The files are copied. The language-dependent tasks are immediately visible.
Press the "Export maintenance tasks" softkey in order to make changes or supplements.
This means that you copy these files to a storage medium, which you can then edit using an
external editor.

Structure of the xml configuration file

The following identifiers are permissible:

Identifier Meaning
<MAINTENANCE_TASK> Main Tag
<TASK_ID> Number of the maintenance task
<INTERVALL> Maintenance interval time
<FIRST_WARNING> Time interval until the first alarm is output.
<NUMBER_OF_WARNING> Number of alarms

The file name can be freely selected, for example task.xml.

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Service Planner
8.3 This is how you import and export maintenance tasks

task.xml
<MAINTENANCE>
<MAINTENANCE_TASK>
<TASK_ID>0</TASK_ID>
<INTERVALL>3</INTERVALL>
<FIRST_WARNING>1</FIRST_WARNING>
<NUMBER_OF_WARNING>1</NUMBER_OF_WARNING>
</MAINTENANCE_TASK>
<MAINTENANCE_TASK>
<TASK_ID>1</TASK_ID>
<INTERVALL>3</INTERVALL>
<FIRST_WARNING>2</FIRST_WARNING>
<NUMBER_OF_WARNING>1</NUMBER_OF_WARNING>
</MAINTENANCE_TASK>
...
<MAINTENANCE_TASK>
<TASK_ID>2</TASK_ID>
<INTERVALL>3</INTERVALL>
<FIRST_WARNING>2</FIRST_WARNING>
<NUMBER_OF_WARNING>1</NUMBER_OF_WARNING>
</MAINTENANCE_TASK
</MAINTENANCE>

Structure of the oem_maintenance_<lng>.ts file

This file has the extension ".ts" and contains all the language-dependent warning texts that
were entered in the dialog. This file is available in the binary format (*.qm) after the system
powers-up the next time.
Target directory: /oem/sinumerik/hmi/lng

oem_maintenance_<lng>.ts
<?xml version="1.0" encoding="utf-8"?>
<!DOCTYPE TS>
<TS>
<context>
<name>maintenance</name>
<message>
<source>1</source>
<translation>Maintenance task 1</translation>
<chars>44</chars>
</message>
<message>
<source>2</source>

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8.3 This is how you import and export maintenance tasks

oem_maintenance_<lng>.ts
<translation>Maintenance task 2</translation>
<chars>44</chars>
</message>
. . .
<message>
<source>32</source>
<translation>Maintenance task 32</translation>
<chars>44</chars>
</message>
</context>
</TS>

Editing text entries

The maintenance texts are entered in the dialog with the values for the interval, time of the
first warning and the number of warnings. In addition, the .ts file can also be edited in the
alarm text editor if the necessary entry is available in the configuration file
"oem_alarms_config.xml".

Integration in the existing language concept

When started, the Service Planner reads the oem_maintenance_<lng>.ts file with the
language set in the language selection menu. If this is not available, the English version is
read which has to be available for the commissioning.

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Service Planner
8.4 Acknowledging maintenance tasks

8.4 Acknowledging maintenance tasks

Acknowledging maintenance tasks

After completion of the maintenance activities, the maintenance tasks are acknowledged by
the PLC user program or in the dialog of the operating software using the "Maintenance
completed" softkey.
The acknowledgment bit for the maintenance task is set by making the acknowledgment in
the dialog, the PLC then deletes "Number of output warnings/alarms" in the actual data and
loads the interval value with the remaining time. This tells the user that the maintenance task
has been successfully acknowledged.
The acknowledgment point in time of a maintenance task has the following effect:
● Acknowledgment before the interval has expired
The maintenance interval can be acknowledged at any time. Premature acknowledgment
means the premature start of a new maintenance interval.
● Acknowledgment after the interval has expired
Acknowledgment of the maintenance interval restarts the task.

Note
Access level for acknowledgment
The access level to acknowledge a maintenance task is defined by the following machine
data: MD51235 $MNS_ACCESS_RESET_SERV_PLANNER
Default setting: Access level 2 "service"

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Easy Extend 9
9.1 Function of Easy Extend

Objective
Easy Extend provides you with a simple facility for commissioning, activating, deactivating or
testing optional equipment. The available equipment and device states are displayed in a list
by the control system. The system can manage a maximum of 64 devices.
Softkeys are used to activate or deactivate a device.
The Easy Extend function is available in the operating area "Parameter" → "Extension menu"
→ "Easy Extend".

Configuration

;0/VFULSW

+0,

+0,!1&.LQWHUIDFH +0,!3/&LQWHUIDFH

1&.3/&'5,9(

Figure 9-1 Mode of operation of Easy Extend

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Easy Extend
9.1 Function of Easy Extend

To use Easy Extend, the following functions should be configured by the machine
manufacturer:
● PLC ↔ HMI interface
The optional devices are managed via the interface between the user interface and the
PLC.
● Script processing
The machine manufacturer saves the sequences to be executed for commissioning,
activating, deactivating or testing a device, in a statement script.
● Parameter dialog (optional)
The parameter dialog shows device information that is saved in the script file.

Storage of the files

The files belonging to Easy Extend are stored on the CompactFlash Card of the system in
directory "oem" (MANUFACTURER) and "oem_i" (INDIVIDUAL).

File Name Target directory

Text file oem_aggregate_xxx.ts /oem/sinumerik/hmi/lng/
/oem_i/sinumerik/hmi/lng/
Script file agm.xml /oem/sinumerik/hmi/dvm
/oem_i/sinumerik/hmi/dvm
Archive file Any /oem/sinumerik/hmi/dvm/archives
/oem_i/sinumerik/hmi/dvm/archives
PLC user program Any PLC

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 Easy Extend
9.2 Configuration in the PLC user program

9.2 Configuration in the PLC user program

Loading configurations
The configurations created are transferred to the manufacturer directory of the control, with
the script and text file. Additionally, the corresponding PLC user program should be loaded.

Programming the equipment

Communication between the operator component and the PLC takes place in the PLC user
program via data block DB9905, in which 128 words are reserved to manage a maximum of
64 devices.
Four bytes with the following meanings are used for each device:

Byte Bit Description

0 0 == 1 Device has been started up (HMI acknowledgment)
1 == 1 Device is to be activated (HMI request)
2 == 1 Device is to be deactivated (HMI request)
3-7 Reserved
1 0-7 Reserved
2 0 == 1 Device is active (PLC acknowledgment)
1 == 1 Device has an error
2-7 Reserved
3 0-7 Unique identifier for the device

Adding axes
If the machine is extended with machine axes, it is important to install the drive objects (DO)
in a fixed sequence because the start-up archive contains the constellation of the machine
manufacturer's reference machine and cannot be applied if the sequence is changed.
It is recommended that the following settings be selected for the "control components":
● NC data
● PLC data
● Drive data
– ACX format (binary)

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Easy Extend
9.2 Configuration in the PLC user program

Note
Commissioning archive
 In order to be able to use a commissioning archive in the Easy Extend script, these
archives must be created without HMI data!
Changing the machine configuration
 Should there be any need to edit the drive machine data, this should be adapted in the
control first. This procedure should be repeated for all devices and constellations.

See also
This is how you create a commissioning archive (Page 393)

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9.3 Option bits for machine manufacturers and dealers

9.3 Option bits for machine manufacturers and dealers

Distribution of the option bits

The option bits are managed in blocks of 16 bits. According to the default setting, block 3 is
reserved for dealers. This means that machine manufacturers have 48 options and dealers
have 16 options.
The Easy Extend function uses the following machine data to manage options:
MD14510 $MN_USER_DATA_INT[0] to MD14510 $MN_USER_DATA_INT[3]
This assignment of the addresses can also be redefined in the script using the identifier
OPTION_MD so that dealers can specify their own address area. If the dealer wishes to offer
more than 16 options for this machine type, then the blocks not used should be determined.
This must be coordinated with the machine manufacturer.
Block 3 must be programmed in the script using operations to communicate the dealer area.
Further, a fixed device index should be assigned for every device.
Example, to redefine any area:

<option_md name="address identifier of the data" index="<index>"/>

index - identifier of the area index:
0: device 0 to 16 (default setting)
1: device 17 to 32
2: device 33 to 48
3: device 49 to 64

Emulating the device at the PLC interface

Each device must be assigned a unique index in order to permanently assign devices an
option bit and to be able to access the PLC interface. The areas are permanently assigned
using the attribute option_bit. If an assignment is not made, then the bits and the interface
are defined by the index, which is assigned to the device in the following list:

Index MD14510 Data block Device designation

0 $MN_USER_DATA_INT[0] Bit 0 DB9905.DBB0 Device 1
1 $MN_USER_DATA_INT[0] Bit 1 DB9905.DBB4 Device 2
2 $MN_USER_DATA_INT[0] Bit 2 DB9905.DBB8 Device 3
3 $MN_USER_DATA_INT[0] Bit 3 DB9905.DBB12 Device 4
.... ... ... ...
47 $MN_USER_DATA_INT[2] Bit 15 DB9905.DBB188 Device 48
48 $MN_USER_DATA_INT[3] Bit 0 DB9905.DBB192 Device 49
49 $MN_USER_DATA_INT[3] Bit 1 DB9905.DBB196 Device 50

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Easy Extend
9.3 Option bits for machine manufacturers and dealers

Index MD14510 Data block Device designation

.... ... ... ...
62 $MN_USER_DATA_INT[3] Bit 14 DB9905.DBB248 Device 63
63 $MN_USER_DATA_INT[3] Bit 15 DB9905.DBB252 Device 64

Example of a fixed assignment:

<device option_bit="bit number">

...
</device>

Example

①
②
③
④

Blockwise assignment:
① DB9905.DBB0 Device 1
② DB9905.DBB4 Device 2
...
③ DB9905.DBB192 Device 49
④ DB9905.DBB196 Device 50
Assignment to free locations:
① DB9905.DBB0 Device 1
② DB9905.DBB4 Device 2
...
③ DB9905.DBB72 Device 19
④ DB9905.DBB76 Device 20
...

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9.3 Option bits for machine manufacturers and dealers

Feedback from the PLC

If the dealer cannot integrate his own PLC logic, then the PLC feedback signals must be set
by the script.

See also
Attribute option_bit: Structure of the XML script (Page 257)
XML identifier: OPTION_MD (Page 269)

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9.4 Display on the user interface

9.4 Display on the user interface

Dialogs on the user interface

The following dialogs are available for Easy Extend:
● The control offers a configurable dialog, in which the available devices are shown.
● If first commissioning has not taken place yet, the control opens the commissioning
dialog.
If a commissioning procedure is programmed for the unit (XML statement: "START_UP"),
and the device has not been commissioned yet, the control starts the commissioning
procedure.
This involves a complete data backup before the commissioning archives saved in the script
file are imported. Standard or data class archives are permitted as archive types: *.arc and
*.ard
● In the event of an error, the commissioning engineer can decide whether to roll back the
commissioning procedure or to rectify possible errors in machine configurations manually.
● Commissioning can be aborted early with the "Cancel" function. The control then copies
the previously saved commissioning files back.
If the machine has to be switched off after successful completion of the commissioning, the
XML statement "POWER_OFF" can be used to program that a corresponding message is
output on the control.

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9.5 Generating language-dependent text

9.5 Generating language-dependent text

Replacement characters for language-dependent text

The system offers the option of defining CONTROL properties (attribute values) during
runtime. In order to use this function, the desired property must be set in a local variable and
the variable name must be transferred to the tag as an attribute value preceded by $
characters.
Example:

<let name="caption_device_variable" type="string">my_device 3</let>

<DEVICE option_bit="8">
<!-- Direct: The entered expression is displayed. -->
<NAME>my device 1</NAME>
</DEVICE>

<DEVICE option_bit="10">
<!-- Indirect: The text saved for the text identifier caption_id_my_device2 is
displayed. -->
<NAME>$$caption_id_my_device2</NAME>
<form>
<init>
<!-- Indirect: The text saved for the text identifier
form_caption_device2 is displayed. -->
<caption>$$form_caption_device2</caption>
</init>
</form>
</DEVICE>
<!-- Indirect: The content of the variable caption_device_variable is displayed. -
->

<DEVICE option_bit="11">
<NAME>$$$caption_device_variable</NAME>
</DEVICE>

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Easy Extend
9.5 Generating language-dependent text

Structure of text file

The XML files with the language-dependent texts must be created in UTF8 format:
Example: oem_aggregate_eng.ts

<?xml version="1.0" encoding="UTF-8" ?>

<!DOCTYPE TS>
<TS>
<context>
<name>EASY_EXTEND</name>
<message>
<source>form_caption_id_my_device2</source>
<translation>my_device2</translation>
<chars>64</chars>
</message>
<message>
<source>form_caption_device2</source>
<translation>my_input_form</translation>
<chars>64</chars>
</message>
</context>
</TS>

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9.6 Examples

9.6 Examples

9.6.1 Example with control elements

Example of a combo box

If "combo box" is selected as the field type, the expressions to be displayed must also be
defined. The <item> identifier should be used for this purpose. The combo box saves the
index of the currently selected text in the variable belonging to the "CONTROL" (variable
name). The index starts with 1.

<control name = "button1" xpos = "10" ypos = "10" fieldtype = "combobox">

<item>text1</item>
<item>text2</item>
<item>text3</item>
<item>text4</item>
</control>

Example of a value assignment

If an arbitrary integer value is to be assigned to an expression, the attribute value="value"
should be added to the identifier. Rather than consecutive numbers, the control variable now
contains the item's assigned value.

<control name = "button1" xpos = "10" ypos = "10" fieldtype = "combobox">

<item value = "10" >text1</item>
<item value = "20" >text2</item>
<item value = "12" >text3</item>
<item value = "1" >text4</item>

</control>

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Easy Extend
9.6 Examples

Note
"hotlink" attribute
The hotlink attribute results in a cyclic update of the corresponding control. This means that
when a value is entered, the following update cycle overwrites the entered value. To avoid
this behavior, the immediate saving of the entries must be activated with the
DATA_ACCESS tag.
Another possibility is to take the the SOFTKEY_OK identifier into the form. This identifier is
performed before the dialog is closed. In this block, the data comparison can be made
between the control and reference variables with the UPDATE_CONTROLS statement.

9.6.2 Example with parameters to support the commissioning

Dialog with additional parameters

The input fields list selected drive parameters.

<DEVICE>
<list_id>3</list_id>
<name> "Test form" </name>
<form>

<init>
<caption>Equipment Manager</caption>
<control name = "edit1" xpos = "400" ypos = "34" refvar = "drive/dc/p105[DO5]"
/>
<control name = "edit1" xpos = "400" ypos = "54" refvar =
"$MC_AXCONF_MACHAX_USED[4]" />
<control name = "edit1" xpos = "400" ypos = "74" refvar = "drive/dc/p971[DO5]"
/>
<control name = "edit1" xpos = "400" ypos = "94" refvar = "drive/dc/r2[DO5]" />
</init>

<paint>
<text xpos = "40" ypos = "34">dc[DO5]/p105</text>
<text xpos = "40" ypos = "54">$MC_AXCONF_MACHAX_USED[4]</text>
<text xpos = "40" ypos = "74">dc[DO5]/p971</text>
<text xpos = "40" ypos = "94">dc[DO5]/r2</text>
</paint>
</form>

</DEVICE>

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Dialog with combo box

<form>

<init>
<caption>selected machine data</caption>
<DATA_ACCESS type="true" />
<!-- switch on the direct access to the NC variables -->
<control name = "edit1" xpos = "322" ypos = "34"
refvar="$MN_AXCONF_MACHAX_NAME_TAB[0]" />
<control name = "edit2" xpos = "322" ypos = "54"
refvar="$MN_AXCONF_MACHAX_NAME_TAB[1]" />
<control name = "edit3" xpos = "322" ypos = "74"
refvar="$MN_AXCONF_MACHAX_NAME_TAB[2]" />
<control name = "edit4" xpos = "322" ypos = "94"
refvar="$MN_AXCONF_MACHAX_NAME_TAB[3]" />

<control name = "edit5" xpos = "322" ypos = "114" refvar="$MA_IS_ROT_AX[AX1]"

hotlink="true" />
<control name = "edit6" xpos = "322" ypos = "134" refvar="$MA_IS_ROT_AX[AX2]"
hotlink="true" />
<control name = "edit7" xpos = "322" ypos = "154" refvar="$MA_IS_ROT_AX[AX3]"
hotlink="true" />

<!-- using the control type combo box to display the rotation axis value -->
<control name = "edit5" xpos = "322" ypos = "194" refvar="$MA_IS_ROT_AX[AX1]"
fieldtype = "combobox" hotlink="true" >
<item value= "0" >no</item>
<item value= "1" >yes</item>
</control>

<control name = "edit6" xpos = "322" ypos = "214" refvar="$MA_IS_ROT_AX[AX2]"

fieldtype = "combobox" hotlink="true" >
<item value= "0" >No</item>
<item value= "1" >yes</item>
</control>

<control name = "edit7" xpos = "322" ypos = "234" refvar="$MA_IS_ROT_AX[AX3]"

fieldtype = "combobox" hotlink="true" >
<item value= "0" >No</item>
<item value= "1" >yes</item>
</control>

</init>

<paint>

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<text xpos = "23" ypos = "34">AXCONF_MACHAX_TAB[0]</text>

<text xpos = "23" ypos = "54">AXCONF_MACHAX_TAB[1]</text>
<text xpos = "23" ypos = "74">AXCONF_MACHAX_TAB[2]</text>
<text xpos = "23" ypos = "94">AXCONF_MACHAX_TAB[3]</text>
<text xpos = "23" ypos = "114">Is rot axis 1</text>
<text xpos = "23" ypos = "134">Is rot axis 2</text>
<text xpos = "23" ypos = "154">Is rot axis 3</text>

<text xpos = "23" ypos = "174">using combo box control</text>

<text xpos = "23" ypos = "194">Is rot axis 1</text>

<text xpos = "23" ypos = "214">Is rot axis 2</text>
<text xpos = "23" ypos = "234">Is rot axis 3</text>

</paint>

</form>

9.6.3 User example for a power unit

Activating the drive object

The drive object to be activated has already been commissioned and deactivated again by
the machine manufacturer, to market the axis (axes) as an option.
To activate the axis carry out the following steps:
● Activate the drive object via p0105.
● Enable the 2nd axis in the channel machine data.
● Back up the drive machine data via p0971.
● Wait until the data has been written.
● Restart the NCK and the drives.

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Programming:

<DEVICE>
<list_id>1</list_id>
<name> "Activate the drive" </name>

<SET_ACTIVE>
<data name = "drive/dc/p105[DO5]">1</data>
<data name = "$MC_AXCONF_MACHAX_USED[4]">5</data>
<data name = "drive/dc/p971[DO5]">1</data>
<while>
<condition> "drive/dc/p971[DO5]" !=0 </condition>
<while>
<control_reset resetnc ="true" resetdrive = "true"/>
</SET_ACTIVE>

<SET_INACTIVE>
<data name = "drive/dc/p105[DO5]">0</data>
<data name = "$MC_AXCONF_MACHAX_USED[4]">0</data>
<data name = "drive/dc/p971[DO5]">1</data>
</while>
<condition> "drive/dc/p971[DO5]" !=0 </condition>
</while>
<control_reset resetnc ="true" resetdrive = "true"/>
</SET_INACTIVE>

</DEVICE>

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Activating the PLC-controlled device

The device is activated and deactivated by the user program using bit memory 100.0.
Programming:

<AGM>
<OPTION_MD NAME= "$MN_USER_DATA_INT[0]" />
<DEVICE>
<LIST_ID>1</LIST_ID>
<NAME> "PLC Device" </NAME>
<SET_ACTIVE>
<SET_ACTIVE>
<DATA NAME= "PLC/M100.0"> 1 </DATA>
</SET_ACTIVE>
<SET_INACTIVE>
<DATA NAME= "PLC/M100.0"> 0 </DATA>
</SET_INACTIVE>
</DEVICE>
</AGM>

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9.7 Description of the script language

Script language: Extended XML

XML (Extended Markup Language) is used as the script language, extended to include data
processing and high-level language elements.
In contrast to standard XML, the language offers the following additional properties:
● Data storage for NC/PLC data, start-up data
● Reading and writing NC/PLC and drive data
● Execution of conditional jumps within an XML block
● Execution of program loops
● Execution of arithmetic operations
● Creation of local variables
● Reading in/creating a commissioning archive
● Displaying messages
Additionally, SinuCom Installer script elements can be processed with the "up" execute
statement.

Program parts of the script

The script is divided into the following areas:
● Identifier for Easy Extend
● Identifier for the device
● Identifier for commissioning the device
● Identifier for activating the device
● Identifier for deactivating the device
● Identifier for testing the device
● Identifier for machine data and high-level language elements
● Identifier for the parameter dialog
The individual identifiers are described in the following sections.

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9.7.1 Special characters and operators

Displaying special characters

Characters with special meanings in XML syntax have to be rewritten if they are to be
displayed correctly by a general XML interpreter.
The following characters are affected:

Character Notation in XML Meaning

< &gt; Greater than
> &lt; Less than
& &amp; --
" &quot; Quotation marks (straight)
' &apos; Apostrophe

Permitted operators
The operation statement processes the following operations:

Operator Notation in XML Meaning

= = Assignment
== == Equal to
! ! Not
!= != Not equal to
> >, &gt; Greater than
< <, &lt; Less than
>= >=, &gt;= Greater than or equal to
<= <=, &lt;= Less than or equal to
| | Bit-by-bit OR operation
|| || Logical OR operation
& &amp; Logical or bit-by-bit AND operation
&& &amp;&amp; Logical AND operation
+ + Addition
- - Subtraction
* * Multiplication
/ / Division

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9.7.2 Structure of the XML script

Overview
The following identifiers are available for the description of the device:
● Identifier for Easy Extend
● Identifier for the device
● Identifier for commissioning the device
● Identifier for activating the device
● Identifier for deactivating the device
● Identifier for testing the device

Description

Identifier <tag> Meaning

AGM Identifier for Easy Extend
DEVICE Identifier for the description of the device.
Attribute: option_bit The device is assigned a fixed bit number for the option
management.
NAME The identifier specifies the name of the device to be displayed in the
dialog.
If a text reference is used, the dialog displays the text which is
saved for the identifier.
START_UP The identifier contains a description of the sequences required for
commissioning the device.
SET_ACTIVE The identifier contains a description of the sequences required to
activate the device.
SET_INACTIVE The identifier contains a description of the sequences required to
shut down the device.
TEST The identifier contains the statements for testing the operating
capability of a device.
UID Unique numerical identifier to identify the device in the PLC ↔ HMI
interface.
VERSION Identifier for a version

Negative acknowledgment of the function execution

With the automatically provided variable "$actionresult", the system can inform the XML
parser of a negative execution result. If the value is set to zero, the parser aborts the function
processing.

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Example

<?xml version="1.0" encoding="utf-8"?>

<!DOCTYPE AGM>
<AGM> Identifier for Easy Extend
<DEVICE>
<NAME> Device 1 </NAME> Identifier for the device
<START_UP> Identifier for commissioning the device
…
</START_UP>
<SET_ACTIVE> Identifier for activating the device
…
</SET_ACTIVE>
<SET_INACTIVE> Identifier for deactivating the device
…
</SET_INACTIVE>
<TEST> Identifier for testing the device
…
</TEST>
</DEVICE>
…
</AGM>

9.7.3 CONTROL_RESET

Description
This identifier allows one or more control components to be restarted. Execution of the script
is only continued when the control has resumed cyclic operation.

Programming

Identifier: CONTROL_RESET
Syntax: <CONTROL_RESET resetnc="TRUE" />
Attributes: resetnc="true" The NC component is restarted.
resetdrive="true" The drive components are restarted.

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9.7.4 DATA

Description
Identifier for access to NCK, PLC and drive data.
Further details are described in Chapter: Addressing the parameters (Page 282)

Programming

Identifier: DATA
Syntax: <data name ="<Address>" > value </data>
Attributes: name Identifier for the variable name

9.7.5 DATA_ACCESS

Description
The identifier controls the behavior of the dialog when user inputs are being saved. The
behavior should be defined within the INIT identifier. If this identifier is not used, inputs are
always buffered.
Exception: The following attribute is set: hotlink = true

Programming

Identifier: DATA_ACCESS
Syntax: --
Attributes: type=true There is no buffering of the input values. The dialog
copies the entered values directly to the reference
variables.
type=false The values are only copied to the reference
variables with the UPDATA_DATA type = "FALSE"
identifier.

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9.7.6 DATA_LIST

Description
This identifier enables the drive and machine data to be buffered or restored. Up to 20
temporary data lists can be created per device.

Note
The system deletes the data lists when the Easy Extend function is exited.

Programming

Identifier: DATA_LIST
Syntax: <DATA_LIST action ="<read/write>" id="<list name>" > </DATA_LIST>
Attributes: action Identifier for variable values:
 action="read"  The values of the listed variables are stored in a
temporary memory.
 The values of the listed variables are added to
 action="append"
an existing list.
 The backed up values of the variables are
 action="write" copied into the relevant machine data.
id Identifier for identifying the temporary memory

Example

< DATA_LIST action ="read" id="<name>">

nck/channel/parameter/r[2]
nck/channel/parameter/r[3]
nck/channel/parameter/r[4]
$MN_USER_DATA_INT[0]
…
</ DATA_LIST >
< DATA_LIST action ="write" id="<name>" />

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9.7.7 DRIVE_VERSION

Description
Identifier for the drive version. The version number is copied to the $driveversion variable
which is valid within the DEVICE identifier.
Further details are described in Chapter: Addressing the parameters (Page 282)

Programming

Identifier: DRIVE_VERSION
Syntax: --
Attributes: --

9.7.8 FILE

Description
The identifier enables the reading in or creation of standard or data class archives.
● Reading in an archive:
The file name of the archive must be specified for reading in an archive.
● Creating an archive:
If the attribute create= "true" is specified, the function creates a standard archive (*.arc)
under the specified name and stores the file in the …/dvm/archives directory.
If the attribute class is also used, the system also creates a data class archive. The
attributes class and group define the contents.

Programming

Identifier: FILE
Syntax: <file name ="<archive name>" />
<file name ="<archive name>" create="true" class="<data classes>"
group="<area>" />

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Attributes: name Identifier for the file name

class Specifies the data classes that are to be contained in
the archive. If several data classes are to be saved, the
classes should be separated by a blank.
The following data classes can be specified:
 user
 manufacturer
 individual
create A commissioning archive is created under the specified
name in the …/dvm/archives/ directory.
If the "class" attribute is not specified, it is a standard
archive with NC/PLC, HMI and drive data.
group Specifies the data groups that are to be contained in
the archive. If several data groups are to be saved, the
groups should be separated by a blank.
The following data groups can be contained in the
archive:
 NC
 PLC
 HMI
 DRIVES

Example

<!-- Create data class archive -->

<file name="user.arc" create="true"
class="user manufacturer individual"
group="nc plc hmi" />

<!—Read archive into the control à

<file name="user.arc" />
; or
<file name="user.ard" />

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9.7.9 FUNCTION

Description
Function call: This identifier carries out the function specified under the attribute "name".

Programming

Identifier: FUNCTION
Syntax: <FUNCTION name = "function name" />
Attributes: name Function name
return Variable name for saving the result of the function
Call parameters: Call parameters are transferred as values of the XML statement.
The listed variables must be separated by a comma. A maximum of 10
parameters can be transferred.
It is also possible to specify constants or text expressions as call
parameters.
The identifier _T should be placed at the start as a means of identifying
a text expression.

Example
The calling function does not expect a return value

<FUNCTION name = "function name" return="variable name" />

; Parameter transfer
<FUNCTION name = "function name"> var1, var2, var3 </FUNCTION>
<FUNCTION name = "function name"> _T"Text", 1.0, 1 </FUNCTION>

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9.7.10 FUNCTION_BODY

Description
Function body: This identifier forms the function body of a subfunction.

Programming

Identifier: FUNCTION_BODY
Syntax:
 Function body <FUNCTION_BODY name = "function name" >
without parameter …
</ FUNCTION_BODY>
 Function body with <FUNCTION_BODY name="function_name" parameter="p1, p2, p3"
parameter >
…
<let name="tmp></let>
<op> tmp = p1 </op>
…
</ FUNCTION_BODY>
 Function body with <FUNCTION_BODY name="function_name" parameter="p1, p2, p3"
return value return="true" >
…
<let name="tmp></let>
<op> tmp = p1 </op>
…
<op> $return= tmp </op>
</ FUNCTION_BODY>
Attributes: name Name of the subfunction's function body
return If the attribute is set to true, the system creates the
local variable $return. The function's return value
which is forwarded to the calling function when
exiting the function body should be copied to this
variable.
(optional)parameter The attribute lists the expected transfer
parameters. The parameters must be separated by
a comma.
When the function body is called, the values of the
parameters specified in the function call are copied
to the transfer parameters listed.

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Example

<function_body name="test" parameter="c1,c2,c3" return="true">

<let name="tmp">0</let>
<op> tmp = c1+c2+c3 </op>
<op> $return= tmp </op>
</function_body>
…
<let name="my_var"> 4 </let>
<function name="test" return=" my_var " > 2, 3, 4</function>
<print text="result=%d"> my_var </print>
…
<op> tmp = c1+c2+c3 </op>
<op> $return= tmp </op>
</function_body>
<let name="my_var"> 4 </let>
<function name="test" return=" my_var " > 2, 3, 4</function>
<print text="result=%d"> my_var </print>
…

9.7.11 INCLUDE

Description
An XML description is included in this statement.

Programming

Identifier: INCLUDE
Syntax: <?include src="file name" ?>
Attributes: src Identifier for the file name

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9.7.12 LET

Description
Identifier for a local variable under the specified name.
The variable remains valid until the end of the higher-level XML block.
Variables which are to be available globally should be created directly after the AGM tag.

Note
Preassignment of a STRING variable
Texts containing more than one line can be assigned to a string variable if the formatted text
is transferred as a value. If a line is to end with a line feed <LF>, the characters "\n" should
be added at the end of the line.

Programming

Identifier: LET
Syntax: <let name ="<Name>" > preassignment </let>
<let name ="<Name>" type="<Variable type>"> preassignment </let>
Attributes: name Identifier for the variable name
type Permissible identifiers for the variable type:
 Integer (INT)
 Double (DOUBLE)
 Float (FLOAT)
 String (STRING)
Default:
If no type is defined, the system creates an integer
variable.
<LET name = "VAR1" type = "INT" />
A variable can be initialized with a value.
<LET name = "VAR1" type = "INT" > 10 </LET>
If values comprising NCK or PLC variables are
saved in a local variable, the assignment operation
automatically adapts the format to that of the
variables which have been loaded.
permanent If the attribute is set to TRUE, the variable value is
saved permanently.
This attribute only applies to global variables!
Syntax:
<let name ="<Name>" type="<Variable type>"
permanent="TRUE" > preassignment </let>

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Example

<LET name="text" type = "string"> F4000 G94\n

G1 X20\n
Z50\n
M2\n
</LET>

9.7.13 MSGBOX

Description
The identifier opens a message window whose return value can be used for branching. If a
text reference is used, the message window displays the text which is saved for the
identifier.

Programming

Identifier: MSGBOX
Syntax: <MSGBOX text="<Text>" caption="<Title>" retvalue="<Variable>"
type="<Acknowledgment>" />

<MSGBOX text="<Text>" caption="<$$Text reference>"

retvalue="<Variable>" type="<Acknowledgment>" />
Attributes: caption Identifier for the title of the message window
retvalue Identifier for the name of the variable to which the
return value is copied:
retval=0 0: OK
retval=1 1: Cancel
type Identifier for acknowledging the message
type="btn_ok"
type="btn_cancel"
type="btn_okcancel"

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9.7.14 OP

Description
Identifier for an execute statement: All permissible operators may be executed. For
accessing the NCK, PLC and drive data, the complete variable name is to be placed in
quotation marks.

Programming

Identifier: OP
Syntax: <op> arithmetic operation </op>
Attributes: --

Example

<OP> tmpVar = "PLC/MB170" </OP>

<OP> tmpVar = "PLC/MB170" + 5 </OP

Character string processing

The operation instruction is able to process character strings and assign the results to the
string variable specified in the equation.
The identifier _T should be placed at the start as a means of identifying text terms.
Formatting of variable values is also possible. The identifier _F should be placed at the start
of the formatting regulation, followed by the format instruction.
The address is then specified for the variable.

Example

<LET name="buffer" type="string"></LET>

…
…
<op> buffer = _T"unformatted value R0= " + "nck/Channel/Parameter/R[0]" + _T" and "
+ _T"$$85051" + _T" formatted value R1 " + _F%9.3f"nck/Channel/Parameter/R[1]" </op>

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9.7.15 OPTION_MD

Description
The identifier allows option machine data to be redefined. As delivered, the system uses
MD14510 $MN_USER_DATA_INT[0] to $MN_USER_DATA_INT[3].
If the PLC user program manages the options, the appropriate data words must be provided
in a data block or GUD.
The data is structured in bits. Starting with bit 0, there is a fixed assignment of the bits to the
listed devices, i.e. bit 0 is assigned to device 1, bit 1 to device 2, etc. If more than 16 devices
are managed, the address identifiers of the device groups 1-3 are assigned via the area
index.

Note
Converting the value range
The value range of MD14510 $MN_USER_DATA_INT[i] is from -32768 to +32767. To
activate the devices bit-by-bit via the machine data dialog, the bit combination must be
converted to decimal representation.

Programming

Identifier: OPTION_MD
Syntax: Area 0:
<option_md name = "Address identifier of the data" />
OR:
<option_md name = "Address identifier of the data" index= "0"/>
Area 1 to 3:
<option_md name = "Address identifier of the data" index= "Area index"/>
Attributes: name Identifier for the address, e.g.
$MN_USER_DATA_INT[0]
index Identifier for the area index:
0 (default setting): Device 1 to 16
1: Device 17 to 32
2: Device 33 to 48
3: Device 49 to 64

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9.7.16 PASSWORD

Description
If this identifier is assigned to a device, a softkey appears when the option is not set
requesting the input of a password for this device. The character string is processed by the
PLC and the result forwarded to the HMI via the option data.

Programming

Identifier: PASSWORD
Syntax: <password refvar = "variable name" />
Attributes: refvar Name of the reference variable

Example:
<password refvar="plc/db9900.dbd0" />

9.7.17 PLC_INTERFACE

Description
This identifier permits the PLC ↔ HMI interface to be redefined. The system expects 128
addressable words.
Default: DB9905

Programming

Identifier: PLC_INTERFACE
Syntax: <plc_interface name = "Address identifier of the data" />
Attributes: name Identifier for the address, e.g. "plc/mb170"

Example: plc/mb170

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9.7.18 POWER_OFF

Description
Identifier for a message prompting the operator to switch the machine off. The message text
is permanently saved in the system.

Programming

Identifier: POWER_OFF
Syntax: <power_off />
Attributes: --

9.7.19 PRINT

Description
The identifier outputs a text in the message line or copies the text to the specified variable. If
the text contains formatting identifiers, the variable values are inserted at the appropriate
place.
● The specified "%n" results in a line break in the displayed text.
● The character '%' results in the formatting of the variable specified as the value:
%[Flags] [Width] [.decimal places] type

Parameter Application
Flags Optional character to define the formatting for the task:
 Right or left-justified (- left-justified)
 Add leading zeros (0)
 Fill with blanks
Width The argument defines the minimum output width for a non-negative number. If
the value to be output has fewer places than the argument defined, the
missing spaces are filled with blanks.
Decimal places:
With floating-point numbers, the optional parameter defines the number of
decimal places.

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Parameter Application
Type The type character defines which data formats are transferred for the PRINT
instruction. This character must be specified.
The following data formats are supported:
 d: Integer value
 f: Floating-point number
 s: String
Values Number of variables whose values are to be inserted into the text. The variable
types must match the corresponding type identifier for the formatting
instruction.

Programming

Identifier: PRINT
Syntax: <print name = "Variable name" text="text %formatting"> Variable, …
</print>
Attributes: name Name of the variable where the text is to be stored.
text Text

9.7.20 WAITING

Description
After a reset of the NC or the drive, there is a wait for the restart of the respective
component.

Programming

Identifier: WAITING
Syntax: <WAITING WAITINGFORNC ="TRUE" />
Attributes: waitingfornc="true" There is a wait for the restart of the NC.
waitingfordrive="true" There is a wait for the restart of the drive.

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9.7.21 ?up

Description
SinuCom Installer:
This section contains the script language for the SinuCom Installer. If the code from a
SinuCom Installer file is to be included, the INCLUDE (Page 265) statement must be used.

Programming

Identifier: ?up
Syntax: <?up
<?include src="Filename" ?>
?>
Attributes: --

9.7.22 XML identifiers for the dialog

Dialog for the parameterization

A dialog can be configured for each device so that additional parameters can be set or
output during runtime. This is displayed by pressing the "Additional parameters" softkey.
The following dialog elements are available:
● Input dialog
● Dialog title
● Combined input/output field
● Text display
● Image display

Description

Identifier <tag> Meaning

CAPTION Identifier for the title of the dialog:
Syntax: <caption> title </caption>
CLOSE Dialog message:
This identifier is executed before the dialog is closed.

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Identifier <tag> Meaning

FORM Identifier for a user dialog.
Attribute color: Color coding of the background color
INIT Dialog message:
Identifier for initializing the dialog.
The identifier is executed immediately after the dialog is created. All the input
elements and hotlinks for the dialog should be created here.
PAINT Dialog message:
Identifier for displaying all texts and images of a dialog.
This identifier is executed when the dialog is shown.
TIMER Dialog message:
This identifier is called cyclically

Example

<?xml version="1.0" encoding="utf-8"?>

<!DOCTYPE AGM>
<AGM>
<DEVICE>
<NAME> Device 1 </NAME>
<START_UP>
…
</START_UP>
<SET_ACTIVE>
…
</SET_ACTIVE>
…
<FORM> Identifier for a user dialog
<INIT>
<CONTROL name = edit1 /CONTROL> Identifier for an input field
</INIT>
<PAINT> Identifier for text or image display
<TEXT>hello world !</TEXT>
</PAINT>
</FORM>

</DEVICE>
…
</AGM>

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9.7.23 BOX

Description
Identifier for drawing a filled rectangle at the specified position, colored as specified.

Programming

Identifier: BOX
Syntax: <box xpos="X position" ypos = "Y position" width="X extension" height="Y
extension" color="Color code" />
Attributes: xpos Position in the X direction (zero point in the left upper corner)
ypos Position in the Y direction (zero point in the left upper corner)
width Extension in X direction (in pixels)
height Extension in Y direction (in pixels)
color Color

9.7.24 CONTROL

Description
Identifier for creating control elements.
Default: fieldtype="edit" The data can be edited.

Programming

Identifier: CONTROL
Syntax: <control name = "edit1" xpos = "X position" ypos = "Y position" refvar="NC
variable" hotlink="true" format="Format" display_format="FLOAT" />
Attributes: name Name of the field: A local variable of the same
name is created for each field.
xpos Position in the X direction (zero point in the left
upper corner)
ypos Position in the Y direction (zero point in the left
upper corner)
fieldtype Field type:
 fieldtype="edit"  The data can be edited.
 fieldtype="readonly"  The data can be read.
 fieldtype="combobox"  Identifiers are shown instead of the data.

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format The attribute defines the display format of the

specified variables, e.g. left-justified or the
number of decimal places.
display_format The attribute defines the processing format of the
specified variables. When accessing a PLC float
variable, this attribute must be used, as the
access is realized by reading a double word.
The following data formats are permissible:
 FLOAT
 INT
 DOUBLE
 STRING
hotlink Identifier for a field that is updated (=TRUE)
immediately when the data is changed.
refvar Identifier for a reference variable (NC, PLC or
drive variable)

Note
Cyclic update
The "hotlink" attribute results in a cyclic update of the corresponding control.
This means that If a value is entered, the following update cycle overwrites the entered
value.
To avoid this behavior, the immediate saving of the entries must be activated with the
DATA_ACCESS identifier.

Example
If "combo box" is selected as the field type, the expressions to be displayed must also be
defined. The <item> identifier should be used for this:
The combo box saves the index of the currently selected text in the variable belonging to the
"CONTROL" (variable name). The index starts with 1.

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Syntax: <item>expression</item>

<control name = "button1" xpos = "10" ypos = "10" fieldtype="combo box">

<item>text1</item>
<item>text2</item>
<item>text3</item>
<item>text4</item>
</control>

; If an arbitrary integer value is to be assigned to an expression, the

attribute value="value" should be added to the item identifier.
; Rather than consecutive numbers, the control variable now contains the
item's assigned value.

<control name = "button1" xpos = "10" ypos = "10" fieldtype="combo box">

<item value = "10" >text1</item>
<item value = "20" >text2</item>
<item value = "12" >text3</item>
<item value = "1" >text4</item>
</control>

9.7.25 IMG

Description
Identifier for displaying a pixel graphic in the directory: ../oem/sinumerik/hmi/dvm
● The bitmaps must be stored in BMP or PNG format.
● Lower-case letters should be used for all file names.
● If the image display is to differ from the original in terms of size, the attributes width and
height can be used to define the dimensions.

Programming

Identifier: IMG
Syntax: <img name = "<Name>" xpos = "X position" ypos = "Y position" height =
"Scaling in Y" width = "Scaling in X" />

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Attributes: name Extension in Y direction (in pixels)

xpos Position in the X direction (zero point in the left upper corner)
ypos Position in the Y direction (zero point in the left upper corner)
width Scaling in X (optional)
height Scaling in Y (optional)

9.7.26 PROPERTY

Description
The identifier specifies additional properties of an operator control.

Programming

Identifier: PROPERTY
Syntax: <property attribute="<Value>" />
Attributes: max Maximum input value
min Minimum input value
default Default

Example

<control name = "edit" xpos = "10" ypos = "10" width = "100" hotlink="true"
refvar="nck/Channel/GeometricAxis/actProgPos[1]" >
<property min="0" />
<property max="1000" />
</control>

<control name = "edit1" xpos = "10" ypos = "10" >

<property min = "20" />
<property max = "40" />
<property default="25" />
</control>

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9.7.27 REQUEST

Description
This identifier is only valid within the INIT statement of a form. This identifier is used to add a
variable to the cyclic reading service (hotlink).

Programming

Identifier: REQUEST
Syntax: <REQUEST name = "NC variable" />
Attributes: name Address identifier

9.7.28 SOFTKEY_OK, SOFTKEY_CANCEL

Description
The identifier SOFTKEY_OK overwrites the standard behavior when closing a dialog by
means of the "OK" softkey. The identifier SOFTKEY_CANCEL overwrites the standard
behavior when closing a dialog by means of the "CANCEL" softkey.
The following functions can be performed within this identifier:
● Data manipulation
● Conditional processing
● Loop processing

Programming

Identifier: SOFTKEY_OK
Syntax: <SOFTKEY_OK>
…
</SOFTKEY_OK>
Identifier: SOFTKEY_CANCEL
Syntax: <SOFTKEY_CANCEL>
…
</SOFTKEY_CANCEL>

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9.7.29 TEXT

Description
Identifier for displaying text

Programming

Identifier: TEXT
Syntax: <text xpos="X position" ypos = "Y position" color="Color code"> Text
</text>
Attributes: xpos Position in the X direction (zero point in the left upper corner)
ypos Position in the Y direction (zero point in the left upper corner)
color Color

9.7.30 TYPE_CAST

Description
Identifier to convert the data type of a local variable.

Programming

Identifier: TYPE_CAST
Syntax: <type_cast name="variable name" type=" new type" />
Attributes: name Name of variable
type New data type
convert Interprets the bit combination (indirect assignment)

Example

<let name="v1" type="string" >1234.566</let>

<let name="result" type="double" />
…
<type_cast name="v1" type="double" />
<op> result = v1 *23.5 </op>
…

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Special case:
If a PLC double word is to be processed as a floating-point number, an assignment to a local
variable is necessary. So that the binary value can be saved correctly, the format of the local
variables must be of the INTEGER type.
It is then converted to a floating-point number with the TYPE_CAST operation. In order to be
able to interpret the integer value as a floating-point number, use the convert attribute
instead of the type attribute. It interprets the bit combination of the integer value as a float
value and changes the format specification of the variables to float.

<let name="plc_float" />

<let name="result" type="float" />
…
…
<timer>

<type_cast name="plc_float" type="int" />

<op> plc_float = "PLC/MD100"</op>
<type_cast name="plc_float" convert="float" />

<op> result = plc_float *1.2 </op>

</timer>

9.7.31 UPDATE_CONTROLS

Description
This identifier performs a comparison between the operator controls and the reference
variables.

Programming

Identifier: UPDATE_CONTROLS
Syntax: <update_controls type="<Direction>"/>
Attributes: type The attribute defines the direction of the data
comparison.
 TRUE The data is read from the reference variables
and copied to the operator controls.
 FALSE The data is copied from the operator
controls to the reference variables.

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9.7.32 Addressing the parameters

Addressing parameters
Address identifiers for the desired data must be created to address NC variables, PLC
blocks or drive data. An address consists of the subpaths component name and variable
address. A slash should be used as a separating character.
Addressing PLC data blocks

Data format f: B: Byte

W: Word
D: Double word
x address: Valid PLC address identifier
Bit addressing: b = Bit number

The following addresses are permissible:

DBx.DB(f) Data block

I(f)x
Input
Q(f)x
Output
M(f)x
Bit memory
V(f)x
Variable

Data format identification is not applicable for bit addressing:

DBx.DBXx.b Data block

Ix.b
Input
Qx.b
Output
Mx.b
Bit memory
Vx.b
Variable

Example:
<data name = "plc/mb170">1</data>

<data name = "plc/db9905.dbb0"> 0 </data>

<data name = "plc/i0.1"> 1 </data>

<op> plc/m19.2 = 1 </op>

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Addressing NC variables
Addressing starts with the path section nck. This section is followed by the data address; its
structure should be taken from the OEM Package Parameter Manual 2.
Example:
<let name = "tempStatus"></let>

<op> tempStatus = "nck/channel/state/chanstatus" </op>

Addressing the machine data and setting data

Machine data and setting data is identified by the character $, followed by the name of the
data.
● Machine data:
$Mx_<name[index, AX<axis_number>]>
● HMI machine data:
$MxS_<name[index, AX<axis_number>]>
● Option data:
$Ox_<name[index, AX<axis_number>]>
● Setting data:
$Sx_<name[index, AX<axis_number>]>
$SxS_<name[index, AX<axis_number>]>

Structure Meaning
x: N General machine or setting data
C Channel-specific machine or setting data
A Axis-specific machine or setting data
index: For a field, the parameter indicates the index of the data.
AX<axis_number>: The required axis (<axis_number>) has to be specified for axis-
specific data.
Alternatively, the axis index can be read from a local variable
using a "substitution character" $<variable name>: e.g.
AX$localvariable

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Example:
<data name ="$MN_AXCONF_MACHAX_NAME_TAB[0] ">X1</data>

● Direct addressing of the axis:

<data name ="$MA_CTRLOUT_MODULE_NR[0, AX1] ">1</data>

● Indirect addressing of the axis:

<let name ="axisIndex"> 1 </let>

<data name ="$MA_CTRLOUT_MODULE_NR[0, AX$axisIndex] ">1</data>

Addressing the global user data

Addressing starts with the path section gud, followed by the specification of the area
CHANNEL. This address section is followed by the specification of the GUD areas:

GUD areas Assignment

sgud Siemens GUD
mgud Machine manufacturer GUD
ugud User GUD

Then enter the GUD name. If an array is to be addressed, the name is followed by the array
subscript in square brackets.
Example:
<data name ="gud/channel/mgud/syg_rm[0]">1</data>

<op>"gud/channel/mgud/syg_rm[0]" = 5*2 </op>

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9.7.33 Addressing the drive objects

Syntax for Drive Objects (DO)

Addressing starts with the path section "drive". Then the drive device is specified: CU or DC.
The parameter to be set is added to this section.
To address individual objects, the desired object should be entered in square brackets after
the parameter.
Parameter number[do<DO-index>]

Example:p0092[do1]

Note
Numbering
The number of the drive object differs from the numbering used in the drive dialog, since the
CU components, ALM and all connected hubs are integrated in the consecutive numbering.

The DO number can be determined as follows:

All connected drive objects are listed in field p0978 of the relevant CU. The numerical value
of a field corresponds to the slot number of a drive object. It is a question of establishing the
field index for the desired slot and adding one to this number. This value is the DO index
needed for addressing purposes.
If there are drive objects connected to an NX, the index of the last CU drive object should be
established first and the index of the NX drive object should be added to it.
Alternatively, the drive index can be read from a local variable, e.g. DO$localvariable, using
a "substitution character" $<variable name>.
Example:
<data name ="drive/cu/p0092">1</data>

<data name ="drive/dc/p0092[do1] ">1</data>

Indirect addressing:
<let name = "driveIndex> 0 </let>

<op> driveIndex = $ctrlout_module_nr[0, AX1] </op>

<data name ="drive/dc[do$driveIndex]/p0092">1</data>

Addressing an NX
An NX module is treated as another CU, module addressing uses the CU specification,
whereby the desired NX number incremented by one is specified in square brackets after the
parameter.
Parameter number[CU<CU index>]

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Example

<let name="r0002_content"></let>
<let name="p107_content"></let>
<!- Reading of value r0002 from the CU ->
<op> r0002_content = "drive/cu/r0002" </op>
<op> r0002_content = "drive/cu/r0002[CU1]" </op>
<!- Reading of value r0002 from the NX1 ->
<op> r0002_content = "drive/cu/r0002[CU2]" </op>
<!- Reading of value p107[0] from the CU ->
<op> p107_content = "drive/cu/p107[0]" </op>
<print text="%d"> p107_content </print>
<!- Reading of value p107[0] from the NX1 ->
<op> p107_content = "drive/cu/p107[0,CU2]" </op>
<print text="%d"> p107_content </print>

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9.7.34 XML identifiers for statements

Program statements
The following identifiers are permissible for statements:

Identifier <tag> Meaning

IF Conditional statement (IF, THEN, ELSE)
The THEN and ELSE tags are included in the IF tag.
The condition which is stated in the CONDITION tag follows the IF tag. The
further processing of the statements depends upon the result of the
operation. If the result of the function is true, the THEN branch is executed
and the ELSE branch is skipped. If the result of the function is false, the
parser executes the ELSE branch.
Example:
<IF>
<CONDITION> plc/mb170 != 7 </CONDITION>
<THEN>
<OP> plc/mb170 = 7 </OP>
…
</TEHN>
<ELSE>
…
…
</ELSE>

</IF>
THEN Statement for situations where the condition has been met (IF, THEN,
ELSE).
ELSE Statement for situations where the condition has not been met (IF, THEN,
ELSE).

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Identifier <tag> Meaning

FOR The FOR loop is executed as follows:
1. The expression initialization (INIT) is analyzed.
2. The expression test (CONDITION) is analyzed as a Boolean expression.
If the value is false (FALSE) the FOR loop is ended.
3. The following statements are executed.
4. The expression continuation (INCREMENT) is analyzed.
5. Proceed with Step 2.

for (initialization, test, continuation) statements

Syntax:
<FOR>
<INIT>…</INIT>
<CONDITION>…</CONDITION>
<INCREMENT>…</INCREMENT>
Statements
…
</FOR>
BREAK Conditional cancellation of a loop
WHILE The WHILE loop is used to execute a sequence of statements repeatedly
while a condition is met. This condition is tested before the sequence of
statements is executed.

while (test) statements

Syntax:
<WHILE>
<CONDITION>…</CONDITION>
Statements
…
</WHILE>

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Identifier <tag> Meaning

DO_WHILE The DO WHILE loop comprises a block of statements and a condition. The
code within the statement block is executed first, then the condition is
analyzed. If the condition is true, the function executes the code section
again. This is continuously repeated until the condition is false.

do
Statements
while (test)
Syntax:
<DO_WHILE>
Statements
…
<CONDITION>…</CONDITION>
</DO_WHILE>
SWITCH The SWITCH statement describes a multiple choice. A term is evaluated
once and compared with a number of constants. If the term matches the
constants, the statements are processed within the CASE statement.
The DEFAULT statement is processed when none of the constants listed
match the expression.
Syntax:
<SWITCH>
<condition> Expression </condition>
<CASE value="<constant 1>" >
Statements ...
</CASE>
<CASE value="<constant 2>" >
Statements ...
</CASE>
<DEFAULT>
Statements ...
</DEFAULT>

</SWITCH>

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9.8 String functions

9.8 String functions

Overview of the functions

The script language offers various string functions. The function names are reserved and
cannot be overloaded.

Name Function
string.cmp Comparing character strings (string.cmp (Page 290))
string.icmp Comparing character strings without consideration of upper/lower case
(string.icmp (Page 291))
string.left Selecting number of characters from the left (string.left (Page 292))
string.right Selecting number of characters from the right (string.right (Page 293))
string.middle Selecting number of characters from the middle (string.middle
(Page 293))
string.length Determining the length of a character string (string.length (Page 294))
string.replace Replacing character strings (string.replace (Page 295))
string.remove Deleting character strings (string.remove (Page 295))
string.insert Inserting a character string from index (string.insert (Page 297))
string.delete Deleting a number of characters in a character string (string.delete
(Page 296))
string.find Finding a subset of a character string (forwards) (string.find
(Page 298))
string.reversefind Finding a subset of a character string (backwards) (string.reversefind
(Page 298))
string.trimleft Removing blanks from the left (string.trimleft (Page 300))
string.trimright Removing blanks from the right (string.trimright (Page 301))

9.8.1 string.cmp

Description
Two strings are compared with each other.
The function gives a return value of zero if the strings are the same, a value less than zero if
the first string is smaller than the second string or a value greater than zero if the second
string is smaller then the first string.

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Programming

Designation: string.cmp
Syntax: <function name="string.cmp" retvar ="<int var>" > str1, str2 </function>
Parameters: str1 String
str2 Comparison string
rval Result

Example

<let name="rval">0</let>
<let name="str1" type="string">A brown bear hunts a brown dog.</let>
<let name="str2" type="string">A brown bear hunts a brown dog.</let>
<function name="string.cmp" return="rval"> str1, str2 </function>

;Result: rval=0

9.8.2 string.icmp

Description
Two strings are compared (the comparison is not case-sensitive).
The function gives a return value of zero if the strings are the same, a value less than zero if
the first string is smaller than the second string or a value greater than zero if the second
string is smaller then the first string.

Programming

Designation: string.icmp
Syntax: <function name="string.icmp" retvar ="<int var>" > str1, str2 </function>
Parameters: str1 String
str2 Comparison string
rval Result

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Example

<let name="rval">0</let>
<let name="str1" type="string">A brown bear hunts a brown dog.</let>
<let name="str2" type="string">A brown Bear hunts a brown Dog.</let>
<function name="string.icmp" return="rval"> str1, str2 </function>

;Result: rval=0

9.8.3 string.left

Description
The function extracts the first nCount characters from string 1 and copies them to the return
variable.

Programming

Designation: string.left
Syntax: <function name="string.left" return="< result string>"> str1, nCount
</function>
Parameters: str1 String
nCount Number of characters

Example

<let name="str1" type="string">A brown bear hunts a brown dog.</let>

<let name="str2" type="string"></let>
<function name="string.left" return="str2"> str1, 12 </function>

;Result: str2="A brown bear"

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9.8.4 string.right

Description
The function extracts the last nCount characters from string 1 and copies them to the return
variable.

Programming

Designation: string.right
Syntax: <function name="string.right" return="< result string>"> str1, nCount
</function>
Parameters: str1 String
nCount Number of characters

Example

<let name="str1" type="string">A brown bear hunts a brown dog.</let>

<let name="str2" type="string"></let>
<function name="string.right" return="str2"> str1, 10 </function>

;Result: str2="brown dog"

9.8.5 string.middle

Description
The function extracts the specified number of characters from string 1, starting from the iFirst
index, and copies them to the return variable.

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Programming

Designation: string.middle
Syntax: <function name="string.middle" return="< result string>"> str1, iFirst,
nCount </function>
Parameters: str1 String
iFirst Start index
nCount Number of characters
Example

<let name="str1" type="string">A brown bear hunts a brown dog.</let>

<let name="str2" type="string"></let>
<function name="string.middle " return="str2"> str1, 2, 5 </function>

;Result: str2="brown"

9.8.6 string.length

Description
The function gives the number of characters in a string.

Programming

Designation: string.length
Syntax: <function name="string.length" return="< int var>"> str1 </function>
Parameters: str1 String
length Result
Example

<let name="length">0</let>
<let name="str1" type="string">A brown bear hunts a brown dog.</let>
<function name="string.length" return="length"> str1 </function>

; Result: length=31

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9.8.7 string.replace

Description
The function replaces all the substrings found with the new string.

Programming

Designation: string.replace
Syntax: <function name="string.replace"> string, find string, new string </function>
Parameters: string String
find string String to be replaced
new string New string

Example

<let name="str1" type="string">A brown bear hunts a brown dog. </let>

<function name="string.replace" > str1, _T"a brown dog",
_T"a big salmon"</function>

; Result: str1="A brown bear hunts a big salmon."

9.8.8 string.remove

Description
The function deletes all the substrings found.

Programming

Designation: string.remove
Syntax: <function name="string.remove" > string, remove string </function>
Parameters: string String
remove string Substring to be deleted

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Example

<let name="index">0</let>
<let name="str1" type="string">A brown bear hunts a brown dog. </let>
<function name="string.remove" > str1, _T"a brown dog" </function>

; Result: str1="A brown bear hunts ."

9.8.9 string.delete

Description
The function deletes the defined number of characters starting from the start position
specified.

Programming

Designation: string.delete
Syntax: function name="string.delete"> string, start index, nCount </function>
Parameters: string String
start index Start index
nCount Number of characters

Example

<let name="str1" type="string">A brown bear hunts. </let>

<function name="string.delete" > str1, 2, 5 </function>

;Result: str1="A bear hunts."

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9.8.10 string.insert

Description
The function inserts a string at the index specified.

Programming

Designation: string.insert
Syntax: <function name="string.insert"> string, index, insert string </function>
Parameters: string String variable
index Number of characters to be inserted
insert string String to be inserted

Example

<let name="str1" type="string">A brown bear hunts. </let>

<let name="str2" type="string">a brown dog </let>
<function name="string.insert"> str1, 19, str2 </function>

;Result: str1="A brown bear hunts a brown dog."

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9.8 String functions

9.8.11 string.find

Description
The function searches the transferred string for the first match with the substring. If the
substring is found, the function provides the index to the first character (starting with zero),
otherwise -1.

Programming

Designation: string.find
Syntax: <function name="string.find" return="<int val>"> str1, find string </function>
Parameters: string String variable
find string String to be found

Example

<let name="index">0</let>
<let name="str1" type="string">A brown bear hunts a brown dog. </let>
<function name="string.find" return="index"> str1, _T"brown" </function>

; Result: index=2

9.8.12 string.reversefind

Description
The function searches the transferred string for the last match with the substring. If the
substring is found, the function provides the index to the first character (starting with zero),
otherwise -1.

Programming

Designation: string.reversefind
Syntax: <function name="string.reversefind" return="<int val>"> str1, find string
</function>
Parameters: string String variable
find string String to be found

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Example

<let name="index">0</let>
<let name="str1" type="string">A brown bear hunts a brown dog. </let>
<function name="string.reversefind" return="index"> str1, _T"brown" </function>

; Result: index=21

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9.8 String functions

9.8.13 string.trimleft

Description
The function trims the starting characters from a string.

Programming

Designation: string.trimleft
Syntax: <function name="string.trimleft" > str1 </function>
Parameters: str1 String variable

Example

<let name="str1" type="string"> test trim left</let>

<function name="string.trimleft"> str1 </function>

;Result: str1="test trim left"

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9.8.14 string.trimright

Description
The function trims the closing characters from a string.

Programming

Designation: string.trimright
Syntax: <function name="string.trimright" > str1 </function>
Parameters: str1 String variable

Example

<let name="str1" type="string"> test trim right </let>

<function name="string.trimright" > str1 </function>

;Result: str1=" test trim right"

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9.9 Trigonometric functions

9.9 Trigonometric functions

Overview of the functions

The script language offers various trigonometric functions. The function names are reserved
and cannot be overloaded.
Trigonometric functions and inverse functions:

Name Function
sin Sine
cos Cosine
tan Tangent
arcsin Arc sine
arccos Arc cosine
arctan Arc tangent

Sine, cosine, tangent description

The function calculates the sine, cosine, tangent of the value transferred.

Programming

Designation: sin
Syntax: <function name="sin" return="<double val>"> double </function >
Designation: cos
Syntax: <function name="cos" return="<double val>"> double </function >
Designation: tan
Syntax: <function name="tan" return="<double val>"> double </function >
Parameters: double Angle (0° to 360°)

Example

<let name= "sin_val" type="double"></let>

<function name="sin" return="sin_val"> 20.0 </function>

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Arc sine, arc cosine, arc tangent description

The function calculates the arc sine, arc cosine, arc tangent of the value transferred.

Programming of arcsin, arccos

Designation: arcsin
Syntax: <function name="arcsin" return="<double val>"> double </function >
Designation: arccos
Syntax: <function name="arccos" return="<double val>"> double </function >
Parameters: double x in the range from -1 to +1
Value range: arcsin y in the range from -π/2 to +π/2
arccos y in the range from 0 to π

Programming of arctan

Designation: arctan
Syntax: <function name="arctan" return="<double val>"> double </function >
Parameters: double x arbitrary value
Value range: y in the range from -π/2 to +π/2

Example

<let name= "arccos_val" type="double"></let>

<function name="arccos" return="arctan_val"> 0.47 </function>

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10.1 Fundamentals

Tool management (TM)

The tool management (TM) function ensures that the right tool is in the right place on the
machine at all times.
Machines, magazines, loading positions and tool buffers (e.g. spindles, grippers) form a
specific system in which the tools are stored and transported. The tool management
continually informs the NCK of the current location of the tools and logs it using NC part
programs, PLC or HMI initiated tool movements.
During tool management commissioning the specific machine system architecture is mapped
in the control. For example, one or more magazines are set up that are able to pick up tools
at their locations. The "workplace" of a tool is described in the control in the form of value
pairs (magazine number and location number).

Note
Scope of delivery
Tool management is included in the scope of delivery for all controls (M/T version).
The function "Spare tools for tool management" (duplo tools) is an option.

See also
Additional references:
● SINUMERIK 828D Parameter Manual
● A comprehensive description of the tool and magazine parameters and the internal data
structure is to be found in:
→ Description of Functions Tool Management of the SINUMERIK 840D sl
As far as the range of functions is concerned, the NCK part of this documentation is also
valid for the SINUMERIK 828D.
The description of the PLC functions and the communication between NC and PLC in this
documentation is not valid for the SINUMERIK 828D.
● The settings of the tool management user interface are described in:
→ Commissioning Manual Base Software and Operating Software (IM9)

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10.1.1 Structure of the tool management

Function structure
The software components of the control have the following tasks in the tool management:
● HMI:
– Tool data display, input/output
– Magazine data display, input/output
– Load/Unload relocation dialog
● NCK:
The tool management administrates the magazine locations. These locations might be
empty, loaded with tools or assigned to oversized tools in adjacent locations. Empty
locations can be loaded with other tools. The tool management provides the machine
manufacturer with optimized management of tools and magazine locations. Magazine
management provides extended functions such as load, unload or position tools. It also
includes searches for tools, magazine locations and search strategies for replacement
tools.
For the tool monitoring functions, while the active monitoring is running, tools are disabled
and no longer used. To continue machining, an equivalent tool (duplo tool) that is not
disabled is used, if available.
● PLC:
– Execute tool change
– Move tools in the magazine
– Gripper control
– Magazine control if applicable
– Safety interlocks
– Providing the structure of tool movements in transfer step tables
– Acknowledgment of the tool movements with acknowledgment step tables

PLC user program

The PLC user program executes the tool management jobs and acknowledges all position
changes of the tools (and magazines). The monitoring and prevention of collisions is the task
of the PLC user program alone, for example:
● Multiple spindles are using the same magazine.
● The paths of simultaneous jobs cross.
● As long as a large tool is located in the shifter, the chain must not be moved.

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PLC firmware
Functions of the PLC firmware:
● Assignment of tool management jobs to the PLC user program
● Communication of PLC user program acknowledgments to the tool management
● Transfer feedback signals for each acknowledgment (acknowledgment incorrect with
error number of acknowledgment OK) to PLC user program.
● In addition: Register order status

10.1.2 Components of the tool management

Tool list, magazines, magazine list

Circular and chain magazines can be managed. Other types of magazines are mapped on
these. Loading points or loading stations shall be used as the magazine type for loading and
unloading.
A magazine buffer combines all other locations in which tools can be placed (spindle,
gripper, ...).

Note
Default settings for tool magazines
The number of magazines, which the NCK can manage, is permanently set by the system:
 PPU24x.2: Number of magazines = 3
 PPU26x.2: Number of magazines = 3
 PPU28x.2: Number of magazines = 4
Since at least one buffer and one loading point must be available, the PPU24x.2/PPU26x.2
can manage one real magazine and the PPU28x.2 can manage two real magazines.
When the control powers up, depending on the technology, the following tool magazines are
pre-selected and created:
 Milling: one chain magazine with 20 locations, double gripper and a tool carrier
 Turning: one revolver with 8 locations, a tool carrier

Magazines
Information is provided by the system for all locations in the magazine, describing the
content and status of the locations.
The position of a tool is described by an identifier for the magazine and an identifier for the
location. Magazines have an identifier and a number, magazine locations only a number. In
a real magazine (chain, turret, etc.), the position of the tool is identified by the magazine
number assigned during start-up and the location within the magazine.
Example:
The T number of the tool in magazine location 7 in magazine 1: $TC_MPP6[1,7]

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Tool list
The tool list contains all the tools known to the NC. These are the tools in the magazine and
unloaded tools whose data is to be retained. The tool management works with loaded tools
from the tool list.

Magazine list
The magazine list is a location-oriented map of the tool magazine, gripper and spindle. The
tool management only works with the tools from the magazine list. Additional tools without a
magazine assignment can also be selected for tool changes. The tool must be inserted in the
machine manually and removed again manually after machining (manual tool).

Loading magazine
The loading magazine is the 1st internal magazine and is assigned magazine number 9999.
The loading magazine has loading points for loading and unloading tools.
For the allocation of locations, one is fixed, all other locations can be assigned freely.
Location 1 in the loading magazine is used for the fixed assignment. Location 1 is reserved
for loading/unloading to all spindles/tool holders.
All positioning and relocation jobs to any locations (not loading points) are still handled via
location 1. The stated jobs, which refer to a particular loading point, are output at the
interface of this loading point. The loading points are assigned to magazines during start-up
($TC_MDP1). A loading point is an open access point to the magazine, where a tool is
manually loaded and unloaded from the magazine.

Buffer
Buffers are located in the 2nd internal magazine. The buffer includes the spindle, tool holder,
gripper, loader and transfer location. The buffers are managed under magazine number
9998. Each buffer element is assigned a unique location. Any location numbers may be
assigned. It is recommended that all spindles or tool holders be numbered in ascending
order, starting at number 1. The assignment to real magazines or of spindles/tool holders to
other buffers is made during start-up ($TC_MDP2, $TC_MLSR).

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Chain magazine
The setting in MD22550: $MC_TOOL_CHANGE_MODE may only have the value 1 for these
magazine types.
Chain magazines do not as a rule have any additional buffer available for transportation
between magazine and spindle. These additional buffers can contain tools temporarily.
Description of the buffers and loading points:

Magazine Location Meaning

1 xx Real magazine 1 (chain, plate, box), position xx
9998 1 Spindle
9998 2 Gripper
9998 3 Gripper
9998 4 Toolboy
9998 5 Shifter
9999 1 Loading point for spindle, manual tool
9999 2 Magazine loading point

Circular magazine
The setting of MD22550: $MC_TOOL_CHANGE_MODE normally has the value 0.
Circular magazines do not have any additional buffer with which tools can be transported
from the magazine to the spindle. The tools on circular magazines are not physically
transported into the spindle, but are moved into a defined position through rotation of the
turret so that machining can take place with one particular tool. The tool is only transported
to the spindle or tool holder in the software. Transporting the tool to the buffer 9998/1
(spindle) serves to inform the tool management that the turret holding the requested tool has
been turned to the machining position.
The programming command T = identifier initiates the tool change. T = location can be
programmed as an alternative. If T = location, no tool need actually be stored in the location.
Description of the buffers and loading points:

Magazine Location Meaning

1 xx Real magazine 1 (circular), position xx
9998 1 Tool holder
9999 1 Loading point for tool holder, manual tool

If the value 1 is also set for the revolver in MD22550: $MC_TOOL_CHANGE_MODE, the
statement made for the chain magazines also applies here.

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Consider adjacent location

Consider adjacent location is used for oversized tools. When searching for empty locations
(loading, tool change) the bits 4 ... 11 are then evaluated in the magazine location parameter
$TC_MPP4 (half location occupied/reserved).

See also
You can find additional information in the "Machine data for the tool management
(Page 328)" section.

10.1.3 Loading and unloading tools manually

Manual tools
Bit 1 of MD22562: $MC_TOOL_CHANGE_ERROR_MODE decides whether additional tools
without magazine allocation can be selected during tool change. The automatically selected
tool must be inserted in the machine manually and removed again manually after machining.

Responsibility of the operator

The operator must ensure that the data block for the tool on the spindle is in the NCK, or that
he/she puts the appropriate tool onto the spindle for the data block stored in the NCK. Tools
which are loaded manually during machining are referred to as "manual tools".

Note
The responsibility is on the user to comply with the safety regulations via the PLC program.
An alarm (17212, 17214 or 17216) is always output to indicate that a tool change involving a
manual tool has been executed. The alarm is reset by the tool change acknowledgment of
the PLC user program.

The following types of tools are manual tools:

● Oversized tools
● Tools that cannot be stored in the magazine.
● Tools that may not be handled by the gripper system.

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10.2 NC - PLC user interface

Overview
The tool management receives tasks for preparing and carrying out a tool change
(T command, M06), a tool movement (MVTOOL) or magazine positioning (POSM) from the
part program or from the HMI. From these tasks the TM defines the location change needed
for the tool and assigns this to the PLC.
Program components and interfaces:

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Figure 10-1 Interfaces of the tool management

The user interface provides separate data blocks for loading, unloading, relocating and
magazine positioning on the one hand and tool change on the other hand.

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10.2.1 Relocating, unloading, loading tool, positioning magazine

Tool and magazine movements

Per loading point there is one interface for:
● Jobs for loading, unloading, relocating a tool (MVTOOL) and for magazine positioning
(POSM).
Message to the PLC user program:
– Job active
– Job specification
– Job description
The jobs appear on the interface of the loading point from which the tool is to be
exchanged.
● Acknowledgments of the PLC user program
All acknowledgments for a job must take place in the interface of the same loading point.
Acknowledgment errors should also be reset in this interface.
● Feedback from the tool management to the PLC user program
Message to the PLC user program:
– Status of acknowedgment
– Error status
– Map of the acknowledgment bits
● Job status
Selected data from the last intermediate or end acknowledgment is saved. This data is
needed by the PLC firmware for the next acknowledgment to the tool management and is
readable for diagnostic purposes. This data can be used by the user program to restart
after an abort (e.g. reset during a tool change).

Rule
The distribution of jobs to the interfaces takes place according to the following rule:
If the job contains a loading point (9999/x), that interface will be used.
Otherwise, the interface of the first loading point (9999/1) will be used.
All acknowledgments for a job must take place in the interface of the same loading point.

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Interface signal Meaning

xx: Load location
DB40xx.DBX0.0 – DBX 3.6 PLC user program:
Acknowledgments for loading/unloading/relocating or
positioning the magazine
DB40xx.DBX9.0 PLC user program:
Resetting the message "Acknowledgment error"
/DB41xx.DBX100.1) and the diagnostic information in the
feedback interface
DB41xx.DBX0.0 Tool management:
Job for loading/unloading/relocating or positioning the
magazine
DB41xx.DBB1 Tool management: Job specification
DB41xx.DBW 6 – DBW34 Job description
DB41xx.DBX100:0 Positive feedback: Acknowledgment status, acknowledgment
OK, 1 PLC cycle pending
DB41xx.DBX100.1 Negative feedback: Acknowledgment status, acknowledgment
error, static pending
DB41xx.DBB104 Tool management: Feedback error status
DB41xx.DBX108.0 - Map of acknowledgments for load, unload, relocate or position
DB41xx.DBX111.6 magazine. This map belongs to the positive or negative
feedback and remains valid for the same time.
DB41xx.DBW124 – DBW130 Job status

Jobs

DB4100...41xx Signals from tool management [r]

xx: Load location
Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
DBB0 Job
DBB1 Job from NC Positioning Relocating Unloading Loading
program
DBB2 Reserved
DBB3 Reserved
DBB4 Reserved
DBB5 Reserved
DBW6 Source magazine number (INT)
DBW8 Source location number (INT)
DBW10 Target magazine number (INT)
DBW12 Target location number (INT)
DBW14: Load/unload
HMI → PLC without moving
magazine

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Signal description:
● Job:
The interface contains a job. Job processing has not yet been completed with an end
acknowledgment. This signal is reset after transmission of the end acknowledgment to
the tool management.
● Loading:
The "target location" parameter's magazine location should be loaded with a tool via the
"source location" parameter's loading station.
● Unloading:
The tool in the "source location" parameter's magazine location should be unloaded to
the "target location" parameter's unloading station.
● Relocating:
The tool in the "source location" parameter's magazine location should be relocated to
the "target location" parameter's magazine location.
● Positioning:
The "source location" parameter's magazine location should be positioned at the "target
location" parameter's change/loading/unloading station. The tool remains in its magazine
location.
● NC program positions magazine:
The positioning job comes from the part program.
● Loading/unloading without moving magazine:
The signal is set by the HMI when reading in setup data or for the "Unload all tools"
function in addition to the loading and unloading jobs. The signal can be used in the PLC
user program to interlock undesirable magazine movements (e.g. set only total
acknowledgment, no further action). The signal is reset by the system with a valid end
acknowledgment for the job to the tool management.
● Source location:
Magazine and location number of a tool that traverses or should be positioned at a
change or loading station.
● Target location:
Magazine and location number to where a tool is moving or to where a magazine location
should be positioned.

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Acknowledgments

DB4000...40xx Signals to tool management [r/w]

xx: Load location
Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
DBB0 Acknowl- Acknowl- Acknowl- Acknowl- Acknowl- Acknowl- Acknowl- Total
edgment edgment edgment edgment edgment edgment edgment acknowled
step 7 step 6 step 5 step 4 step 3 step 2 step 1 gment
DBB1 Acknowl- Acknowl- Acknowl- Acknowl- Acknowl- Acknowl- Acknowl- Acknowl-
edgment edgment edgment edgment edgment edgment edgment edgment
step 15 step 14 step 13 step 12 step 11 step 10 step 9 step 8
DBB2 Acknowl- Acknowl- Acknowl- Acknowl- Acknowl- Acknowl- Acknowl- Acknowl-
edgment edgment edgment edgment edgment edgment edgment edgment
step 23 step 22 step 21 step 20 step 19 step 18 step 17 step 16
DBB3 Reserved Acknowl- Acknowl- Acknowl- Acknowl- Acknowl- Acknowl- Acknowl-
edgment edgment edgment edgment edgment edgment edgment
step 30 step 29 step 28 step 27 step 26 step 25 step 24
DBB4 Reserved
DBB5 Reserved
DBB6 Reserved
DBB7 Reserved
DBB8 Reserved
DBB9 Resetting the
acknowl-
edgment error

Signal description:
● Total acknowledgment:
At a 0/1 edge the end acknowledgment, with status 99, is sent to the current job (job
complete, all target positions have been reached). As long as the signal is present, no
changes may be made to the data of this interface!
This signal is reset by the PLC firmware after the acknowledgment has been transferred
to the tool management.
● Acknowledgment step 1…30:
At a 0/1 edge, the appropriate acknowledgment step from the acknowledgment step table
is sent to the tool management. As long as the signal is present, no changes may be
made to the data of this interface and the variable transfer-step table!
This signal is reset by the PLC firmware after the acknowledgment has been transferred
to the tool management.
● Resetting the acknowledgment error:
Resetting the message "Acknowledgment error" /DB41xx.DBX100.1) and the diagnostic
information in the feedback interface.

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Feedback reports

DB4100...41xx Signals from tool management [r]

xx: Load location
Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
DBB100 Acknowl- Acknowl-
edgment edgment
error OK
DBB101 Reserved
DBB102 Reserved
DBB103 Reserved
DBW104 Error status (WORD)
DBB106 Reserved
DBB107 Reserved
DBB108 Acknowl- Acknowl- Acknowl- Acknowl- Acknowl- Acknowl- Acknowl- Acknowl-
edgment edgment edgment edgment edgment edgment edgment edgment
step 7 step 6 step 5 step 4 step 3 step 2 step 1 step 0
DBB109 Acknowl- Acknowl- Acknowl- Acknowl- Acknowl- Acknowl- Acknowl- Acknowl-
edgment edgment edgment edgment edgment edgment edgment edgment
step 15 step 14 step 13 step 12 step 11 step 10 step 9 step 8
DBB110 Acknowl- Acknowl- Acknowl- Acknowl- Acknowl- Acknowl- Acknowl- Acknowl-
edgment edgment edgment edgment edgment edgment edgment edgment
step 22 step 22 step 21 step 20 step 19 step 18 step 17 step 16
DBB111 Reserved Acknowl- Acknowl- Acknowl- Acknowl- Acknowl- Acknowl- Acknowl-
edgment edgment edgment edgment edgment edgment edgment
step 30 step 29 step 28 step 27 step 26 step 25 step 24

Signal description:
● Acknowledgment OK (DB41xx.DBX100.0):
The acknowledgment of the PLC user program (area DB40xx.DBB0 to DBB3) was
transferred without error to the tool management. This signal is reset after one PLC cycle.
● Acknowledgment error (DB41xx.DBX100.1):
Negative feedback of acknowledgment status. There is an error in the acknowledgment
of the PLC user program (area DB40xx.DBB0 to DBB3). The cause of the error is
displayed in "Error status."
The "acknowledgment error" bit is only set if the acknowledgment from the PLC firmware
is accepted as error free and the tool management detects and signals an error in the
acknowledged tool transfer (for example, when the target location for tool transfer is
occupied).
Errors that are detected directly by the tool management in the NC before an
acknowledgment is sent by the PLC user program, do not result in the setting of bit 100.1.
If an error is present that prevents transfer of the acknowledgment to the tool
management (error status 1 to 7), the error is only output on the interface of the tool
management and not by the NC (no NC alarm!).
If necessary, signal such errors with a user PLC alarm in the PLC user program.

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This signal remains pending statically until the error has been acknowledged (set the bit
"Reset acknowledgment error" DB40xx.DBX9.0) by the user. The interface in
DB40xx.DBB0 to DBB3 is disabled if bit "acknowledgment error" is pending. Incoming
acknowledgment bits are not evaluated by the PLC firmware and are cleared when bit
"Reset acknowledgment error" is set.
Error status:
If there is an error, the error status (DB41xx.DBB104) contains a diagnostic number unequal
to zero.

Status Meaning
0 No error
1 Multiple acknowledgment signals at the same time
2 Acknowledgment without job
3 Invalid transfer step number
4 There is no job for a position specification
5 The status does not permit a location change (acknowledgment status 0 is
used)
7 An impermissible acknowledgment status has been used
Other values: The number corresponds to the error message of the tool management in the
NCK caused by this transfer

The error status is reset by acknowledgment of the error by the user.

Map of acknowledgments (DB41xx.DBB108 to DBB111)

The acknowledgments last set by the PLC user program (DB40xx.DBB0 to DBB3) are set
and reset by the PLC firmware together with the bits "Acknowledgment OK" or
"Acknowledgment error". If there is an error, the user uses these statically pending bits to
see which acknowledgment step triggered the error. If the PLC user program incorrectly sets
multiple acknowledgment bits, these are also entered one-to-one in the map.

Job status

DB4100...41xx Signals from tool management [r]

xx: Load location
Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
DBW124 Current magazine number of the tool (INT)
DBW126 Current location number of the tool (INT)
DBW128 Target magazine number of the tool (INT)
DBW130 Target location number of the tool (INT)

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10.2.2 Tool change

Interface description
Per tool holder/spindle there is one interface for:
● Jobs for preparing and executing the tool change.
Message to the PLC user program: Job active; job specification and job description.
The jobs appear in the toolholder interface (of the spindle) where a tool is to be
exchanged.
● Acknowledgments of the PLC user program
All acknowledgments for a job must take place in the interface of the same tool holder (of
the same spindle). Acknowledgment errors should also be reset in this interface.
● Feedback from the tool management to the PLC user program
Message to the PLC user program: Acknowledgment status, error status, map of the
acknowledgment bits.
● Job status
Selected data from the last intermediate or end acknowledgment is saved. This data is
needed by the PLC firmware for the next acknowledgment to the tool management and is
readable for diagnostic purposes. This data can be used by the user program to restart
after an abort (e.g. reset during a tool change).

End acknowledgment for tool change

A common end acknowledgment (tool change via T command using turret) or separate end
acknowledgment (Txx and M206 in separate blocks, default milling) is possible for "Prepare
tool change" and "Implement tool change". With the appropriate MD setting, the end
acknowledgment for the job to prepare for a tool change permits the NCK preprocessing to
continue.
The machine data with which the response of block preprocessing, main run, and the various
acknowledgment responses are defined are described in Chapter Settings for the tool
management (Page 328).
The main NCK run can be continued with the end acknowledgment to the job "Carry out tool
change". Therefore, these end acknowledgments should take place as early as possible.
This can mean that the end acknowledgment can take place before the old tool is in the
magazine (e.g. the new tool is in the spindle, the old tool in the toolboy). The rest of the
steps to bring the old tool into the magazine must then be communicated asynchronously.
The same interface should be used as for synchronous acknowledgments.

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Interface signal Meaning

xx: Spindle index / tool holder
DB42xx.DBX0.0 – DBX 3.6 PLC user program:
Preparing and carrying out acknowledgments for tool change
DB42xx.DBX9.0 PLC user program:
Resetting the message "Acknowledgment error"
(DB43xx.DBX100.1) and the diagnostic information in the
feedback interface
DB43xx.DBX0.0 Tool management: Job for "Prepare tool change" and "Execute
tool change"
DB43xx.DBB1 Tool management job specification
DB43xx.DBW 6 – DBW34 Job description
DB43xx.DBX100.0 Positive feedback: Acknowledgment status, acknowledgment OK,
one PLC cycle pending
DB43xx.DBX100.1 Negative feedback: Acknowledgment status, acknowledgment
error, static pending
DB43xx.DBX100:0 Positive feedback: Acknowledgment status, one PLC cycle
pending
DB43xx.DBX100:1 Negative feedback: Acknowledgment status, static pending
DB43xx.DBX100:0 Tool management feedback: Acknowledgment status
DB43xx.DBB104 Tool management feedback: Error status
DB43xx.DBX108.0 - Map of acknowledgments for tool change: This map belongs to the
DB43xx.DBX111.6 positive or negative feedback and remains valid for the same time
DB43xx.DBW124 – DBW138 Job status

Jobs

DB4300...43xx Signals from tool management [r]

xx: Tool holder
Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
DBB0 -- -- -- -- -- -- -- Job
DBB1 Tool Unload Load No old T0 Prepare Change fixed-
remains in manual manual tool change tool location
the tool tool (initiated coded
spindle by: M06)
DBB2 Reserved
DBB3 Reserved
DBB4 Reserved
DBB5 Reserved
DBW6 Source magazine number for new tool (INT)
DBW8 Source location number for new tool (INT)
DBW10 Reserved
DBW12 Reserved

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DB4300...43xx Signals from tool management [r]

DBW14 Reserved
DBW16 Reserved
DBW18 Target magazine number for old tool (INT)
DBW20 Target location number for old tool (INT)
DBW22 Location type (INT)
DBW24 Size left (INT)
DBW26 Size right (INT)
DBW28 Reserved
DBW30 Reserved
DBB32 Tool status for a new tool:
Tool has Tool fixed- Tool being Pre- Measuring Tool Tool Active tool
been in location- changed warning tools disabled enabled
use coded limit
reached
DBB33 Tool status for a new tool:
Manual 1:1 -- Master To be To be Blocked Identifica-
tool exchange tool loaded unloaded tion for
tools in
the buffer
DBW34 New tool: Internal T number of NCK (INT)
DBW36 Reserved
DBW38 Reserved
DBW40 Reserved
DBW42 Reserved
DBW44 Free parameter 1 (DWORD)
DBW48 Free parameter 2 (DWORD)
DBW52 Free parameter 3 (DWORD)

Signal description:
● Job:
The interface contains a job. Job processing has not yet been completed with an end
acknowledgment. This signal is reset after transmission of the end acknowledgment to
the tool management.
● Fixed-location coded: The new tool is fixed-location coded.
● Execute tool change:
The new tool is to be loaded into the tool holder / the spindle. The old tool is to be brought
back to a magazine location. This job always requires an end acknowledgment.
● Prepare a tool change:
Initialize new tools. If necessary, position magazine location for old tool at the changing
point. This job requires an individual end acknowledgment. If there is a parallel job
"Execute change," end acknowledgment for the preparation is not necessary.
● T0: T0 has been programmed (empty tool holder / spindle).

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● No old tool:
Tool change into the previously empty tool holder / spindle.
● Load manual tool:
A manual tool is to be loaded. The HMI displays the tool which is to be loaded.
● Unload manual tool:
The tool is to be changed via manual operation.
● Tool remains in spindle:
The bit is set at a change from tool holder → spindle to tool holder → spindle. Triggers can
be, for example, reset start mode or block search.
● Source location for the new tool:
Magazine and location number from where the new tool comes (mostly a location in a
real magazine).
● Target location for the old tool:
Magazine and location number to where the old tool is to be transported (mostly a
location in a real magazine).
● Origin of the new tool:
– Internal T number: Internal T number of the new tool
– Tool status: Tool status of the new tool
– Location type: Location type of the new tool
– Size: Size (right, left, up, down) of the new tool
– User-definable parameters: Three user-definable parameters which are transferred by
the part program to the PLC user program.

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Acknowledgments

DB4200 ... 42xx Signals to tool management [r/w]

xx: Tool holder
Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
DBB0 Acknowl- Acknowl- Acknowl- Acknowl- Acknowl- Acknowl- Acknowl- Total
edgment edgment edgment edgment edgment edgment edgment acknowl-
step 7 step 6 step 5 step 4 step 3 step 2 step 1 edgment
DBB1 Acknowl- Acknowl- Acknowl- Acknowl- Acknowl- Acknowl- Acknowl- Acknowl-
edgment edgment edgment edgment edgment edgment edgment edgment
step 15 step 14 step 13 step 12 step 11 step 10 step 9 step 8
DBB2 Acknowl- Acknowl- Acknowl- Acknowl- Acknowl- Acknowl- Acknowl- Acknowl-
edgment edgment edgment edgment edgment edgment edgment edgment
step 23 step 22 step 21 step 20 step 19 step 18 step 17 step 16
DBB3 Reserved Acknowl- Acknowl- Acknowl- Acknowl- Acknowl- Acknowl- Acknowl-
edgment edgment edgment edgment edgment edgment edgment
step 30 step 29 step 28 step 27 step 26 step 25 step 24
DBB4 Reserved
DBB5 Reserved
DBB6 Reserved
DBB7 Reserved
DBB8 Reserved
DBB9 Resetting the
acknowl-
edgment
error

Signal description:
● Total acknowledgment:
At a 0/1 edge, the end acknowledgment, with status 99, is sent to the current job (job
complete, all target positions have been reached). As long as the signal is present, no
changes may be made to the data of this interface!
This signal is reset by the PLC firmware after the acknowledgment has been transferred
to the tool management.
● Acknowledgment step 1…30:
At a 0/1 edge, the appropriate acknowledgment step from the acknowledgment step table
is sent to the tool management. As long as the signal is present, no changes may be
made to the data of this interface and the variable transfer-step table!
This signal is reset by the PLC firmware after the acknowledgment has been transferred
to the tool management.
● Resetting the acknowledgment error:
Resetting the message Acknowledgment error (DB43xx.DBX100.1) and the diagnostic
information in the feedback interface.

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Feedback reports

DB4300...43xx Signals from tool management [r]

xx: Load location
Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
DBB100 Acknowl- Acknowl-
edgment edgment
error OK
DBB101 Reserved
DBB102 Reserved
DBB103 Reserved
DBW104 Error status (WORD)
DBB106 Reserved
DBB107 Reserved
DBB108 Acknowl- Acknowl- Acknowl- Acknowl- Acknowl- Acknowl- Acknowl- Acknowl-
edgment edgment edgment edgment edgment edgment edgment edgment
step 7 step 6 step 5 step 4 step 3 step 2 step 1 step 0
DBB109 Acknowl- Acknowl- Acknowl- Acknowl- Acknowl- Acknowl- Acknowl- Acknowl-
edgment edgment edgment edgment edgment edgment edgment edgment
step 15 step 14 step 13 step 12 step 11 step 10 step 9 step 8
DBB110 Acknowl- Acknowl- Acknowl- Acknowl- Acknowl- Acknowl- Acknowl- Acknowl-
edgment edgment edgment edgment edgment edgment edgment edgment
step 23 step 22 step 21 step 20 step 19 step 18 step 17 step 16
DBB111 Reserved Acknowl- Acknowl- Acknowl- Acknowl- Acknowl- Acknowl- Acknowl-
edgment edgment edgment edgment edgment edgment edgment
step 30 step 29 step 28 step 27 step 26 step 25 step 24

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Signal description:
● Acknowledgment OK (DB43xx.DBX100.0): Positive feedback of acknowledgment status.
The acknowledgment of the PLC user program (area DB42xx.DBB0 to DBB3) was
transferred without error to the tool management. This signal is reset after one PLC cycle.
● Acknowledgment error (DB43xx.DBX100.1): Negative feedback of acknowledgment
status.
There is an error in the acknowledgment of the PLC user program (area DB42xx.DBB0 to
DBB3). The cause of the error is displayed in "Error status."
The "acknowledgment error" bit is only set if the acknowledgment from the PLC firmware
is accepted as error free and the tool management detects and signals an error in the
acknowledged tool transfer (for example, when the target location for tool transfer is
occupied).
Errors that are detected directly by the tool management in the NC before an
acknowledgment is sent by the PLC user program, do not result in the setting of bit 100.1.
If an error is present that prevents transfer of the acknowledgment to the tool
management (error status 1 to 7), the error is only output on the interface of the tool
management and not by the NC (no NC alarm!).
If necessary, signal such errors with a user PLC alarm in the PLC user program.
This signal remains pending statically until the error has been acknowledged (set the bit
"Reset acknowledgment error" DB4200.DBX9.0) by the user. The interface in
DB42xx.DBB0 to DBB3 is disabled if bit "acknowledgment error" is pending. Incoming
acknowledgment bits are not evaluated by the PLC firmware and are also cleared when
bit "Reset acknowledgment error" is set.

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Error status:
If there is an error, the error status (DB43xx.DBB104) contains a diagnostic number unequal
to zero.

Status Meaning
0 No error
1 Multiple acknowledgment signals at the same time
2 Acknowledgment without job
3 Invalid transfer step number
4 There is no job for a position specification
5 The status does not permit a location change (acknowledgment status 0 is
used)
7 An impermissible acknowledgment status has been used
Other values: The number corresponds to the error message of the tool management in the
NCK caused by this transfer.

The error status is reset by acknowledgment of the error by the user.

Map of acknowledgments (DB43xx.DBB108 to DBB111)

The acknowledgments last set by the PLC user program (DB42xx.DBB0 to DBB3) are set
and reset by the PLC firmware together with the bits "Acknowledgment OK" or
"Acknowledgment error." If there is an error, the user uses these statically pending bits to
see which acknowledgment step triggered the error. If the PLC user program incorrectly set
multiple acknowledgment bits, these are also entered one-to-one in the map.

Job status

DB4300 ... 43xx Signals from tool management [r]

xx: Tool holder
Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
DBW124 Current magazine number for new tool (INT)
DBW126 Current location number for new tool (INT)
DBW128 Target magazine number for new tool (INT)
DBW130 Target location number for new tool (INT)
DBW132 Current magazine number for old tool (INT)
DBW134 Current location number for old tool (INT)
DBW136 Target magazine number for old tool (INT)
DBW138 Target location number for old tool (INT)

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10.2.3 Transfer-step and acknowledgment-step tables

Configurable step tables

There are configurable tables available in the data blocks TM_CTS (DB9900), TM_VTS
(DB9901) and TM_ACK (DB9902), which are used to describe the tool movement
sequences.

Interface signal Name Meaning

DB9900 TM_CTS Constant transfer-step table (configurable)
DB9901 TM_VTS Variable transfer-step table (can be configured and written
to from PLC user program)
DB9902 TM_ACK Acknowledgment-step table (configurable)

The data blocks DB40xx, 41xx, 42xx and 43xx are system blocks and are created
automatically by the control.
The data blocks DB9900, DB9901 and DB9902 are made available by the Programming
Tool under Libraries / Special data blocks. The blocks are not yet filled with the necessary
data. The user must copy them into the PLC project and edit them.

Transfer-step tables
The individual tool movements are defined as transfer steps – tool from magazine location
x/y to magazine location m/n. Acknowledgment steps can be defined with these transfer
steps. DB9900 contains permanently configured transfer steps (constant transfer-step table).
DB 9901 can be changed by the PLC user program; for example, for acknowledging
intermediate steps like magazine locations for tool change preparation (variable transfer-step
table).

DB9900 Constant transfer-step table [r]

Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
DBW0 Transfer step 1 Source magazine number (INT)
DBW2 Transfer step 1 Source location number (INT)
DBW4 Transfer step 1 Target magazine number (INT)
DBW6 Transfer step 1 Target location number (INT)
DBW8 Transfer step 2 Source magazine number (INT)
DBW10 Transfer step 2 Source location number (INT)
DBW12 Transfer step 2 Target magazine number (INT)
DBW14 Transfer step 2 Target location number (INT)
…
DBW504 Transfer step 64 Source magazine number (INT)
DBW506 Transfer step 64 Source location number (INT)
DBW508 Transfer step 64 Target magazine number (INT)
DBW510 Transfer step 64 Target location number (INT)

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DB9901 Variable transfer-step table [rw]

Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
DBW0 Transfer step 101 Source magazine number (INT)
DBW2 Transfer step 101 Source location number (INT)
DBW4 Transfer step 101 Target magazine number (INT)
DBW6 Transfer step 101 Target location number (INT)
DBB 8 Transfer step 102 Source magazine number (INT)
DBW10 Transfer step 102 Source location number (INT)
DBW12 Transfer step 102 Target magazine number (INT)
DBW14 Transfer step 102 Target location number (INT)
…
DBW504 Transfer step 164 Source magazine number (INT)
DBW506 Transfer step 164 Source location number (INT)
DBW508 Transfer step 164 Target magazine number (INT)
DBW510 Transfer step 164 Target location number (INT)

Acknowledgment step table

Each entry indexes two transfer steps (for the new and old tool) and gives the corresponding
status reached. The acknowledgment-step table in DB9902 is used jointly for
acknowledgments on the interface of the loading point and on the interface of the tool holder.

DB9902 Acknowledgment-step table [r]

Byte Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
DBB0 Acknowledgment step 1 Transfer step for new tool (BYTE)
DBB1 Acknowledgment step 1 Transfer step for old tool (BYTE)
DBB2 Acknowledgment step 1 Acknowledgment status (BYTE)
DBB3 Acknowledgment step 1 reserved
DBB4 Acknowledgment step 2 Transfer step for new tool (BYTE)
DBB5 Acknowledgment step 2 Transfer step for old tool (BYTE)
DBB6 Acknowledgment step 2 Acknowledgment status (BYTE)
DBB7 Acknowledgment step 2 reserved
…
DBB116 Acknowledgment step 30 Transfer step for new tool (BYTE)
DBB117 Acknowledgment step 30 Transfer step for old tool (BYTE)
DBB118 Acknowledgment step 30 Acknowledgment status (BYTE)
DBB119 Acknowledgment step 30 reserved

See also
PLC Program Blocks (Page 337)

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10.3 Machine data for the tool management

10.3.1 Settings for the tool management

Machine data (default setting)

The following machine data has already been preset for tool management or will be set with
"default data" during booting: These settings can be changed as necessary.

MD number Designation Value

10715[0] M_NO_FCT_CYLE 6 (M version)
10716[0] M_NO_FCT_CYLCLE_NAME L6 (M version)
10717 T_NO_FCT_CYLCLE_NAME TCHANGE (T version)
17500 MAXNUM_REPLACEMENT_TOOLS 0
20124 TOOL_MANAGEMENT_TOOLHOLDER 1
20270 CUTTING_EDGE_DEFAULT 1
20310 TOOL_MANAGEMENT_MASK 181400F (T version)
180400F (M version)
22550 TOOL_CHANGE_MODE 0 (T version)
1 (M version)
22560 TOOL_CHANGE_MCODE 206
22562 TOOL_CHANGE_ERROR_MODE 0 (for manual tool)

MD20270: $MC_CUTTING_EDGE_DEFAULT
If no cutting edge is programmed after a tool change, the cutting edge number set in
$MC_CUTTING_EDGE_DEFAULT is used.

MD20270: $MC_CUTTING_EDGE_DEFAULT
Basic setting of tool cutting edge without programming (DWORD)
>0 Number of the cutting edge that is selected with M206 Cutting edge selection is also
active if followed by D programming.
=1 Default setting
=0 No cutting edge is initially active after a tool change. Any tool offset active before tool
change is deselected (corresponds to D0!). Cutting edge selection only active with D
programming.
= -1 Tool edge number of old tool also applies to new tool.
= -2 Tool edge offset of old tool remains active until D is programmed.

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The setting in MD20270 affects the block preparation of the NC. To prevent preprocessing
stop from occurring when tool change command is called until it is acknowledged again,
perform NC functions without tool offset in the tool change subprogram, for example,
traversing axes or output of auxiliary functions.
Example:
Requirement: MD20270: $MC_CUTTING_EDGE_DEFAULT= 0 or = -2
After the tool change command M206 the axes can continue travel without having to wait for
the tool change acknowledgment and execute traversing blocks without tool compensation.
Travel only stops in a block with compensation selected (D no.) until end of tool change is
signaled by the PLC.
Sequence in the part program:

N10 T="Drill18" ; Tool change preparation

N20 M6 ; Tool change subprogram called
Tool change subprogram L6:
N10 M206 ; Tool change
N20 D0 : Compensation deselected
N40 Y150 M79 ; Traverse machine axes
N50 G01 D1 X10 ; Activate tool compensation.
; Check whether tool has been changed.
; Preprocessing stop is maintained until tool change
preparation is completed. The main run waits at N50 (D1)
until tool change has been executed and acknowledged.

MD20310: $MC_TOOL_MANAGEMENT_MASK
Settings:

MD20310: $MC_TOOL_MANAGEMENT_MASK
Activating the tool management functions
T and M version:
Bit 0 =1 Tool management active:
The functions of tool management are enabled for the current channel.
Bit 1 =1 Monitoring functions of tool management active:
The functions for monitoring tools (tool life and workpiece count) are enabled.
Bit 2 =1 OEM functions active
Bit 3 =1 Adjacent location consideration active
Bit 14 =1 Tool and offset selection according to the settings in:
MD20110 $MC_RESET_MODE_MASK
MD20112 $MC_START_MODE_MASK
Bit 23 =1 With offset selection no synchronization with main run.

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MD20310: $MC_TOOL_MANAGEMENT_MASK
Bit 24 =1 Using an asynchronous transfer with acknowledgment status 201, you can move
a tool to a location reserved for another tool with "reserved for tool from buffer".
This location reservation is then removed before the movement is executed
("Reserved for new tool to be loaded" (bit value="H8") remains effective).
Additionally only for T version:
Bit 16 =1 T location number is active.

If a locked tool is at the programmed location, the location of a replacement tool (if available)
is output as job from the tool management when the "Spare tools for tool management"
option is set.

Channel MD52270: $MCS_TM_FUNCTION_MASK

Settings:

SD52270: $MCS_TM_FUNCTION_MASK
Tool management function mask
Bit 0: Creating a tool at the magazine location is not permitted.
Tools can only be created outside of the magazine.
Bit 1: Load/unload lock, if the machine is not in the reset state.
Tools can only be loaded/unloaded when the relevant channel is in the reset state.
Bit 2: Load/unload lock for EMERGENCY STOP.
Tools can only be loaded/unloaded when EMERGENCY STOP is not active.
Bit 3: Tool in/out of spindle load/unload locked.
Tools cannot be loaded to or unloaded from the spindle.
Bit 4: Loading is performed directly into the spindle.
Tools are only loaded directly into the spindle.
Bit 5: Reserved
Bit 6: Reserved
Bit 7: Create tool using the T number.
The T number of the tool must be entered when creating a tool.
Bit 8: Hide tool relocation.
The "Relocate tool" function is hidden in the user interface.
Bit 9: Hide magazine positioning.
The "Position magazine" function is hidden in the user interface.
Bit 10: Reactivate tool with magazine positioning.
Before reactivating, the tool is positioned at the loading point.
Bit 11: Reactivate tool in all monitoring types.
When reactivating a tool, all the monitoring types for this tool enabled in the NC are
reactivated. I.e. also the monitoring types that are not set for the relevant tool, but are
only in the background.
Bit 12: Hide reactivating tool.
The "Reactivate tool" function is hidden in the user interface.

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Default setting for turning technology

Two machine data items determine the function for turning technology:
● MD22550: $MC_TOOL_CHANGE_MODE = 0
Setting for a revolver magazine: The new tool is changed immediately with the T function.
No additional M command is used. No distinction is made between Prepare tool change
and Execute tool change.
The function "Manual tools" is not enabled for this case.
● MD20310: $MC_TOOL_MANAGEMENT_MASK = 81400F (bit 16=1)
Bit 16 is used to set the tool programming type:
T = "x" with x as tool identifier
Tx, with x as location number of the magazine containing the tool used for machining.
When the function is active, T1 selects the tool in location number 1 instead of the tool
with identifier "1". Then the identifier of the tool in this location is ascertained (e.g.
"FINISHING TOOL") The procedure is as if T="FINISHING_TOOL" had been
programmed.
If T = location number, no tool need actually be stored in the location.
● MD10717: $MN_T_NO_FCT_CYCLE_NAME = TCHANGE
Name of tool change cycle for T function replacement.
For a description, refer to Section Example: Tool change cycle for turning machine
(Page 366)
● ISO dialects
Default setting for programming the tool offset:

MD10888 $MN_EXTERN_DIGITS_TOOL_NO = 0
MD10889 $MN_EXTERN_DIGITS_OFFSET_NO = 2
MD10890 $MN_EXTERN_TOOLPROG_MODE = 4

Programming T101 and T0101 leads to the same result: T1 H01

Configuring the magazine

The magazine configuration can be created either with the start-up tool or with a
configuration program. The configuration program is selected and started as a normal part
program.
An NC POWER ON is needed after changing the magazine configuration. The changed
configuration is only displayed after restarting the NC.

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See also
Examples:
● Configuration of a chain magazine with a dual gripper (Page 371)
● Configuration of a revolver magazine (Page 360)
The program is also to be found on the Toolbox CD.

References
Further information:
● SINUMERIK 828D List Manual: Machine data and interface signals
● SINUMERIK 802D sl/828D/840D sl: Function Manual: ISO dialects
– The description "Substitution by a replacement cycle for a tool selection block" is valid
for the ISO mode (G291).
– The description "Tool change and tool offsets" is valid when programming the tool
offset.

10.3.2 Dependency between MD20360 and SD54215

Settings for the tool management

The settings for the tool management are made in the following setting data:

SD54215: $SNS_TM_FUNCTION_MASK_SET
Tool management function mask
Bit 0: Diameter display for rotating tools:
Cutting edge parameters 6 (cutting edge radius) and 15 (wear radius) are not displayed
as a radius value for the following tool types, but as a diameter value: Types 100 to 299,
580, 710, 711, 712, 713, 714 and 725.
Cutting edge parameter 7 (outside radius) is not displayed as a radius value for the
following tool types, but as a diameter value: Types 140 and 714.
Bit 1: M4 is the standard direction of rotation for all turning tools. When creating turning tools,
the direction of rotation is pre-assigned with M4.
Bit 2: A name is not suggested when creating a tool.
Bit 3: Input lock, tool name and tool type for loaded tools. For loaded tools, the tool name and
the tool type can no longer be changed.
Bit 4: Input lock for loaded tools if the channel is not in the reset state.

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SD54215: $SNS_TM_FUNCTION_MASK_SET
Bit 5: Tool wear entries are added: Wear data is entered in addition to the already existing wear
value.
Bit 6: Only numerical entries are permitted in the "Tool identifier".
Bit 7: Hide tool monitoring parameters. The tool monitoring parameters are hidden in the user
interface.
Bit 8: Diameter display for face axis - geometry. The geometry value of the transverse axis is
displayed as a diameter value, if a transverse axis is defined in MD20100
$DIAMETER_AX_DEF and SD42940 $TOOL_LENGTH_CONST is set to 18 and
SD42950 $TOOL_LENGTH_TYPE is set to 2.
Bit 9: Diameter display for face axis - wear. The wear value of the transverse axis is displayed
as a diameter value, if a transverse axis is defined in MD20100 $DIAMETER_AX_DEF
and SD42940 $TOOL_LENGTH_CONST is set to 18 and SD42950
$TOOL_LENGTH_TYPE is set to 2.
Bit 10: Enable tool load/relocate to buffer storage locations. The magazine number can be
entered into the load dialog box. It is therefore possible to access the buffer storage via
magazine number 9998.
Bit 11: Creating new tools at gripper locations is blocked.
Bit 12: Measuring tools are not unloaded when the "Unload all" function is executed.

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10.3 Machine data for the tool management

Dependency between SD54215 and MD20360

The setting data SD54215 $TM_FUNCTION_MASK_SET and the machine data MD20360
$TOOL_PARAMETER_DEF_MASK have the following dependencies:

Dependency Description Recommendation

SD54215 ⇔ MD20360
Bit 9 ⇔ Bit 0 If bit 0 is set in MD20360, then SD54215 It is recommended that the setting
bit 9 has no effect because the NC MD20360 bit 0 and bit 1 not be used.
already returns the linear wear value of Instead, use SD54215 bit 9 and bit 8.
the transverse axis as a diameter value.
MD20360 bit 0 and bit 1 are effective
Bit 8 ⇔ Bit 1 If bit 1 is set in MD20360, then SD54215 only for turning and grinding tools. This
bit 8 has no effect because the NC setting therefore cannot be used on a
already returns the linear geometry value turning/milling machine because the
of the transverse axis as a diameter value. linear component of the transverse axis
applies for turning tools in the diameter
and for milling tools in the radius. When
the setting data is used, only the display
goes to diameter, the internal value in
the NC remains at radius.
Bit 0 ⇔ Bit 11 If bit 11 is set in MD20360, then SD54215 It is recommended that the setting
bit 0 has no effect with regard to cutting MD20360 bit 11 and bit 12 not be used.
edge parameter 6 (tool nose radius) Instead, set SD54215 bit 0.
because the NC already returns the tool
MD20360 bit 11 and bit 12 apply to all
nose radius as a diameter value.
tool types, i.e. also to turning tools. This
Bit 0 ⇔ Bit 12 If bit 12 is set in MD20360, then SD54215 setting therefore cannot be used on a
bit 0 has no effect with regard to cutting turning/milling machine because the tool
edge parameter 15 (wear radius) because nose radius of a turning tool should
the NC already returns the wear radius as never be specified in the diameter.
a diameter value. When the setting data is used, only the
display goes to diameter, the internal
value in the NC remains at radius.

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10.3.3 Tool measuring in JOG

Tool call for tool measuring in JOG

For special applications (e.g. measuring cycles in JOG), it is necessary to load a specific tool
(e.g. miller_15, duplo number 2) - independent of its status - onto the spindle or the
toolholder; this can be the case, for example, if a tool was being used but was locked by the
tool monitoring function. For the new release, it should now be measured.
The NC command TCA is available to call a tool independent of the status and by selecting
duplo and tool holder number; this is used when measuring tools in JOG.

TCA ("Tool name", duplo No., toolholder No.)

TCA behaves like the T command with respect to alarm and command output to the PLC.
Boundary conditions:
The following boundary conditions must be observed for an active T function replacement
(default setting for turning):
● TCA cannot be substituted (T replacement cycle).
● The cycle defined in MD10717: $MN_T_NO_FCT_CYCLE_NAME and executed with the
T call, is not started with the TCA command.
To ensure that a tool change cycle also starts when TCA is programmed, the language
command TCA must be redefined in _TCA (default setting NC).
● The machine functions of the TCHANGE.SPF must be transferred into the TCA.SPF
cycle. The TCA.SPF cycle is in the Toolbox CD.
Example:
The following example describes the sequence:

PROC TCA(STRING[64] _TOOL_NAME,INT _DUPLO,INT _TH_NO)

;VERSION: 01.00.07. Oct 22, 2009
;CHANGE: 01.00.07. Oct 22, 2009
TCA(_TOOL_NAME,_DUPLO,_TH_NO) ;Tool call to NC
; here, insert the machine functions for the change
M17

Note
The offset selection corresponding to MD20270: $MC_CUTTING_EDGE_DEFAULT acts in
the same way as for the T command. TCA and D must not be programmed in the same
block.

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Measuring in JOG without electronic probe

For manual measuring functions in the JOG operating mode, for which a rotating spindle is
required, the following applies:
● The channel state must be reset at the instant in time that the measured value is
transferred.
● The spindle can be moved or positioned either using the T,S,M menu or using the bits in
DB380x.DBB5006.
● The following preconditions apply when using the DB380x.DBB5006 technology functions
with fixed speed:

Setting the machine data

MD10709 $MN_PROG_SD_POWERON_INIT_TAB [0] = 0 setting data to be initialized
MD35035 $MA_SPIND_FUNCTION_MASK Bit 4=0 Spindle functions
Bit 5=1
SD43200 $SA_SPIND_S Speed setting value

Note
The entry in SD43200 $SA_SPIND_S is kept at power on.
With these settings, the spindle velocity for manual operation, which is set in SD41200
$SN_JOG_SPIND_SET_VELO, is no longer effective.

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10.4 PLC Program Blocks

10.4.1 Acknowledgment process

Information to tool management

The tool management expects acknowledgment of its orders in order to track and carry the
actual tool positions. At least one acknowledgment is required for each order. This is
sufficient for many applications.
Acknowledgment takes place either via the table defined in DB9902, or in one step with the
total acknowledgment (DB40xx/42xx DBX0.0) after a completely finished tool management
order using a 0/1 edge (set) of the corresponding bits in the user interface.
As long as the acknowledgment signal is present, no changes may be made to the data of
this interface! This signal is reset by the PLC firmware after the acknowledgment has been
transmitted to the tool management. In certain circumstances resetting may take place after
several PLC cycles.
There are further advantages if the tool management is also informed of intermediate
positions:
● Information about intermediate positions:
If the intermediate tool positions are known in the tool management, the allocation of the
buffer magazine may be queried. This makes powering up easier after switching off and
on again or after canceling a command (e.g. via reset). If the tool currently being changed
is needed again immediately, it can be loaded back into the spindle from a buffer location
without loading it into the magazine first.
● Information about magazine positions:
If the tool management knows at which magazine location there is a transfer point
(changing point for the spindle, loading point), it can determine the shortest paths in the
magazine for finding an empty location or for selecting a new tool. During orders the tool
management can usually recognize the magazine position from intermediate
acknowledgments (e.g. tool transfer between the real magazine and the buffer) or from
the end acknowledgment (e.g. "magazine positioning" order complete). If the magazine is
positioned by the PLC user program itself (e.g. by means of HMI or machine keys)
without a tool management order, this must be communicated to the tool management
via synchronous signals.

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10.4.2 Types of acknowledgment

Tool and magazine movements

The tool management distinguishes between synchronous acknowledgment and an
asynchronous job-independent message.
Synchronous acknowledgment
● Acknowledgment of the intermediate steps of a job (tool management registers the
current position changes of tools, part program must wait).
The tool management is informed of intermediate steps of a job by an intermediate
acknowledgment. In intermediate acknowledgments, only the target position of the
intermediate step is relevant. The source position is known from the job or the last
intermediate acknowledgment. During a tool change, two tools (new and old) can also be
acknowledged simultaneously. Intermediate acknowledgments are only possible before
the end acknowledgment.
● End acknowledgment of a job (part program can be continued)
An end acknowledgment is necessary for every job. The end acknowledgment allows the
part program to continue and frees up the job interface for new jobs. It should take place
as soon as possible (e.g. as soon as the new tool is in the spindle and a collision is no
longer expected). The tool management can be informed asynchronously of further steps
after the end acknowledgment of a job (e.g. the return path of the old tool into the
magazine).
Asynchronous job-independent message
Position change of a tool or magazine ("asynchronous message", e.g. when the PLC
changes a tool position via machine control panel operation without tool change job).
An asynchronous message can be used to inform the tool management of a tool or
magazine movement, independently of a job. An asynchronous message must always
contain a source position (from) and target position (to).
Tool movements within a magazine (relocate tool) can only be carried out with magazine
locations which are actually occupied. Empty transfers are not permissible. Two
asynchronous transfers can be implemented in a single message. In this case the interface
must be used for tool change DB42xx.

Effect of acknowledgments
Effect of acknowledgments on the job and the part program:
● Intermediate and end acknowledgment take place synchronously with the job.
– The part program must wait.
– No new job can come yet.
● Message of an asynchronous transfer:
– The part program continues to run.
– The message is completely independent of any job.

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10.4.3 Acknowledgment states

Acknowledgment states and their meaning:

The status indicated by the respective type of acknowledgment is shown in the following
table:

Acknowledgment Meaning
Synchronous end 1 Job finished at the specified position:
acknowledgment The tools are in the positions specified. The part program can be
continued.
3 Job canceled:
The job is canceled, previously acknowledged tool position
changes will be kept. The cancel command itself does not
trigger any position acknowledgments or changes in the tool
management.
6 End acknowledgment for "Move tool" from the real magazine to
a buffer (gripper, spindle) with reservation of the old location in
the magazine for this tool. Same meaning as status 1.
7 Repeat "prepare tool change" job:
The tool change was informed of a new tool position in advance.
The "prepare tool change" job is to be recalculated with this
position. This is permissible only for preparation commands
which have not yet been acknowledged.
99 Total acknowledgment: Job complete, all positions reached.
All the tools concerned are in the positions specified in the job.
The part program can be continued. All target positions from the
job have been reached.
Synchronous 105 Intermediate position for tool:
intermediate The tools are moved from the source position specified in the
acknowledgment job, or from the last acknowledged intermediate position, to the
specified target position.
Communicating an 201 Communicate tool movement:
asynchronous transfer The tool is moved from the source position to the specified
target position. When moving from a location in a real magazine
to an intermediate buffer location, the source location is
reserved for the tool.
Also observe MD20310, bit 24 (Page 328).
204 Communicate magazine position:
The magazine location is in the change/load/unload point of the
specified target location.

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10.4 PLC Program Blocks

Overview of evaluated table parameters

Acknowledgment status 1 3 6 7 99 105 201 204

New tool Transfer step x - x - - x x x
 from magazine - - - - - - xx xx

 from location - - - - - - xx xx

 to magazine xx - xx - - xx xx zz

 to location xx - xx - - xx xx zz

Old tool Transfer step x - - - - x x -

 from magazine - - - - - - xx -

 from location - - - - - - xx -

 to magazine xx - - - - xx xx -

 to location xx - - - - xx xx -

Legend:
- Date not relevant
x Number (1…n) of the transfer step from the transfer-step table
xx Magazine number, location number of the tool
zz Magazine number, location number of the load / unload or changing point

The status overview issues the following information:

● Depending on their meaning, the states 1, 6, 105, 201 and 204 should be combined in
the acknowledgment table with the transfer steps to make useful acknowledgment steps.
● If status 1 is coded with both transfer step numbers = 0, this acknowledgment step serves
as an end acknowledgment of the current status reached via intermediate
acknowledgments.
● If a tool has been moved for a real magazine to a buffer (relocate, MVTOOL),
acknowledgment with status 6 or total acknowledgment reserves the source location for
this tool ($TC_MPP4 bit 1 and bit 2). The behavior is the same as for the removal of a
tool from the magazine during tool change. With status 1, there is no reservation of the
source location during relocation or MVTOOL.
● Statuses 3 and 7 need only to be coded once in the acknowledgment-step table, as no
transfers steps are evaluated.
● Status 99 does not need to be coded, it is specified by the "total acknowledgment" bit.

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Typical sequence of any job with total acknowledgment

2UGHU


7RWDODFNQRZOHGJPHQW

$FNQRZOHGJPHQW2.

Signal description:
① The PLC user program recognizes from the 0/1 edge of the signal DB43xx.DBX0.0 (job) that a
new job has been assigned by the tool management.
② The PLC user program sets the acknowledgment signal in DB42xx.DBX0.0 (total
acknowledgment). With activation of the 0/1 edge, the PLC firmware starts transferring the
acknowledgment to the tool management.
③ After successful transmission of the acknowledgment to the tool management, the PLC
firmware sets a PLC cycle to 1 for the signal "acknowledgment OK" and at the same time the
job signal and the acknowledgment bit are reset to 0.

Typical sequence of any job with total acknowledgment and end acknowledgment

2UGHU

,QWHUPHGLDWHDFNQRZOHGJPHQW


(QGDFNQRZOHGJPHQW

$FNQRZOHGJPHQW2.

Signal description:
① The PLC user program recognizes from the 0/1 edge of the signal DB43xx.DBX0.0 (job) that a
new job has been assigned by the tool management.
② The PLC user program acknowledges the transfer steps, configured in DB9900, DB9901 and
DB9902, with acknowledgment status 105. The tool management updates the tool positions
using the transfer steps of the acknowledgments.
③ The execution of the job is acknowledged by the PLC user program with acknowledgment
status 1. After successful transmission of the acknowledgment to the tool management, the
PLC firmware sets a PLC cycle to 1 for the signal "acknowledgment OK" and at the same time
the job signal and the acknowledgment bit are reset to 0.

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Sequence of the tool management with block splitting (machine data setting milling)

Txx M6 ;

Program L6 is called with M6 (basic setting)

2UGHU


([HFXWHWRROFKDQJH

3UHSDUHDWRROFKDQJH


,QWHUPHGLDWHDFNQRZOHGJPHQW


(QGDFNQRZOHGJPHQW

$FNQRZOHGJPHQW2.

Signal description:
① The PLC user program receives a new job. The job "prepare tool change" and the job "execute
tool change" are issued one after the other. Txx and M206 have been programmed in separate
NC blocks. Only the job "prepare tool change" is present in the interface in DB43xx. The job
"execute tool change" is output only after the end acknowledgment for the job for tool
preparation.
② Bit DB43xx.DBX0.0 (job) is reset with acknowledgment of the "prepare tool change" job. If the
change command (M206) has already run through the NC main run, the new job is immediately
output at the interface.
③ The "execute tool change" job is acknowledged as a normal job. The end acknowledgment OK
is returned and the bit for the job is simultaneously reset.
The description of the job ("execute tool change" and "prepare tool change") is not reset. Byte
1 of DB43xx is not overwritten until the next job.

Note
MD20270, MD20310:
The response of the interface in DB43xx.DBB1 and of NC block processing is affected by the
setting in MD20270: $MC_CUTTING_EDGE_DEFAULT and MD20310:
$MC_TOOL_MANAGEMENT_MASK bit 5, 6, 7, and 8.
This sequence described here corresponds to the presetting of the machine data.

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Sequence of the tool management without block splitting (machine data setting milling)

Txx Myy ;

Myy is the setting from MD22560: $MC_TOOL_CHANGE_M_CODE

This type of programming is not recommended!

2UGHU

([HFXWHWRROFKDQJH

3UHSDUHDWRROFKDQJH


,QWHUPHGLDWHDFNQRZOHGJPHQW


(QGDFNQRZOHGJPHQW

$FNQRZOHGJPHQW2.

Signal description:
① The PLC user program receives a new job. The job "prepare tool change" and the job "execute
tool change" are issued simultaneously. Txx and M206 have been programmed in one NC
block.
② Several intermediate steps are acknowledged. The state of the job remains unchanged. The
positions of the tools are updated using the transfer steps of the acknowledgments from the
tool management.
③ The end acknowledgment OK is returned and the bit for the job is simultaneously reset.
The description of the job ("execute tool change" and "prepare tool change") is not reset. Byte
1 of DB43xx is not overwritten until the next job.

Note
MD20310: $MC_TOOL_MANAGEMENT_MASK
The response of the interface in DB43xx.DBB1 is affected by the setting in MD20310 bit 10.
This sequence described here corresponds to the presetting of the machine data.

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10.4.4 Configuring step tables

Configuring step tables

You can find the transfer-step tables (TM_CTS, DB9900 and TM_VTS, DB9901) and the
acknowledgment-step table (TM_ACK, DB9902) in the Programming Tool under "Libraries"
→ "Special data blocks". The blocks are copied into a project with a double-click.
The structure of the data blocks is permanently fixed.
The blocks are not yet filled with the necessary data. The user must edit them in the
Programming Tool, via the menu "View" → "Data block". The constant tables (TM_CTS,
DB9900 and TM_ACK, DB9902) are configured by writing the initial data block values in the
Programming Tool.
The initial data block values are loaded into the control, along with the PLC user program.
Changed initial values are not activated until the PLC is restarted!

Configuring the transfer steps

Any changes to the tool and magazine positions must be communicated to the tool
management by the PLC user program. A table of all mechanical single movements which
should be acknowledged / communicated helps with this. For each tool transfer, the table
contains the corresponding tool start and target position, or for positioning a magazine
location at a transfer point (change, load, unload point), the magazine position and the name
of the transfer point.
● The transfer steps 1 … 64 are permanently configured in TM_CTS (DB9900) and can be
changed only by reloading.
● The transfer steps 101 … 164 in TM_VTS (DB9901) can be completely or partially
overwritten by the PLC user program (e.g. by entering the current magazine location).

Coding for position from a job

In the constant transfer-step table, the locations of real magazines are not identified by their
actual values (e. g. 1/14 for magazine 1 location 14) but with symbolic values (0/1) or (0/2).
Otherwise the transfer-step table would be huge for large magazines.

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These symbolic values have the following meaning:

Magazine / Location Meaning

(0/1) The source position of the only or new tool from the job should be used.
(0/2) The target position of the old tool from the job should be used.
(0/3) The target position of the only tool or new tool from the job should be used.

This symbolic notation form can only be used for synchronous intermediate and end
acknowledgments, since asynchronous messages do not have a job as a reference.

Example: Constant transfer-step table

Transfer step Address Name Start value Comment

DB9900
1 0.0 SrcMag_1 0 Source magazine number of the
transfer step
2.0 SrcPos_1 1 Source position number of the
transfer step
4.0 DstMag_1 0 Target magazine number of the
transfer step
6.0 DstPos_1 1 Target position number of the
transfer step
2 8.0 SrcMag_2 0 Source magazine number of the
transfer step
10.0 SrcPos_2 1 Source position number of the
transfer step
12.0 DstMag_2 9998 Target magazine number of the
transfer step
14.0 DstPos_2 2 Target position number of the
transfer step

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Example as a complete step

Transfer of to Comment
step
Magazine Location Magazine Location
1 0 1 0 1 Prepare Tool: The magazine is
positioned at the changing point of the
new tool.
2 0 1 9998 2 Tool change: Tool from magazine to
gripper 1
3 9998 1 9998 3 Tool change: Tool from spindle to
gripper 2
4 9998 2 9998 1 Tool change: Tool from gripper 1 to
spindle
5 9998 3 0 2 Tool change: Tool from gripper 2 to
magazine

Example: Variable transfer-step table

Transfer Address Name Start value Comment

step DB9901
101 0.0 SrcMag_101 1 Source magazine number of the
transfer step
2.0 SrcPos_101 0 Source position number of the
transfer step
4.0 DstMag_101 9998 Target magazine number of the
transfer step
6.0 DstPos_101 1 Target position number of the
transfer step
102 8.0 SrcMag_102 1 Source magazine number of the
transfer step
10.0 SrcPos_102 0 Source position number of the
transfer step
12.0 DstMag_102 9998 Target magazine number of the
transfer step
14.0 DstPos_102 2 Target position number of the
transfer step

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Example as a complete step

Transfer of to Comment
step
Magazine Location Magazine Location
101 1 0 9998 1 "Prepare tool change": The magazine
is positioned at the changing point.
The source position must be entered
by the PLC user program.
102 1 0 9998 2 "Prepare tool change": Tool from
magazine to buffer. The source
position must be entered by the PLC
user program.

10.4.5 Configuring acknowledgment steps

Configuring the acknowledgment steps

The PLC 31 provides acknowledgment steps to acknowledge tool and magazine
movements. These are activated via the corresponding bits on the user interface. The data
of these acknowledgment steps (with the exception of special case acknowledgment step 9:
total acknowledgment) are stored in acknowledgment step table TM_ACK (DB9902). The
transfer steps (number of the transfer step from the transfer step table) for the old and new
tool and an acknowledgment status are combined in one acknowledgment status.
It is important to include an acknowledgment step with the status 3 in this table, so that
potential errors can be reset. The numbers for the transfer in this acknowledgment step are 0.

Special meaning of transfer step 0

Only the transfer steps assigned to the acknowledgment step are executed. If only one or no
transfer step is assigned, no tool transfer will be carried out for the tool with transfer step = 0.
The tool is not available or remains at its original location.

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Example: Acknowledgment step table

Acknowl- Address Name Start value Comment

edgment DB9902
step
1 0.0 TsNewT_1 0 Transfer step number of the new tool
1.0 TsOldT_1 0 Transfer step number of the old tool
2.0 State_1 3 Status to NCK
2 4.0 TsNewT_2 1 Transfer step number of the new tool
5.0 TsOldT_2 0 Transfer step number of the old tool
6.0 State_2 1 Status to NCK

Example as a complete step

Acknowl- Transfer step Acknowl- Comment

edgment edgment
New tool Old tool
step status
1 0 0 3 "Cancel order" command.
2 2 0 1 Prepare Tool: The tool is taken from the
magazine (changing point) and placed
into gripper 1.

Acknowledgment is given by setting the corresponding bits in the user interface:

● DB40xx for loading/unloading / relocating or positioning the magazine
● DB42xx for "prepare tool change" and "execute tool change"
After processing, the acknowledgment bit is reset one PLC cycle by the PLC firmware.
In the same data block where the acknowledgments have taken place, for a PLC cycle the
feedback message is output in bit 100.0 (acknowledgment OK), or as a static signal in bit
100.1 (acknowledgment error); the error status is output in byte 104 for an acknowledgment
error, and in bytes DBB108 to DBB111 the acknowledgment bits last set are output. The
user can use these bits to see which acknowledgment step triggered the error. If the PLC
user program incorrectly set multiple acknowledgment bits, these are also entered one-to-
one in the map. Resetting of the error status occurs when the user acknowledges the error in
DB40xx.DBX9.0 or DB42xx.DBX9.0.

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10.4.6 Adjust the PLC user program

Adjust the PLC user program

The control of mechanical processes, monitoring and prevention of potential collisions and
the acknowledgment of tool position changes are the task of the PLC user program.

See also
In the PLC project on the Toolbox CD you can find examples of transfer steps and their
acknowledgments, for a turning machine with a circular magazine and a milling machine with
a chain magazine and dual gripper:
● Application example for milling machine (Page 371)
● Application example for turning machine (Page 360)
These blocks are function examples for the acknowledgment of different tool management
jobs.

Acknowledging jobs
Many tool movements or tool management jobs can be directly acknowledged using total
acknowledgment at bit 0.0 of the interface, without previous intermediate acknowledgment.
For example:
● Turns of a circular magazine
● Loading/unloading (only for systems without additional buffers such as handling systems,
loaders, etc.)
● Changing manual tools
● Positioning a magazine

Rules for acknowledgment

If intermediate steps are useful, several rules must be observed during acknowledgment:
The PLC user program must ensure that all acknowledgments are transferred correctly to
the tool management.
● Only one acknowledgment signal at a time may be sent to the tool management.
● Synchronous acknowledgments are permissible only for the pending job
● Only valid transfer-step numbers may be used (1 - 64, 100 - 164). For asynchronous
messages, at least one transfer step must be input for status 201, for status 204 a
transfer step for the new tool must be input.
● Coded positions in the transfer steps may only be used for synchronous
acknowledgments and only with the values 0/1, 0/2 or 0/3.
● No illegal acknowledgment states may be used.

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● Magazine positioning with a job may only receive a synchronous acknowledgment (end
acknowledgment). Intermediate positions must be reported to the tool management with
asynchronous messages.
● Acknowledgment signals must be reset by the PLC basic program. After an
acknowledgment bit is set, the user interface may not be changed until the feedback
message in DB41xx/DB43xx DBB100!
● Asynchronous messages with two transfer steps must be acknowledged on the tool
change interface (DB42xx).

10.4.7 Information on magazine location

Overview
It is possible to read up to eight NC variables in one job using the existing NC services
interface (DB1200).

Variable $TC_MPP2 with index 7: Location type

Parameter assignment:

Read variable from Address Signal Valid values

the NCK
Job DB1200.DBX0.0 Start 0/1
DB1200.DBX0.1 Write variable 0
DB1200.DBB1 Number of variables 1…8
Parameter DB120x.DBW1000 Variables index 7
DB120x.DBW1002 Location number 1 … 31999
DB120x.DBW1004 Magazine number 1 … 9999
Result DB1200.DBX2000.0 Job completed 0/1
DB1200.DBX2000.1 Error in job 0/1
DB120x.DBX3000.0 Variable is valid 0/1
DB120x.DBB3001 Access result 0/3/5/10
DB120x.DBW3004 Data from NCK variable n

Legend:
n > 0: Location type for virtual location
n = 0: "match all" (buffer)
n = 9999: undefined (no virtual location)

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Variable $TC_MPP4 with index 8: Location state

Parameter assignment:

Read variable from Address Signal Valid values

the NCK
Job DB1200.DBX0.0 Start 0/1
DB1200.DBX0.1 Write variable 0
DB1200.DBB1 Number of variables 1…8
Parameter DB120x.DBW1000 Variables index 8
DB120x.DBW1002 Location number 1 … 31999
DB120x.DBW1004 Magazine number 1 … 9999
Result DB1200.DBX2000.0 Job completed 0/1
DB1200.DBX2000.1 Error in job 0/1
DB120x.DBX3000.0 Variable is valid 0/1
DB120x.DBB3001 Access result 0/3/5/10
DB120x.DBW3004 Data from NCK variable n

Legend:
n=1 locked
n=2 free (<> occupied)
n=4 reserved for tool in buffer
n=8 reserved for tool to be loaded
n = 16 occupied in left half location
n = 32 occupied in right half location
n = 64 occupied in upper half location
n = 128 occupied in lower half location

Variable $TC_MPP6 with index 9: T number of the tool at this location

Parameter assignment:

Read variable from Address Signal Valid values

the NCK
Job DB1200.DBX0.0 Start 0/1
DB1200.DBX0.1 Write variable 0
DB1200.DBB1 Number of variables 1…8
Parameter DB120x.DBW1000 Variables index 9
DB120x.DBW1002 Location number 1 … 31999
DB120x.DBW1004 Magazine number 1 … 9999
Result DB1200.DBX2000.0 Job completed 0/1
DB1200.DBX2000.1 Error in job 0/1

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10.4 PLC Program Blocks

Read variable from Address Signal Valid values

the NCK
DB120x.DBX3000.0 Variable is valid 0/1
DB120x.DBB3001 Access result 0/3/5/10
DB120x.DBW3004 Data from NCK variable n
n = T number of the tool on the parameterized location

Error (for all variables)

In case of error, DB120x.DBX3000.0 = 0 and an entry is made in the access result:

Values in DB120x.DBB3001
0 No error
3 Illegal access to object
5 Invalid address
10 Object does not exist

10.4.8 PI service: TMMVTL

Function
With PI service TMMVTL, it is possible to initiate a job to relocate a tool from the PLC. After
an error-free "PI Start," the tool management performs an empty location search in the target
magazine for the tool on the defined source location. Subsequently the PLC receives a job
for relocating the tool (user interface DB41xx.DBB0).

Parameter assignment
Starting program instance services in the NCK area:

PI service Address Signal Valid values

Job DB1200.DBX4000.0 Start 0/1
DB1200.DBB4001 PI index 5
Parameter DB1200.DBW4004 Tool number 1 ... 31999
(internal T number)
DB1200.DBW4006 Source location number 1 ... 31999
DB1200.DBW4008 Source magazine number 1 ... 31999
DB1200.DBW4010 Target location number -1
DB1200.DBW4012 Target magazine number 1 ... 32000
Result DB1200.DBX5000.0 Job completed 0/1
DB1200.DBX5000.1 Error in job 0/1

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10.4 PLC Program Blocks

The tool can be specified either via a T number or by means of the location and magazine
numbers. The value -1 is entered at unused specification points.
With the parameter, target location number =-1, a search is made in the complete magazine
for an empty location for the tool according to the search strategy that has been selected. If a
target location is specified, then a check is made as to whether the location with the
specified target location number is free and suitable for the particular tool.
For a target magazine number = -1, a search is made in a buffer for the tool corresponding
to the assignment obtained from $TC_MDP2.

Application
Examples:
● When using buffers to return the tool (for example Toolboy and/or shifter), an explicit
empty location search in the magazine may be needed during the asynchronous return
transport. In this case the PLC does not have to note the original location, the PI service
searches for a suitable location.
● A tool is to be moved from a background magazine to the front magazine.

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Tool management
10.5 Example: Loading/unloading

10.5 Example: Loading/unloading

Programming
For loading, tools are placed directly in the magazine or the spindle; for unloading, they are
removed directly from the magazine. Normally, a single acknowledgment from the operator
or the PLC user program (tool holder is closed again) is sufficient as a message that the
process is complete. There is no need to configure a transfer step. The total
acknowledgment can be set in DB40xx.DBX0.0.
Acknowledgment to tool management:

Acknowledgment Acknowledgment bit Transfer step new Transfer step old Status
step tool tool
xxx DB4000.DBX0.0 -- -- (99)

Figure 10-2 Programming in PLC user program

Loading procedures using handling systems or transporting the tool from the spindle into the
magazine can be performed using further asynchronous messages.
Different loading sequences are described below:

Loading via the spindle with preselection of a magazine location

You can create a new tool directly on the chosen free magazine location or, using the "load"
dialog, move a tool from the tool list, which is not located in the magazine, to a magazine
location.
1. A job from the tool management is always output at the interface for the loading point.
You must acknowledge this job.
2. Then move this tool, which is not yet positioned in the magazine, into the spindle with Txx
M6 or via an asynchronous transfer.
3. Then manually place the tool into the spindle and deposit it in the magazine with T0 M6.
The procedure is always possible irrespective of whether manual tools are allowed. If
manual tools are permitted, this sequence of operations must always be observed when
loading via the spindle.
The tools can be oversized or fixed-location coded.

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10.5 Example: Loading/unloading

Loading via the spindle without preselection of a magazine location

You can create a new tool directly on the spindle or, using the "load" dialog, move a tool
from the tool list, which is not located in the magazine, to the spindle.
1. A job from the tool management is always output at the interface for the loading point.
You must acknowledge this job.
2. Then manually place the tool into the spindle and deposit it in the magazine with T0 M6.
A free location is selected by the tool management in which the tool can be deposited.
This sequence is only possible if the manual tools function is not set MD22562:
$MC_TOOL_CHANGE_ERROR_MODE Bit 1=0 (default setting).
The tools can be oversized or fixed-location coded.

Loading directly into the magazine

Position the relevant magazine location next to the loading position. You can create a new
tool directly on the chosen free magazine location or, using the "load" dialog, move a tool
from the tool list, which is not located in the magazine, to the selected magazine location.
1. A job from the tool management is always output at the interface for the loading point.
You must acknowledge this job.
2. Now place the tool in the magazine.
This sequence is not subject to any restrictions or constraints.

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Tool management
10.6 Example: Change manual tools

10.6 Example: Change manual tools

Programming
In MD22562: $MC_TOOL_CHANGE_ERROR_MODE Bit 1=1, additional tools without
magazine allocation have been selected by the NC part program. The selected tool must be
inserted in the machine manually and removed again manually after machining ("manual
tools").
The operator must ensure that the data block for the tool on the spindle is in the NCK, or that
he/she puts the appropriate tool onto the spindle for the data block stored in the NCK.

Note
The responsibility is on the user to comply with the safety regulations via the PLC user
program.

The PLC user program is informed with DB43xx.DBX1.5 and DBX1.6 whether a manual tool
is involved in a tool change job. With alarm 17212: "Channel %1, Manual tool %2, Duplo No.
%3, Load to toolholder %4" or Alarm 17214. "Remove manual tool from spindle/tool holder,"
the operator is requested to execute the tool change.
The alarms are reset after a tool change by the acknowledgment from the PLC.

Starting position 1
The manual tool in the spindle should be exchanged for another manual tool
Job from tool management to the PLC user program (tool change):
DB4300.DBX0.0, DBX1.2, DBX1.5 and DBX1.6 ("Prepare tool change")

DB43xx.DBW6 Source magazine number 9999

DB43xx.DBW8 Source location number 1
DB43xx.DBW10 Target magazine number 9999
DB43xx.DBW12 Target location number 1

Acknowledgment "Prepare tool change":

Acknowledgment Acknowledgment bit Transfer step for Transfer step for Status
step the new tool the old tool
xxx DB4200.DBXx.x 0 0 1

Displayed on the interface:

DB4300.DBX0.0 /1.1, DBX1.5 and DBX1.6 ("Execute")

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10.6 Example: Change manual tools

The job remains otherwise unchanged, the tools are still at the starting positions.
An intermediate step can be inserted for acknowledging the removal of the old tool:
Synchronous acknowledgment: The tool is no longer in the spindle:

Transfer step From to Comment

Magazine Loca- Magazine Loca-
tion tion
6 9998 1 9999 1 Tool removed from the spindle
DB9900.DBW40

Acknowledgment Acknowledgment bit Transfer step for Transfer step for Status
step the new tool the old tool
xxx DB4200.DBXx.x 0 6 105

After intermediate acknowledgment of the empty spindle and insertion of the new tool in the
spindle, the tool change is terminated with a total acknowledgment:

Acknowledgment Acknowledgment bit Transfer step for Transfer step for Status
step the new tool the old tool
DB4200.DBX0.0 (99)

Starting position 2
A manual tool is in the spindle and is to be replaced by a tool from the magazine
Job from tool management to the PLC user program (tool change):
DB4300.DBX0.0, DBX1.2 and DBX1.6 ("Prepare tool change")

DB43xx.DBW6 Source magazine number 1

DB43xx.DBW8 Source location number 6
DB43xx.DBW10 Target magazine number 9999
DB43xx.DBW12 Target location number 1

Acknowledgment "Prepare tool change":

Acknowl- Acknowledgment bit Transfer step for the Transfer step for the Status
edgment step new tool old tool
xxx DB4200.DBXx.x 0 0 1

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Tool management
10.6 Example: Change manual tools

Displayed on the interface:

DB4300.DBX0.0 /1.1 and 1.6 ("Execute tool change")
The job remains otherwise unchanged, the tools are still at the starting positions.
Synchronous acknowledgment: The old tool is no longer in the spindle:

Transfer step From to Comment

Magazine Loca- Magazine Loca-
tion tion
6 9998 1 9999 1 Asynchronous message, unload
DB9900.DBW40 the tool from the spindle

Acknowl- Acknowledgment bit Transfer step for the Transfer step for the Status
edgment step new tool old tool
xxx DB4200.DBXx.x 0 6 105

The spindle is now empty, the old tool is outside the magazine.
Next step: Synchronous acknowledgment, new tool to gripper 1

Transfer step of to Comment

Magazine Loca- Magazine Loca-
tion tion
3 0 1 9998 2 New tool to gripper 1
DB9900.DBW16

Acknowl- Acknowledgment bit Transfer step for the Transfer step for the Status
edgment step new tool old tool
xxx DB4200.DBXx.x 3 0 105

The job is unchanged.

Next step: Synchronous acknowledgment, new tool from gripper 1 to spindle:

Transfer step of to Comment

Magazine Loca- Magazine Loca-
tion tion
4 9998 2 9998 1 New tool from gripper 1 to spindle
DB9900.DBW24

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10.6 Example: Change manual tools

Acknowl- Acknowledgment bit Transfer step for the Transfer step for the Status
edgment step new tool old tool
xxx DB4200.DBXx.x 4 0 105

This completes the tool movement.

End acknowledgment:

Acknowl- Acknowledgment bit Transfer step for the Transfer step for the Status
edgment step new tool old tool
xxx DB4200.DBXx.x 0 0 1

The step New tool from gripper 1 to spindle can be omitted and replaced by a total
acknowledgment. This also informs the tool management that all tools are in their target
positions.

Acknowl- Acknowledgment bit Transfer step for the Transfer step for the Status
edgment step new tool old tool
DB4200.DBX0.0 (99)

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Tool management
10.7 Application example for turning machine

10.7 Application example for turning machine

10.7.1 Example: Turning machine with revolver magazine (MAGKONF_MPF)

Example file
You can find the program for configuring the magazine in the Toolbox.
The program can be read into the control and should be adjusted for the specific machine
concerned.

Configuration

0DJD]LQH UHYROYHU
7RROKROGHU 

6SLQGOH &KDQJLQJSRLQW


/RDGDQGXQORDG 


1 ... 4 Transfer steps

Figure 10-3 Turning machine with revolver magazine

Description of the program

To start with, all the old magazine definitions and tools are deleted. As the program
sequence continues, all magazines and buffers are newly created and assigned by writing
the magazine parameters.
Search strategies for tools and magazine locations can be defined in N70.
For revolver magazines it is advisable to define all locations as fixed-location coded. For
magazine type 3 N320 $TC_MAP3[NUM_MAG] = 81 (Bit6 = 1) is set.
The chain magazine locations are set up from N430 to N500. Magazine location type = 0
means that the magazine location can be loaded with tools of different location types.
The buffers are set up from N520 onwards.
From N920, the buffers are assigned to the spindle / tool holder and the magazine.
After the magazine configuration program has finished running, restart the NC using (NCK
reset).

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10.7 Application example for turning machine

See also
You will find a precise description of the parameters used in the Tool Management Function
Manual of SINUMERIK 840D sl.

Example MAG_CONF_MPF
1. Plant configuration:
– 1 revolver magazine with 8 locations (can be set up in N40)
– 1 loading point
– 3 buffer locations (can be set up in N50, assignments from N540)
2. Part program:

;MAG_CONF_MPF
N10 def int NUM_MAG,MAG_TYPE, LOCATIONS,
PLACE, NUM_BUFFER, NUM_LOAD, PLACE_SEARCH
;
N20 NUM_MAG = 1 ;Number of the magazine
N30 MAG_TYPE = 3 ;Magazine type (1: chain,
3: revolver, 5: box magazine)
N40 LOCATIONS = 8 ;Number of magazine locations
N50 NUM_BUFFER = 1 ;Number of buffers (spindle,
gripper)
N60 NUM_LOAD = 1 ; Number of loading points
N70 PLACE_SEARCH = 257 ; Type of search strategy
;= 257 Bit13=0 no exchange of the old tool on the location of the new tool
;Setting for pickup magazine
;=12289 Bit13=1 exchange old tool on the location of the new tool
;Setting for chain magazine
N80;
N90;
;Check parameters
N100 STOPRE
N110 if ((NUM_MAG==0)or(LOCATIONS==0))
N120 Err1:STOPRE
N130 MSG("Wrong Parameter --> Cancel")
N140 G04 F4
N150 STOPRE
N160 M0
N170 GOTOB Err1
N180 endif
N190; Magazine configuration
N200;
N210;

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10.7 Application example for turning machine

N220; Delete old data when magazine 1 is set up

N230 if NUM_MAG ==1
N240 $TC_MAP1[0]=0 ; Delete magazine
N250 $TC_DP1[0,0]=0 ; Delete Tools
N260 STOPRE
N270 endif
; Configuration
;
N280 $TC_MAMP2= PLACE_SEARCH ; Type of search strategy
;
; Magazine
; Set up magazine
N290 $TC_MAP1[NUM_MAG]= MAG_TYPE
N300 $TC_MAP2[NUM_MAG]="MAGAZINE"<<NUM_MAG
N310 if MAG_TYPE == 3
N320 $TC_MAP3[NUM_MAG]=81 ; Magazine status, all locations
fixed-location coded for revolver
magazine
N330 else
N340 $TC_MAP3[NUM_MAG]=17 ; Magazine status
N350 endif
N360 $TC_MAP4[NUM_MAG]=-1
N370 $TC_MAP5[NUM_MAG]=-1
N380 $TC_MAP6[NUM_MAG]=1 ; Number of lines in magazine
N390 $TC_MAP8[NUM_MAG]=0
N400 $TC_MAP9[NUM_MAG]=0
N410 $TC_MAP7[NUM_MAG]=LOCATIONS ; Number of magazine locations
N420 $TC_MAP10[NUM_MAG]=PLACE_SEARCH
;
; Magazine locations
N430 for PLACE=1 to LOCATIONS
N440 STOPRE
N450 $TC_MPP1[NUM_MAG,PLACE]=1 ; Location type
N460 $TC_MPP2[NUM_MAG,PLACE]=0 ; Location type, 0 compatible with
every tool location type
N470 $TC_MPP3[NUM_MAG,PLACE]=1 ; Consider adjacent location On (Off
would be 0)
N480 $TC_MPP4[NUM_MAG,PLACE]=2 ; Location status
N490 $TC_MPP5[NUM_MAG,PLACE]=PLACE ; Location type index
N500 endfor
N510 STOPRE
;
N520; Definition of buffer magazine (always number 9998)
;

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10.7 Application example for turning machine

N530 $TC_MAP1[9998]=7 ; Magazine type 7: Buffer

N540 $TC_MAP2[9998]="BUFFER"<<NUM_MAG
N550 $TC_MAP3[9998]=17 ; Magazine status
N560 $TC_MAP6[9998]=1 ; Number of lines
N570 $TC_MAP7[9998]=NUM_BUFFER ; Number of locations
;
; Locations in the buffer
;Spindle
N580 $TC_MPP1[9998,1]=2 ; Location type (here spindle)
N590 $TC_MPP2[9998,1]=0 ; Location type (here always 0)
N600 $TC_MPP3[9998,1]=0 ; Consider adjacent location Off
N610 $TC_MPP4[9998,1]=2 ; Location status
N620 $TC_MPP5[9998,1]=1 ; Location type index
;
N630; Gripper
N640 FOR PLACE=2 to NUM_BUFFER
N650 STOPRE
N660 $TC_MPP1[9998,PLACE]=3 ;(here gripper)
N670 $TC_MPP2[9998,PLACE]=0 ;(here always 0)
N680 $TC_MPP3[9998,PLACE]=0 ; Consider adjacent location Off
N690 $TC_MPP4[9998,PLACE]=2 ; Location status
N700 $TC_MPP5[9998,PLACE]=PLACE ; Location type index
N710 endfor
N720 STOPRE
;
;
N730; Definition of loading magazine (always number 9999)
;
N740 $TC_MAP1[9999]=9 ; Magazine type 9: Loading magazine
N750 $TC_MAP2[9999]="LOADING
MAGAZINE"<<NUM_MAG
N760 $TC_MAP3[9999]=17 ; Magazine status
N770 $TC_MAP4[9999]=-1
N780 $TC_MAP5[9999]=-1
N790 $TC_MAP6[9999]=1 ; Number of lines
N800 $TC_MAP7[9999]=NUM_LOAD ; Number of locations
N810 STOPRE;
;
N820; Loading magazine locations
;
N830 for PLACE=1 to NUM_LOAD
N840 STOPRE
N850 $TC_MPP1[9999,PLACE]=7 ; Location type Loading point
N860 $TC_MPP2[9999,PLACE]=0 ; Location type (here always 0)

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10.7 Application example for turning machine

N870 $TC_MPP3[9999,PLACE]=0 ; Consider adjacent location Off

N880 $TC_MPP4[9999,PLACE]=2 ; Location status
N890 $TC_MPP5[9999,PLACE]=PLACE ; Location type index
N900 endfor
N910 STOPRE
;
;
N920; Offsets (clearances) ; Clearances to magazine
;
; Buffer
N930 for PLACE=1 to NUM_BUFFER
N940 $TC_MDP2[1,PLACE]=0
N950 endfor
N960 STOPRE
;
;Loading points
N970 for PLACE=1 to NUM_LOAD
N980 stopre
N990 $TC_MDP1[1,PLACE]=0
N1000 endfor

N1010 M30 ; End

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Display in operating software

Figure 10-4 Turning machine tool list

10.7.2 Example: Acknowledgment steps (turning machine)

Acknowledgment steps
Generally, the mechanical sequences on a turning machine are simpler than those for a
milling machine. In the configuration described in the previous chapter without additional
buffer, tool changes can be acknowledged after the mechanical movements without transfer
steps. The PLC user program must detect incoming jobs in the job interfaces and execute
the mechanical movements.
Total acknowledgment to tool management:

Acknowledgment Acknowledgment bit Transfer step new Transfer step old Status
step tool tool
-- DB4000.DBX0.0 -- -- (99)
-- DB4200.DBX0.0 -- -- (99)

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Tool management
10.7 Application example for turning machine

Figure 10-5 Programming in PLC user program

An asynchronous message can be used for magazine movements without a job from the tool
management.
Acknowledgment to tool management:

Acknowledgment Acknowledgment bit Transfer step new Transfer step old Status
step tool tool
xxx DB4000.DBXx.x 101 0 204

Transfer step Source Objective Comment

Maga- Location Maga- Location
zine zine
101 1 n 9998 1 The variable location in Magazine
DB9901.DBW0 1 is positioned at the changing
point to the spindle.

n is the actual location number (n ≠ 0) to be entered by the PLC user program in the variable transfer
table.

10.7.3 Example: Tool change cycle for turning machine

Transfer variables
With MD10717: $MN_T_NO_FCT_CYCLE_NAME (name of cycle to be executed instead of
the T function, e.g. "TCHANGE"), you can set that a cycle is run when the T command is
called. The cycle is run through at every T call, irrespective of whether a new tool or the
already active tool is called. The position of the revolver can be set on the programmed tool
in this cycle (POSM). This is necessary when the revolver has been positioned manually
after a tool selection and the tool has not been deselected. In this case, the NC does not
issue a new job for tool change at the interface.

Sample program
Prerequisite is that the tool management has been informed of each magazine movement.
The example has been created for machine data with the turning technology default setting.
The "Spare tools for tool management" option is not active.

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10.7 Application example for turning machine

Transfer variables of the T replacement cycle:

Tag Description
$SC_T T number of the tool (numerical)
$SC_T_Prog Bool variable that shows whether a T word is available in $C_T.
$C_TS Identifier for tool (string)
$C_TS_Prog Bool variable that shows whether an identifier is available in $C_TS.
$C_TE Address extension of the T word
$C_D Programmed D number
$C_D_Prog Bool variable that shows whether an offset number is available in $C_D.
$C_DL Programmed additive/setup offset
$C_DL_Prog Bool variable that shows whether an offset number is available in $C_DL.

In the following example, a job for positioning the magazine with POSM is output at the
interface. During the magazine positioning, the block processing of the NC must be
controlled by the PLC user program. In most cases, it is useful to set the load or feed disable
during this time. As soon as the position setpoint specified in the job is reached
(asynchronous message of the magazine position), the job is terminated with total
acknowledgment.

PROC L6 SAVE SBLOF DISPLOF

IF $C_T_PROG==1 ; T is numeric
IF $C_T==0 ; T=0
T=0
ENDIF
IF $C_T>0
IF $C_T<=$TC_MAP7[1] ; Does the magazine location exist?
POSM($C_T) ; Position magazine
ENDIF
T=$C_T ; T programming of location number
ENDIF
ENDIF

IF $C_TS_PROG==1 ; T is an identifier
_TNO_NEW=GETT($C_TS,1) ; Querying of T number
IF _TNO_NEW>0 ; Does the T number exist?
_TL_NEW=$A_MYMLN[_TNO_NEW] ; Querying of location number
ENDIF
IF _TL_NEW>0 ; Is the tool in the magazine?
POSM(_TL_NEW) ; Position magazine
ENDIF
T=$C_TS ; T programming without address extension
ENDIF
M17

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10.7 Application example for turning machine

See also
The function is available irrespective of tool management and is described in full in: Function
Manual, Basic Functions, "Mode Group, Channel, Program Operation, Reset Behavior (K1)."

10.7.4 Example: Turning machine with counterspindle

Magazine configuration
In the magazine configuration the magazine is assigned twice as many locations as actually
exist, e.g. in the case of revolver with 12 locations, 24 locations are set up. Location 1-12 for
the main spindle, location 13-24 for the counterspindle.
The user program positions the magazine in such a way that, for example, the same position
is approached for location 1 and location 13. So each real magazine location corresponds to
a virtual magazine location for the main spindle and a virtual magazine location for the
counterspindle.

10.7.5 Example: Test for empty buffer

Procedure
Read the T number of a tool in gripper 1 and 2:
1. In the PLC user program, enter the parameters in DB1200.
2. In DB1200.DBX0.0, set the start for reading the location states.
Once the order has been successfully executed, the results are entered starting from
DB1200.DBB3000:

Read variable from the Address Signal Values

NCK
Parameters DB1200.DBW1000 Variables index 9
DB1200.DBW1002 Location number 2
DB1200.DBW1004 Magazine number 9998
DB1201.DBW1000 Variables index 9
DB1201.DBW1002 Location number 3
DB1201.DBW1004 Magazine number 9998
Order DB1200.DBX0.1 Write variable 0
DB1200.DBX0.2 PI service 0
DB1200.DBB1 Number of variables 2
DB1200.DBX0.0 Start →1

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10.7 Application example for turning machine

Read variable from the Address Signal Values

NCK
Result DB1200.DBB2000.0 Order completed 1
DB1200.DBX2000.1 Error in order 0
DB1200.DBX3000.0 Variable is valid 1
DB1200.DBB3001 Access result 0
DB1200.DBW3004 Data from NCK variable n
DB1201.DBX3000.0 Variable is valid 1
DB1201.DBB3001 Access result n
DB1201.DBW3004 Data from NCK variable 0

10.7.6 Example: Transporting a tool from a buffer into the magazine

Procedure
A tool is to be moved from a buffer (for example, of a gripper) into the magazine. The empty
location search for the tool from gripper 1 (magazine 9998, location 2) is executed with PI
Service TMMVTL and an order to relocate the tool is generated.
In the PLC user program, enter the parameters in DB1200, and in DB1200.DBX4000.0, set
the start signal of the PI service.

Start PI Services in the Address Signal Values

NCK area
Parameter DB1200.DBW4004 Tool number 0
DB1200.DBW4006 Source location number 2
DB1200.DBW4008 Source magazine number 9998
DB1201.DBW4010 Target location number -1
DB1201.DBW4012 Target magazine number 1
Job DB1200.DBB4001 PI index 5
DB1200.DBX4000.0 Start →1
Result DB1200.DBB5000.0 Job completed 1
DB1200.DBX5000.1 Error in job 0

DB410x.DBX0.0 delivers an order to relocate the tool from the buffer. The target location in
magazine 1 is in DB4100.DBW12. With it, the PLC user program can execute the necessary
sequence.

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10.7.7 Example: Repeat "Prepare tool change" order

Sequence: Repeat the command

For a milling machine with toolboy and shifter, the asynchronous transfer message and order
can cross:
● The toolboy was acknowledged to the tool management as the target position for the old
tool with the end acknowledgment.
● The part program is continued with the new tool and after a very short time needs the
previous (old) tool once more.
● The tool management generates the next preparation order for the tool change with the
toolboy as the source position for what will then be the new tool.
● At the same time the PLC user program transfered the tool from the toolboy into the
shifter.
● The PLC user progamm communicates the tool movement from the toolboy to the shifter
asynchronously and starts onward transport to the magazine.
● In the next cycle the AWP recognizes the new order to relocate the tool from the toolboy
to the spindle.
But the tool is no longer in the toolboy! The PLC user program must detect such a condition
(monitoring: does toolboy or shifter contain a tool?). It can now cancel the return of the tool
into the magazine. A repeat order (Status 7) can then be requested from the tool
management:
● Meanwhile, the tool management has received the message that the tool is in the shifter.
● It generates a new preparation order with the source position shifter for the new tool.

Note
The acknowledgment to repeat the order "Prepare tool change" may only be issued
before the end acknowledgment of the "Prepare tool change" order!

Acknowledgment to tool management:

Acknowledgment Acknowledgment bit Transfer step new Transfer step old Status
step tool tool
xxx DB4000.DBXx.x 0 0 7

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10.8 Application example for milling machine

10.8 Application example for milling machine

10.8.1 Example: Milling machine with chain magazine and dual gripper
(MAGKONF_EXAMPLE_MPF)

Example file
You can find the program for configuring the magazine in the Toolbox.
The program can be read into the control and should be adjusted for the specific machine
concerned.

Configuration
0DJD]LQH
*ULSSHU


 
6SLQGOH
   

&KDQJLQJSRLQW







*ULSSHU 

0DJD]LQHORDGLQJSRLQW
/RDGDQGXQORDG
PDJD]LQH 

1 ... 11 Transfer steps

Figure 10-6 Milling machine with chain magazine

Description of the buffers and loading points:

Magazine Location Meaning

1 xx Real magazine (chain, plate, box), position xx
9998 1 Spindle
9998 2 Gripper 1
9998 3 Gripper 2
9999 1 Magazine loading point

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Tool management
10.8 Application example for milling machine

Description of the program

To start with, all the old magazine definitions and tools are deleted. As the program
sequence continues, all magazines and buffers are newly created and assigned by writing
the magazine parameters.
Search strategies for tools and magazine locations can be selected in N70. Here it is
determined whether the tool can be placed directly in the new tool location, when changing
out of the spindle. This makes the tool change possible in a single mechanical sequence, so
shorter changeover times can be achieved. This sequence is not possible for pickup
magazines.
The chain magazine locations are set up from N430 to N500. Magazine location type = 0
means that the magazine location can be loaded with tools of different location types.
The buffers are set up from N520 onwards. If additional buffers are available (toolboy,
shifter...), the number should be changed in N50.
Additionally available loading points should be dealt with in the same way in N60.
From N920, the buffers are assigned to the spindle / tool holder and the magazine.
After the magazine configuration program has finished running, restart the NC (NCK reset).

See also
Further information:
● The configuration of a disk-type magazine with fixed-location coding is performed as for
the configuration of a revolver magazine: Example: Turning machine with revolver
magazine (MAGKONF_MPF) (Page 360)
● You will find a precise description of the parameters used in the Tool Management
Function Manual of SINUMERIK 840D sl.

Example MAG_CONF_MPF
1. Plant configuration:
– 1 chain magazine with 8 locations (can be set up in N40)
– 1 loading point
– 3 buffer locations (can be set up in N50, assignments from N540)
2. Part program:

;MAG_CONF_MPF
N10 def int NUM_MAG,MAG_TYPE, LOCATIONS,
PLACE, NUM_BUFFER, NUM_LOAD, PLACE_SEARCH
;
N20 NUM_MAG = 1 ;Number of the magazine
N30 MAG_TYPE = 1 ;Magazine type (1: chain,
3: revolver, 5: box magazine)
N40 LOCATIONS = 8 ;Number of magazine locations

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N50 NUM_BUFFER = 3 ;Number of buffers (spindle, gripper)

N60 NUM_LOAD = 1 ; Number of loading points
N70 PLACE_SEARCH = 12289 ; Type of search strategy
;= 257 Bit13=0 no exchange of the old tool on the location of the new tool
;Setting for pickup magazine
;=12289 Bit13=1 exchange old tool on the location of the new tool
;Setting for chain magazine
N80;
N90;
;Check parameters
N100 STOPRE
N110 if ((NUM_MAG==0)or(LOCATIONS==0))
N120 Err1:STOPRE
N130 MSG("Wrong Parameter --> Cancel")
N140 G04 F4
N150 STOPRE
N160 M0
N170 GOTOB Err1
N180 endif
N190; Magazine configuration
N200;
N210;
N220; Delete old data when magazine 1 is set up
N230 if NUM_MAG ==1
N240 $TC_MAP1[0]=0 ; Delete magazine
N250 $TC_DP1[0,0]=0 ; Delete Tools
N260 STOPRE
N270 endif
; Configuration
;
N280 $TC_MAMP2= PLACE_SEARCH ; Type of search strategy
;
; Magazine
; Set up magazine
N290 $TC_MAP1[NUM_MAG]= MAG_TYPE
N300 $TC_MAP2[NUM_MAG]="MAGAZINE"<<NUM_MAG
N310 if MAG_TYPE == 3
N320 $TC_MAP3[NUM_MAG]=81 ; Magazine status, all locations
fixed-location coded for revolver
magazine
N330 else
N340 $TC_MAP3[NUM_MAG]=17 ; Magazine status
N350 endif
N360 $TC_MAP4[NUM_MAG]=-1

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Tool management
10.8 Application example for milling machine

N370 $TC_MAP5[NUM_MAG]=-1
N380 $TC_MAP6[NUM_MAG]=1 ; Number of lines in magazine
N390 $TC_MAP8[NUM_MAG]=0
N400 $TC_MAP9[NUM_MAG]=0
N410 $TC_MAP7[NUM_MAG]=LOCATIONS ; Number of magazine locations
N420 $TC_MAP10[NUM_MAG]=PLACE_SEARCH
;
; Magazine locations
N430 for PLACE=1 to LOCATIONS
N440 STOPRE
N450 $TC_MPP1[NUM_MAG,PLACE]=1 ; Location type
N460 $TC_MPP2[NUM_MAG,PLACE]=0 ; Location type, 0 compatible with
every tool location type
N470 $TC_MPP3[NUM_MAG,PLACE]=1 ; Consider adjacent location On (Off
would be 0)
N480 $TC_MPP4[NUM_MAG,PLACE]=2 ; Location status
N490 $TC_MPP5[NUM_MAG,PLACE]=PLACE ; Location type index
N500 endfor
N510 STOPRE
;
N520; Definition of buffer magazine (always number 9998)
;
N530 $TC_MAP1[9998]=7 ; Magazine type 7: Buffer
N540 $TC_MAP2[9998]="BUFFER"<<NUM_MAG
N550 $TC_MAP3[9998]=17 ; Magazine status
N560 $TC_MAP6[9998]=1 ; Number of lines
N570 $TC_MAP7[9998]=NUM_BUFFER ; Number of locations
;
; Locations in the buffer
;Spindle
N580 $TC_MPP1[9998,1]=2 ; Location type (here spindle)
N590 $TC_MPP2[9998,1]=0 ; Location type (here always 0)
N600 $TC_MPP3[9998,1]=0 ; Consider adjacent location Off
N610 $TC_MPP4[9998,1]=2 ; Location status
N620 $TC_MPP5[9998,1]=1 ; Location type index
;
N630; Gripper
N640 FOR PLACE=2 to NUM_BUFFER
N650 STOPRE
N660 $TC_MPP1[9998,PLACE]=3 ;(here gripper)
N670 $TC_MPP2[9998,PLACE]=0 ;(here always 0)
N680 $TC_MPP3[9998,PLACE]=0 ; Consider adjacent location Off
N690 $TC_MPP4[9998,PLACE]=2 ; Location status
N700 $TC_MPP5[9998,PLACE]=PLACE ; Location type index

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 Tool management
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N710 endfor
N720 STOPRE
;
;
N730; Definition of loading magazine (always number 9999)
;
N740 $TC_MAP1[9999]=9 ; Magazine type 9: Loading magazine
N750 $TC_MAP2[9999]="LOADING
MAGAZINE"<<NUM_MAG
N760 $TC_MAP3[9999]=17 ; Magazine status
N770 $TC_MAP4[9999]=-1
N780 $TC_MAP5[9999]=-1
N790 $TC_MAP6[9999]=1 ; Number of lines
N800 $TC_MAP7[9999]=NUM_LOAD ; Number of locations
N810 STOPRE;
;
N820; Loading magazine locations
;
N830 for PLACE=1 to NUM_LOAD
N840 STOPRE
N850 $TC_MPP1[9999,PLACE]=7 ; Location type Loading point
N860 $TC_MPP2[9999,PLACE]=0 ; Location type (here always 0)
N870 $TC_MPP3[9999,PLACE]=0 ; Consider adjacent location Off
N880 $TC_MPP4[9999,PLACE]=2 ; Location status
N890 $TC_MPP5[9999,PLACE]=PLACE ; Location type index
N900 endfor
N910 STOPRE
;
;
N920; Offsets (clearances) ; Clearances to magazine
;
; Buffer
N930 for PLACE=1 to NUM_BUFFER
N940 $TC_MDP2[1,PLACE]=0
N950 endfor
N960 STOPRE
;
;Loading points
N970 for PLACE=1 to NUM_LOAD
N980 stopre
N990 $TC_MDP1[1,PLACE]=0
N1000 endfor

N1010 M30 ; End

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Tool management
10.8 Application example for milling machine

Display in operating software

Figure 10-7 Tool list Milling machine

10.8.2 Flow chart: Tool change

Tool change program sequence (PLC)

The sequence described here describes the change between magazine and spindle. The
changing of manual tools as well as loading and unloading are not taken into account. These
sequences are described in:
● Example: Loading/unloading (Page 354)
● Example: Change manual tools (Page 356)
The machine data default setting is selected such that the job for "Prepare tool change" is
triggered with the T command on the interface:
N10 T = "Tool name" M6

The block preprocessing is not interrupted. M6 is used to start the tool change subprogram
(L6) at the same time. As soon as the job for "Prepare tool change" has been acknowledged
and in the tool change subprogram the M code for tool change output has been reached, the
"Execute tool change" job is output to the interface (block splitting).

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10.8 Application example for milling machine

A tool change command (M206) must always precede a prepare tool change command. A
change command without a previous "Prepare tool change" job will not initiate a job from the
tool management.
You will find the expression 1:1 change in the program sequence. This means that the tool
change will be carried out in a single cycle. The tool from the spindle (old tool) will be set
down at the magazine location of the new tool. No additional magazine positioning is
required. In this case, the target location of the old tool in the tool management job is the
same as the source location of the new tool (DB43xx.DBW6 and DBW8 are equal to DBW18
and DBW20).
A 1:1 change is not possible for:
● Tools with different location types
● Different tool sizes
● Fixed-location tools
By programming T0 in the NC program, a tool change is initiated without a new tool. Only the
spindle tool is transported to the magazine (empty the spindle).
① ... ⑭ refer to the steps in the flow chart below.
You can see the different acknowledgment options from the steps. Job-related
acknowledgments and asynchronous messages are used.
Please take the transfer steps used from the table in Section Example: Acknowledgment
steps (milling machine) (Page 386)

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Tool management
10.8 Application example for milling machine

"Tool change" flow chart

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1R 
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/RFDWLRQIURPWKHROGWRROWR
WKHFKDQJLQJSRLQW

<HV


-RESUHSDUHWRROFKDQJH
0DJD]LQHSRVLWLRQLQJ DFNQRZOHGJH
/RFDWLRQIURPWKHQHZWRROWR
WKHFKDQJLQJSRLQW


2OGWRROIURPVSLQGOHWR
-RESHUIRUPWRRO JULSSHU
FKDQJH


2OGWRROIURPJULSSHUWR
 PDJD]LQH
1R
FKDQJHUHTXHVWHG"


<HV <HV
7"

2OGWRROIURPWKHVSLQGOHWR
JULSSHUDQGQHZWRROIURPWKH 1R
PDJD]LQHWRJULSSHU

0DJD]LQHSRVLWLRQLQJ
 /RFDWLRQIURPWKHQHZWRROWR
WKHFKDQJLQJSRLQW
2OGWRROIURPJULSSHUWR
PDJD]LQHDQGQHZWRROIURP
JULSSHUWRVSLQGOH

1HZWRROIURPPDJD]LQHWR
 JULSSHU
(QGDFNQRZOHGJPHQW


1HZWRROIURPJULSSHUWR
VSLQGOH

1: 1 change: The old tool is deposited in the location of the new tool.

Figure 10-8 Flow chart

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 Tool management
10.8 Application example for milling machine

Description of the Procedure

● NC program:
T command or T command with simultaneous tool change call (M6)
● Interface signals:
Job from TM: DB43xx.DBX0.0 (job bit) and
DB43xx.DBB1 (command bits): Prepare change (DB43xx.DBX1.2)
● Magazine and location number of the tools to be moved:
DB43xx.DBW6 to DBW20: Source location of the new tool, target location of the old tool

Step 1: 1:1 change requested

Request: Source location of the new tool == Target location of the old tool, Normal case:
There is a tool in the tool holder and a new tool is being requested. Both tools have the same
location type and the same tool size in the magazine list, the tools are not fixed-location
coded.
The old tool is set down on the magazine location of the new tool, in a direct exchange (1:1
change). If there is no old tool in the tool holder (DB4300.DBX1.4), the same sequence takes
place. In this case, the magazine positions the new tool to the changing point.
→ continue with Step 2
Request: Source location of new tool >< Target location of old tool, Special cases:
The TM is informed by DB43xx.DBX1.3 whether the active tool from the tool holder should
be removed (T0). In this case, the magazine positions the storage location of the old tool
(that is currently in the spindle) to the changing point.
The magazine location for the old tool is also positioned to the changing point if the old tool
cannot be stored on the new tool location (1:1 change not possible). The cause could be
different location types or tool sizes, or that a fixed-location coded tool is involved. In this
case, the tool change is carried out in two steps. First the old tool in the magazine is set
down and then the new tool is transported to the spindle.
→ continue with Step 3

Step 2: Position magazine, location from new tool to changing point.

← Previous step: Step 1
For example, the magazine movement can be executed via an NC rotary axis controlled by a
PLC. The movement should be notified to the tool management. The magazine position is
thus updated at the user interface, in the views of the tool and magazine lists.
The target position is read from DB4300.DBW8 (location number for new tool – source) and
written to DB9901.DBW2 (transfer step 101). If there is magazine coincidence at the target
position, the step is acknowledged asynchronously:

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Tool management
10.8 Application example for milling machine

Acknowl- Acknowledgment bit Transfer step new Transfer step old Status
edgment tool tool
step
4 DB4200.DBX0.4 101 0 204

Acknowledgment to TM:

Transfer step From to Comment

Magazine Loca- Magazine Loca-
tion tion
101 1 n 9998 1 The variable location in magazine 1
DB9901.DBW0 is positioned at the changing point to
the spindle.

n: is here the actual location number (n ≠ 0) to be entered by the PLC user program in the variable
transfer table.

→ continue with Step 4

Step 3: Positioning the magazine; location from the old tool to the changing point.
← Previous step: Step 1
Same as Step 2, however, the magazine target location is obtained from DB4300.DBW20
(location number for old tool - target).
Acknowledgment to TM:

Acknowl- Acknowledgment bit Transfer step new Transfer step old Status
edgment tool tool
step
4 DB4200.DBX0.4 101 0 204

Transfer step from to Comment

Magazine Loca- Magazine Loca-
tion tion
101 1 n 9998 1 The variable location in magazine 1
DB9901.DBW0 is positioned at the changing point to
the spindle.

n: is here the actual location number (n ≠ 0) to be entered by the PLC user program in the variable
transfer table.

→ continue with Step 4

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Step 4: Acknowledge prepare tool change job

← Previous step: Step 2 or Step 3
With this, the preparation for the tool change is complete for many systems.
Acknowledgment to TM:

Acknowl- Acknowledgment bit Transfer step new Transfer step old Status
edgment tool tool
step
1 DB4200.DBX0.1 0 0 1

→ continue with Step 5

● NC program:
M206 initiates the job for execute tool change
● Interface signals:
Job from TM: DB43xx.DBX0.0 (job bit)
DB43xx.DBB1 (command bits): Execute change (DB43xx.DBX1.1)
● Magazine and location number of the tools to be moved:
DB43xx.DBW6 to DBW20: Source location of the new tool, target location of the old tool

Step 5: 1:1 change requested

← Previous step: No previous step, entry point in the sequence for "Execute tool change" job
Similarly to Step 1, it is checked whether a direct change or a change in two steps is to be
executed:
● 1:1 change possible: → continue with Step 6
● 1:1 change not possible: → continue with Step 9

Step 6: Old tool from the spindle to gripper 2 and new tool from the magazine to gripper 1
← Previous step: Step 5
The PLC program controls the machine functions with which the gripper movements, tool
clamping, etc. are performed. As soon as the mechanical movements are completed and
acknowledged in the PLC user program, the tool movements are acknowledged to the tool
management.
Acknowledgment to TM:

Acknowl- Acknowledgment bit Transfer step new Transfer step old Status
edgment tool tool
step
5 DB4200.DBX0.5 1 2 105

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Tool management
10.8 Application example for milling machine

Transfer step From to Comment

Magazine Loca- Magazine Loca-
tion tion
1 0 1 9998 2 New tool from magazine to gripper 1
DB9900.DBW0 Step 6 or Step 13
2 9998 1 9998 3 Old tool from spindle to gripper 2
DB9900.DBW8 Step 6 or Step 9

→ continue with Step 7.

Step 7: Old tool from gripper 2 to magazine and new tool from gripper 1 to spindle
← Previous step: Step 6
The PLC program controls the machine functions for the gripper movements, tool clamping,
etc. As soon as the mechanical movements are completed and acknowledged in the PLC
user program, the tool movements are acknowledged to the tool management.
Acknowledgment to tool management:

Acknowl- Acknowledgment bit Transfer step new Transfer step old Status
edgment step tool tool
7 DB4200.DBX0.7 3 4 105

Transfer step From to Comment

Magazine Loca- Magazine Loca-
tion tion
3 9998 2 9998 1 New tool from gripper 1 to spindle
DB9900.DBW16 Step 7 or Step 14
4 9998 3 0 2 Old tool from gripper 2 to magazine
DB9900.DBW24 Step 7 or Step 10

→ continue with Step 8

Step 8: End acknowledgment

← Previous step: Step 7 or Step 14
End acknowledgment takes place with tool changeover in the initial setting, or in a state
where the machine can continue machining. Here it is possible that there are still mechanical
movements to be executed before the tool change can be completed.

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 Tool management
10.8 Application example for milling machine

Acknowledgment to tool management:

Acknowl- Acknowledgment bit Transfer step new Transfer step old Status
edgment step tool tool
1 DB4200.DBX0.1 0 0 1

→ continue with Step 9

Step 9: Old tool from spindle to gripper 2

← Previous step: Step 5
The PLC program controls the machine functions with which the gripper movements, tool
clamping, etc. are performed. As soon as the mechanical movements are completed and
acknowledged in the PLC user program, the tool movements are acknowledged to the tool
management.
Acknowledgment to tool management:

Acknowl- Acknowledgment bit Transfer step new Transfer step old Status
edgment step tool tool
8 DB4200.DBX1.0 0 2 105

Transfer step From to Comment

Magazine Loca- Magazine Loca-
tion tion
2 9998 1 9998 3 Old tool from spindle to gripper 2
DB9900.DBW8 Step 6 or Step 9

→ continue with Step 10

Step 10: Old tool from gripper 2 to magazine

← Previous step: Step 9
The PLC program controls the machine functions with which the gripper movements, tool
clamping, etc. are performed. As soon as the mechanical movements are completed and
acknowledged in the PLC user program, the tool movements are acknowledged to the tool
management.

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Tool management
10.8 Application example for milling machine

Acknowledgment to tool management:

Acknowl- Acknowledgment bit Transfer step new Transfer step old Status
edgment step tool tool
9 DB4200.DBX1.1 0 4 105

Transfer step From to Comment

Magazine Loca- Magazine Loca-
tion tion
4 9998 3 0 2 Old tool from gripper 2 to magazine
DB9900.DBW24 Step 7 or Step 10

→ continue with Step 11

Step 11: T0 ?
← Previous step: Step 10
Request: Is T0 set in the tool change job?
DB43xx.DBX1.3
If only the tool holder should be emptied, the tool change can be completed:
→ continue with Step 8
Do you want to place a new tool in the tool holder?
→ continue with Step 12

Step 12: Magazine position location from new tool to changing point
← Previous step: Step 11
Sequence as in Step 2
Acknowledgment to tool management:

Acknowl- Acknowledgment bit Transfer step new Transfer step old Status
edgment tool tool
step
4 DB4200.DBX0.4 101 0 204

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 Tool management
10.8 Application example for milling machine

Transfer step From to Comment

Magazine Loca- Magazine Loca-
tion tion
101 1 n 9998 1 The variable location in magazine 1
DB9901.DBW0 is positioned at the changing point to
the spindle.

n: is here the actual location number (n ≠ 0) to be entered by the PLC user program in the variable
transfer table.

→ continue with Step 13

Step 13: New tool from magazine to gripper 1

← Previous step: Step 12
The PLC program controls the machine functions used to execute gripper movements, tool
clamping, etc.
Acknowledgment to tool management:

Acknowl- Acknowledgment bit Transfer step new Transfer step old Status
edgment step tool tool
10 DB4200.DBX1.2 1 0 105

Transfer step From to Comment

Magazine Loca- Magazine Loca-
tion tion
1 0 1 9998 2 New tool from magazine to gripper 1
DB9900.DBW0 Step 6 or Step 13

→ continue with Step 14

Step 14: New tool from gripper 1 to spindle

← Previous step: Step 13
The PLC user program controls the machine functions with which the gripper movements,
tool clamping, etc. are performed. As soon as the mechanical movements are completed
and acknowledged in the PLC user program, the tool movements are acknowledged to the
tool management.
The tool change can be ended.

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Tool management
10.8 Application example for milling machine

Acknowledgment to tool management:

Acknowl- Acknowledgment bit Transfer step new Transfer step old Status
edgment step tool tool
11 DB4200.DBX1.3 3 0 105

Transfer step From to Comment

Magazine Loca- Magazine Loca-
tion tion
3 9998 2 9998 1 New tool from gripper 1 to spindle
DB9900.DBW16 Step 7 or Step 14

→ continue with Step 8

10.8.3 Example: Acknowledgment steps (milling machine)

Constant transfer step table

Transfer step of to Comment

Magazine Loca- Magazine Loca-
tion tion
1 0 1 9998 2 New tool from magazine to gripper
DB9900.DBW0 1
Step ⑥ or ⑬
2 9998 9998 3
DB9900.DBW8 Step ⑥ or ⑨
3 9998 9998 1
DB9900.DBW16 Step ⑦ or ⑩
4 9998 3 0 2
DB9900.DBW24 Step ⑦ or ⑭
5 0 2 9998 1 Storage location of the old tool
DB9900.DBW32
6 0 1 9998 1 Magazine location with the new tool
DB9900.DBW40 to the changing point
Step ② or ⑫
7 -- -- -- --
DB9900.DBW48

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Variable transfer step table

Transfer step of to Comment

Magazine Loca- Magazine Loca-
tion tion
101 1 n 9998 1 The variable location in Magazine 1
DB9901.DBW0 is positioned at the changing point
to the spindle.
102 -- -- -- --
DB9901.DBW8

n: here is the actual location number (n ≠ 0) to be entered by the PLC user program in the variable
transfer table.

Acknowledgment step table

Acknowledgment Transfer step Acknowl- Comment

step edgment
Old tool New tool
status
1 0 0 1 End acknowledgment,
DB9902.DBW0 Step ④ and ⑧
2 0 0 3 Cancel order
DB9902.DBW4
3 0 0 105 Intermediate acknowledgment
DB9902.DBW8 for subsequent order, Step ④
4 101 0 204 Variable magazine location to
DB9902.DBW12 changing point
5 1 2 105 Intermediate acknowledgment
DB9902.DBW16 Step ⑥
6 0 5 105 Intermediate acknowledgment
DB9902.DBW20 Step ③
7 3 4 105 Intermediate acknowledgment
DB9902.DBW24 Step ⑦
8 0 2 105 Intermediate acknowledgment
DB9902.DBW28 Step ⑨
9 0 4 105 Intermediate acknowledgment
DB9902.DBW32 Step ⑩
10 1 0 105 Intermediate acknowledgment
DB9902.DBW36 Step ⑬
11 3 0 105 Intermediate acknowledgment
DB9902.DBW40 Step ⑭
12 -- -- --
DB9902.DBW44

Note: The step numbers ① ... ⑭ refer to the flow chart in Chapter Flow chart: Tool change
(Page 376)

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Tool management
10.8 Application example for milling machine

10.8.4 Example: Tool change cycle for milling machine

Sample program

PROC L6 SAVE DISPLOF

;----------------------------------------------------------------
; Example of a tool change cycle for machine manufacturers
;----------------------------------------------------------------
DEF INT _WZ_IN_SP,_WZ_VOR
DEF REAL _SPP= ... ; spindle position
;
IF(NOT $P_SEARCH) ; if no block search
_WZ_IN_SP=$TC_MPP6[9998,1] ; tool in spindle
GETSELT(_WZ_VOR) ; previously selected tool
;
IF(_WZ_IN_SP<>_WZ_VOR) ; if another tool
SPOS=_SPP ; position spindle
G0 ; approach tool change position:
G75 Z=0
WAITS(1)
ENDIF
ELSE
ENDIF
;
; Load tool: Tool management and PLC
M206
M17
;----------------------------------------------------------------
; END
;----------------------------------------------------------------

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Easy Archive 11
11.1 Backing up and archiving data

Overview
In line with the data segregation in data classes, an archive can be created separately for
each data area and for each data class.
The data class "System" is an exception. This data is set permanently and becomes
effective at the first installation or a default initialization. For this reason, data backup of
system data is unnecessary, as this data class contains no data created during
commissioning or during the machine run-time.
A system archive delivered by Siemens can, for example, contain a new NCK version or an
integrated HMI version or also a cycle hotfix.

NOTICE
Protection of the system data
All system data and data contained in the "System" data class in the HMI, NCK, PLC and
drive areas may not be affected.
System data cannot be changed through operation, by writing from a part program,
subroutine or cycle and by importing an archive.
When you load user data with a USB FlashDrive, the data volume must not be larger than
4 MB!

Identification of archives
Every archive contains the following identifiers:
● Data class: M, I, U
● Type of control: 828D TE or 828D ME
● Time stamp: Date and time when the archive was created
● Version designation: Software version with which this archive was created
● Serial number of the system CompactFlash card
These markings allow filters to be set when reading in, determining which archive may be
read in to which control variant, depending on the data class and the software version.

Compatibility of the data

SINUMERIK 802D sl PLC archives can be transferred to a SINUMERIK 828D control variant
using the Programming Tool.

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Easy Archive
11.2 Saving data in archives

11.2 Saving data in archives

When should you back up the start-up data?

The following times are recommended for performing a data backup:
● After commissioning
● After changing machine-specific settings
● After replacing a hardware component
● Before a software upgrade

Backing up and restoring data

To back up and restore data, in the "Start-up" operating area press the:
● "Save data" softkey for an internal data backup of the entire memory
● "Startup archives" softkey to
– Create a commissioning archive
– Read-in a commissioning archive

Data areas
The following data areas are backed up in a commissioning archive:

Components Data
NC data  Compile cycles
 Standard and user cycles
 Definitions and macros
 Machine data
 Setting data
 Option data
 Global (GUD) and local (LUD) user data
 Tool and magazine data
 Protection zone data
 R parameters
 Work offsets
 Compensation data
 Part programs
 Subroutines
 Workpieces

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 Easy Archive
11.2 Saving data in archives

Components Data
PLC data  Main program (MAIN)
 Data blocks (DBs)
 User program
Drive data Binary format or ASCII format
HMI data  Texts: PLC alarm texts, cycle alarm texts, part program message texts
from the machine manufacturer
 Templates: Individual templates, workpiece templates
 Applications: Software applications, for example of the machine
manufacturer
 Configurations
 Configuration: Configurations, incl. display machine data
 Help: Online help files
 Version data
 Reports: For example, action log, screenshots
 Program lists
 Dictionaries: For simplified Chinese and traditional Chinese (IME)
 Data backups: Channel data, axis data, etc. in ASCII format
 Programs on a local drive: Programs that are in the user memory area of
the CompactFlash card.

Note
The commissioning archives are saved taking into account the data classes (ARD file type).
The drive data is saved as binary data which cannot be edited.

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Easy Archive
11.2 Saving data in archives

Memory areas for archives

Archives can be stored in the following memory areas:
● On the user CompactFlash card: in any directory
● On the CompactFlash card at:
/user/sinumerik/data/archive

or:
/oem/sinumerik/data/archive

● On a USB FlashDrive

NOTICE
USB FlashDrives
USB flash drives are not suitable as persistent memory media.

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 Easy Archive
11.3 This is how you create a commissioning archive

11.3 This is how you create a commissioning archive

Overview
Control components can be saved individually or jointly. Creating a separate commissioning
archive for each component is recommended, so that the files can be read in again
independently of each other.

Precondition
The access level "Service" is required.

Creating a commissioning archive

Procedure:
1. Select the "Startup" operating area.
2. Press the menu forward key and then the "Startup archive" softkey.
The "Startup" window is opened.
3. Select the "Create startup archive" option and confirm with "OK".
The "Create startup archive" window is opened:

Figure 11-1 Creating a commissioning archive

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Easy Archive
11.3 This is how you create a commissioning archive

4. Choose whether the data classes should be "ignored" or "considered" using the
<SELECT> key:
– Select "ignored" to archive all data belonging to the control component.
– Select "considered" to write only the data in the data classes selected under
"Selection" in the archive.
5. Select the control component(s) for the archive.
6. Make use of the option to enter a comment and the creator of the archive.
7. Press the "OK" softkey to create the archive.
The "Create archive: Select archive" window opens.
8. Select a directory or press the "New directory" softkey to create a new subdirectory.
The "New Directory" window opens.
9. Enter a name and confirm with "OK."
The directory is created below the selected folder.
The "Create archive: Name" window opens.
10.Enter a name and confirm with "OK."
An archive file is created in the selected directory.

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 Easy Archive
11.4 This is how you import a commissioning archive

11.4 This is how you import a commissioning archive

Precondition
The access level "User" is necessary for reading in an archive.

Reading-in a commissioning archive

Procedure:
1. Select the "Startup" operating area.
2. Press the menu forward key and then the "Startup archive" softkey.
The "Startup" window is opened.
3. Select the "Read in startup archive" option and confirm with "OK".
The "Select startup archive" window is opened.
4. Select the archive and confirm with "OK".
5. To read in the archive, acknowledge the confirmation prompt with "OK".
The "Read In Archive" window opens and a progress message box appears for the read-
in process.
6. Press the "Cancel" softkey to cancel the read-in process.

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Easy Archive
11.5 This is how you back up just the machine data that have changed

11.5 This is how you back up just the machine data that have changed

Requirement
The access level "Service" is required.

Delta backup only for machine data that has changed

Using the general MD11210 $MN_UPLOAD_MD_CHANGES_ONLY, you can set whether all
machine data should be backed up in the archive, or only the machine data that differs from
the default setting:
See also: MD11210 $MN_UPLOAD_MD_CHANGES_ONLY

MD11210 $MN_UPLOAD_MD_CHANGES_ONLY
Backing up just machine data that has changed
= FFH (default setting)
Bit 0
...

Bit 7

Note
Effect of MD11210
MD11210 $MN_UPLOAD_MD_CHANGES_ONLY is only effective for type *.arc archives.

Generating an archive
Procedure:
1. Insert the storage medium (CompactFlash card or USB FlashDrive) in the appropriate slot
at the front of the control.
2. To generate a type *.arc archive press the keys <Ctrl> + <Alt> + C.
Result:
An archive is generated on the storage medium:
The archive name has the following structure: CompleteArchive_Date_Time.arc
Example:
CompleteArchive2010-08-11_08-36-15.arc stands for an archive generated on 11.08.2010 at
8:36:15.

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 Easy Archive
11.6 Example: Data archiving "Easy Archive" (use case)

11.6 Example: Data archiving "Easy Archive" (use case)

Easy Archive
With "Easy Archive", the SINUMERIK 828D has a fundamentally new procedure for data
archiving. This procedure is tailored exactly to the needs of series machine manufacture.
"Easy Archive" is based on a strict separation between SINUMERIK system software,
customized OEM data (machine data, manufacturer cycles) and operator data (part
programs, tool offsets). There is a further separation for customized data; for data that is the
same for all machines of that type, and for data that has been adjusted for an individual
machine.
This will be clarified with an example:

User example
A machine manufacturer builds a vertical machining center in series. The customized data is
created on a prototype machine. This prototype machine's customized data set will later be
ported to all series machines (cloned). After porting the data, however, individual settings are
made on each individual machine.

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For example, reference cams and ball bearing spindles are measured and entered as
individual customized data. If an error occurs at the end user, the error is reproduced and
solved on the prototype machine. If a complete archive from the prototype machine is now
transferred to the affected machine, the individual customized data of this machine is
overwritten by the individual customized data of the prototype machine.
For the SINUMERIK 828D, the machine manufacturer's customized data, to which no
individual change has been made, may be archived separately. If this archive is transferred
to the affected machine, it is ensured that the individual customized data and the end user
data are retained. So the machine manufacturer's update process is simplified considerably.

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Easy Archive
11.6 Example: Data archiving "Easy Archive" (use case)

Advantages
The advantage of the "Easy Archive" is that archive creation occurs directly at the
SINUMERIK 828D user interface. So no separate PC is needed for the archive.
By separating the system data from the customized and user data, the SINUMERIK 828D
system updates can be completely carried out by the OEMs, without changes to the
customized data. A system update can be carried out by the end user themselves in a short
time.

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 Easy Archive
11.7 Parameterizing the serial interface

11.7 Parameterizing the serial interface

Data exchange
Data exchange via the serial interface is possible from the following operating areas:
● "Program manager" operating area
● "Start-up" operating area → "System data" softkey
Press the following softkeys to set the interface parameters:

Note
If the interface is already assigned, e.g. because a modem is connected, data exchange via
the serial interface is not possible and a message is output.

Description of parameters

Figure 11-3 Setting parameters

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Easy Archive
11.7 Parameterizing the serial interface

Parameter Permissible values

Protocol: RTS/CTS (default setting)
Xon/Xoff
Transmission: normal
backed up (default setting)
Baud rate: 19200 (default setting)
300 ... 19200 max.
Archive format: Punched tape
Binary format (PC format) → only with RTS/CTS protocol

Interface: COM1
Parity: None (default setting)
Even
Odd
Stop bits: 1 (default setting)
2
Data bits: 5 bits
6 bits
7 bits
8 bits (default setting)
Xon (only for setting Xon/Xoff) 11
Xoff (only for setting Xon/Xoff) 13
End of transmission (hex) 1a
Time monitoring (sec) 4

Deactivating V24
The following machine data should be set to deactivate the interface for data exchange:
● MD51233 $MNS_ENABLE_GSM_MODEM = 0 (Voreinstellung)
The V24 interface is enabled for data transfer.
● MD51233 $MNS_ENABLE_GSM_MODEM = 1
The softkeys for data transfer are then no longer displayed.
The GSM modem is activated using this setting.

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Appendix A
A.1 Table: Language code in file names

Supported languages
Standard languages:

Language Abbreviation in file name

Chinese (simplified) chs
Chinese (traditional) cht
German deu
English eng
Spanish esp
French Fra
Italian Ita
Korean kor
Portuguese (Brazil) ptb

Other languages:

Language Abbreviation in file name

Czech csy
Danish dan
Finnish fin
Hungarian hun
Japanese jpn
Dutch nld
Polish plk
Rumanian rom
Russian rus
Slovak sky
Slovene slv
Swedish sve
Turkish trk

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Appendix
A.2 List of abbreviations

A.2 List of abbreviations

Abbreviation Meaning Explanation

ALM Active Line Module
ASCII American Standard Code for Information
Interchange
AUTO "Automatic" operating mode
BAG Mode group
BERO Proximity limit switch with feedback oscillator
BICO Binector Connector Interconnection technology for the drive
CEC Cross Error Compensation
CNC Computerized Numerical Control
DB Data Block in the PLC
DBB Data Block Byte in the PLC
dbSI drive based Safety Integrated Safety functions integrated in the drive
DBW Data Block Word in the PLC
DBX Data Block Bit in the PLC
DDE Dynamic Data Exchange
DDS Drive Data Set
DIN Deutsche Industrie Norm
DO Drive object
DRAM Dynamic Random Access Memory Dynamic memory block
DRF Differential Resolver Function Differential resolver function (handwheel)
DRY DRY run DRY run feedrate
EDS Encoder Data Set
ESR Extended Stop and Retract
FIFO First In - First Out Method of storing and retrieving data in a memory
GUD Global User Data
HD Hard Disk
HSC High-Speed Cutting
HW Hardware
IGBT Insulated Gate Bipolar Transistor
IME Input Method Editor Entering Asian characters
INC Increment
INI Initializing Data
IPO Interpolator
IRT Isochronous Real Time Isochronous communication
ISO International Standardization Organization
JOG "Jogging" operating mode Jogging via the direction keys
LEC Leadscrew Error Compensation
LED Light Emitting Diode
LUD Local User Data

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 Appendix
A.2 List of abbreviations

MAIN Main program Main program (OB1, PLC)

MB Megabyte
MCP Machine Control Panel
MCS Machine Coordinate System
MD Machine data
MDA "Manual Data Automatic" operating mode Manual input
MDS Motor Data Set
MLFB Machine-Readable Product Code
MPF Main Program File Main program (NC part program)
MPI Multi Point Interface
NCK Numerical Control Kernel
NCU Numerical Control Unit NCK hardware unit
OEM Original Equipment Manufacturer
OPI Operator Panel Interface
PCU Programmable Control Unit
PG Programming device
PI Program Instance
PLC Programmable Logic Control
POU Program organization unit in the PLC user program
PPU Panel Processing Unit Panel-based control
PZD Process data for drives
QEC Quadrant Error Compensation
REF POINT "Reference point approach" in JOG mode
REPOS "Repositioning" in JOG mode
RPA R-Parameter Active Memory area on the NCK for R parameter
numbers
RTC Real Time Clock
SBL Single Block
SBR Subroutine Subroutine (PLC)
SD Setting Data
SDB System Data Block
SEA Setting Data Active Identifier (file type) for setting data
SK Softkey
SLM Smart Line Module
SPF Subprogram file Subprogram (NC)
SRAM Static Random Access Memory Static memory block
SW Software
TEA Testing Data Aktive Identifier for machine data
TM Tool Management
TMMG Tool Magazine Management
TO Tool Offset
TOA Tool Offset Active Identifier (file type) for tool offsets
VPM Voltage Protection Module

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Appendix
A.2 List of abbreviations

VSM Voltage Sensing Module

WCS Workpiece Coordinate System
WO Work Offset
ZOA Zero Offset Active Identifier (file type) for work offset data

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 Appendix
A.3 Documentation overview SINUMERIK 828D

A.3 Documentation overview SINUMERIK 828D

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Appendix
A.3 Documentation overview SINUMERIK 828D

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Glossary

Active Line Module (ALM)

A controlled, self-commutating infeed/feedback unit (with IGBTs in infeed/feedback direction)
which supplies a DC-link voltage for the → Motor Modules.

Basic infeed
Overall functionality of an infeed with → Basic Line Module, including the additional
components required (filters, switching devices, etc.).

Basic Line Module

Unregulated line infeed unit (diode bridge or thyristor bridge, without feedback) for rectifying
the line voltage of the → DC link.

Certificate of License (CoL)

The CoL is the proof of the → license. The product may only be used by the holder of the
→ license or authorized persons. The CoL includes the following data relevant for the license
management:
● Product name
● → License number
● Delivery note number
● → Hardware serial number

CompactFlash card
As the carrier of all non-volatile data in a SINUMERIK solution line control system, the
CompactFlash card represents the identity of this control system. The CompactFlash card is
a memory card that can be plugged into the → control unit from outside. The CompactFlash
card also contains the following data relevant for the license management:
● → Hardware serial number
● License information including the → license key

Control Unit
Central open and closed-loop control module. The following Control Units are available:
● SIMOTION Control Units, e.g. D425 and D435
● SINAMICS Control Units, e.g. CU320
● SINUMERIK solution line Control Units, e.g. NCU, PPU

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Glossary

Double Motor Module (DMM)

Two motors can be connected to and operated with a Double Motor Module. See → Motor
Module.

Drive
The drive includes the (electric or hydraulic) motor, the actuator (converter, valve), the
control unit, the measuring system and the supply components (line infeed module, pressure
accumulator). For electric drives, a distinction is made between a converter system and an
inverter system. With a converter system (e.g. → MICROMASTER 4), the line infeed, the
actuator, and the control component form a single device from the point of view of the user.
With an inverter system (e.g. → SINAMICS S), the supply is ensured by means of → Line
Modules, thereby realizing a DC link to which the → Inverters (→ Motor Modules) are
connected. The (→ Control Unit) is implemented as a separate device and connected to the
other components by means of → DRIVE-CLiQ.

Drive component
Hardware component connected to a → Control Unit via → DRIVE-CLiQ or in some other
way. Drive components include: → Motor Modules, → Line Modules, → Motors, → Sensor
Modules and → Terminal Modules. The overall arrangement of a Control Unit including the
connected drive components is known as the → Drive unit.

Drive line-up
A drive line-up comprises a → Control Unit as well as the → Motor Modules and → Line
Modules connected via → DRIVE-CLiQ.

Drive object (DO)

A drive object is a self-contained software function with its own → Parameters and, if
necessary, its own → Faults and → Alarms. Drive objects may exist by default (e.g. onboard
I/O), can be created individually (e.g. → Terminal Board 30, TB30) or also as multiples (e.g.
→ Servo control). As a rule, each drive object has its own window for parameterization and
diagnostic purposes.

Drive parameters
Parameters of a drive axis that include, for example, the parameters of the corresponding
controllers, as well as the motor and encoder data. The parameters of the higher-level
technology functions (positioning, ramp-function generator), however, are called →
Application parameters.

Drive system
A drive system includes all components of a family of products (e.g. SINAMICS) belonging to
a drive. A drive system includes components such as → Line Modules, → Motor Modules,
→ Encoders, → Motors, → Terminal Modules and → Sensor Modules, as well as
complementary components such as reactors, filters, lines, etc.

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 Glossary

Drive unit
The drive unit includes all components, which are connected via → DRIVE-CLiQ and
required for carrying out a drive task: → Motor Module → Control Unit → Line Module and the
required → Firmware and → Motors, but not complementary components (such as filters and
reactors). Several → Drives can be implemented in one drive unit. See → Drive system

DRIVE-CLiQ
Abbreviation for "Drive Component Link with IQ".
Communication system for connecting the various components of a SINAMICS drive system,
such as the → Control Unit, → Line Modules, → Motor Modules, → Motors and speed/position
encoders.
DRIVE-CLiQ is based on Industrial Ethernet using twisted-pair lines. The DRIVE-CLiQ line
provides the send and receive signals, as well as the +24 V power supply.

Encoder
Records and makes positions available for electronic processing. Depending on their
mechanical design, encoders can be incorporated in the → Motor (→ Motor encoder) or
mounted on the external mechanics (→ External encoder). Depending on the type of motion,
a distinction is made between rotary encoders (also called shaft encoders) and translatory
encoders (e.g. → Linear encoder). In terms of measured value provision, we distinguish
between → Absolute encoders (code sensors) and → Incremental encoders. See →
Incremental encoder TTL/HTL → Incremental encoder sin/cos 1 Vpp → Resolver.

External encoder
Position encoder that is not built in or mounted on the → Motor, but is attached outside to the
working machine or via a mechanical intermediate element. The external encoder (externally
mounted encoder) is used for direct position detection.

Hardware
In the context of license management of SINUMERIK → software products, hardware refers
to the component of a SINUMERIK control system to which → licenses are assigned on the
basis of its unique identifier. The license information is also saved to non-volatile memory on
this component, e.g. on a → CompactFlash card.

Hardware serial number

The hardware serial number is a permanent part of the → CompactFlash card. It is used to
identify a control system uniquely. The hardware serial number can be determined by:
● → Certificate of License
● User interface
● Label on the CompactFlash card

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Glossary

Individual (I) data class

This data class covers data concerning a particular machine and is also created during
commissioning by the OEM, or later by the dealer. This data class will be referred to as "I" in
the rest of this document.

Infeed
Input component of a converter system for generating a DC-link voltage for feeding one or
several → Motor Modules, including all components required, such as → Line Modules, fuses,
reactors, line filters and firmware, as well as proportional computing power (if required) in a
→ Control Unit.

License
A license gives the user the legal right to use a → software product. Evidence of this right is
provided by the following:
● → Certificate of License (CoL)
● → License key

License key
The License Key is the "technical representative" of the sum of all the → licenses that are
assigned to one particular piece of → hardware, which is uniquely marked by its → hardware
serial number.

License number
The license number is the feature of a → license used for its unique identification.

Line Module
A Line Module is a power component which creates the DC-link voltage for one or several →
Motor Modules from a three-phase mains voltage. The following three Line Module types are
used for SINAMICS: → Basic Line Module, → Smart Line Module and → Active Line Module.
The overall function of an infeed, including the required additional components such as →
Line reactor, proportional computing power in a → Control Unit, switching devices, etc. is
called → Basic infeed, → Smart infeed, and → Active infeed.

Manufacturer (M) data class

This data class covers all data defined by the machine manufacturer (OEM) when a machine
in a model series is commissioned for the first time. For the rest of this document it will be
referred to as "M".

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 Glossary

Motor
For the electric motors that can be driven by → SINAMICS, a basic distinction is made
between rotary and linear motors with regard to their direction of motion, and between
synchronous and induction motors with regard to their electromagnetic operating principle.
For SINAMICS, the motors are connected to a → Motor Module. See → Synchronous motor
→ Induction motor → Motor encoder → External encoder.

Motor encoder
An → Encoder integrated in the motor or attached to the motor, e.g. → Resolver, →
Incremental encoder TTL/HTL or → Incremental encoder sin/cos 1 Vpp. The encoder is used
for detecting the motor speed. In the case of synchronous motors, also for detection of the
rotor position angle (the commutation angle for the motor currents). For drives without an
additional → Direct position measuring system, it is also used as a → Position encoder for
position control. In addition to the motor encoders, there are → External encoders for →
Direct position sensing.

Motor Module
A Motor Module is a power unit (DC-AC inverter) that provides the power supply for the
motor(s) connected to it. Power is supplied via the → DC link of the → Drive unit. A Motor
Module must be connected to a → Control Unit via → DRIVE-CLiQ. The open-loop and
closed-loop control functions of the Motor Module are stored in the Control Unit. There are
Single Motor Modules and → Double Motor Modules.

Option
One option is a SINUMERIK → software product that is not contained in the basic version
and which requires the purchase of a → license for its use.

Parameter
Variable quantity within the drive system that the user can read and, in some cases, write.
For → SINAMICS, a parameter meets all specifications defined for drive parameters in the →
PROFIdrive profile. See → Display parameter → Adjustable parameter

Product
A product is marked by the data below within the license management of SINUMERIK
→ software products:
● Product designation
● Order number
● → License number

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Glossary

Sensor Module
Hardware module for evaluating speed/position encoder signals and providing detected
actual values as numerical values at a → DRIVE-CLiQ socket. There are three mechanical
variants of Sensor Modules:
● SMCxx = Sensor Module Cabinet-Mounted = Sensor Module for the snap-on mounting in
the control cabinet.
● SME = Sensor Module Externally Mounted = Sensor Module with high degree of
protection for mounting outside the control cabinet.

Servo control
This type of closed-loop control enables operation with a high dynamic response and
precision for → Motors with → Motor encoders. In addition to speed control, position control
can be included.

Servo drive
An electric servo drive consists of a motor, a → Motor Module and a → Servo control and, in
most cases, a speed and position encoder. Electric servo drives generally work very
precisely and with a high dynamic response. They are designed for cycle times of up to 100
ms. In many cases, they have a very short-time overload capacity, thus allowing particularly
fast acceleration. Servo drives are available as rotary and as linear drives.

Smart Line Module (SLM)

Unregulated line infeed/feedback unit with a diode bridge for feeding; stall-protected, line-
commutated feedback via IGBTs. The Smart Line Module provides the DC-link voltage for
the → Motor Modules.

Software product
The term software product is generally used to describe a product that is installed on a piece
of → hardware to process data. Within the license management of SINUMERIK software
products, a corresponding → license is required to use each software product.

System (S) data class

This data class covers data in the Siemens and System directories on the CompactFlash
Card. For the rest of this document it will be referred to as "S".

User (U) data class

This data class covers all user data as well as data that is created during the machine
runtime, for example the maintenance interval timer. This data class will be referred to as "U"
in the rest of this document.

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 Glossary

User views
User views are user-specific groups of machine data. They are used to call all relevant
machine data in a certain operating state from various areas for processing.
The user views are stored on the CompactFlash card with the following path:
user/sinumerik/hmi/template/user_views

The following user views are already available as template:

● Electrical_Startup
● Mechanical_Startup
● Optimizing_Axis

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Glossary

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Index

Activating a GSM modem, 400

Actual data table, 228
Addressing
$ DO, 285
GUD, 284
$MC_CUTTING_EDGE_DEFAULT (MD20270), 328 MD, 283
$MC_TOOL_CHANGE_ERROR_MODE NC variables, 283
(MD22562), 310, 328, 355, 356 NX, 285
$MC_TOOL_CHANGE_MCODE (MD22560), 328 Parameter, 282
$MC_TOOL_CHANGE_MODE (MD22550), 309, 328 Setting data, 283
$MC_TOOL_MANAGEMENT_MASK (MD20310), 329 Adjacent location, 310
$MC_TOOL_MANAGEMENT_TOOLHOLDER Advanced Surface, 91
(MD20124), 328 Alarms
$MCS_TM_FUNCTION_MASK (MD52270), 330 Configuring variables, 57
$MN_M_NO_FCT_CYCLE_NAME (MD10716), 328 Filter events, 59
$MN_MAXNUM_REPLACEMENT_TOOLS Language code, 401
(MD17500), 328 Log, 59
$MN_PLC_DEACT_IMAGE_LADDR_IN (MD12986), 81 Structure, 56
$MN_PLC_DEACT_IMAGE_LADDR_OUT Archive
(MD12987), 81 Memory area, 392
$MN_T_NO_FCT_CYCLE_NAME (MD10717), 331
$MN_UPLOAD_MD_CHANGES_ONLY
(MD11210), 396 B
$MN_USER_DATA_INT (MD14510), 243, 269
$MN_USER_DATA_PLC_ALARM (MD14516), 57 Buffer, 308
$MNS_ACCESS_RESET_SERV_PLANNER
(MD51235), 238
$SNS_TM_FUNCTION_MASK_SET (SD54215), 332 C
Certificate of License (CoL), 53
Chain magazine, 309
1 Circular magazine, 309
1:1 Change, 377 Circularity test
Carry out measurement, 208
Examples of the position setpoint filter, 209
A Optimization example 1, 210
Optimization example 2, 211
Access levels, 41 Optimization example 3, 212
Access MyMachine /P2P, 13 Save graphic, 213
Acknowledgment Save parameters, 213
Access level, 238 Setting parameters, 208
Maintenance task, 229, 238 Commissioning archive, 390
Process, 337 Create, 393
Rules, 349 Read-in, 395
Status, 339 CompactFlash card, 53
Synchronous, 338 Company network, 21
TM, 315 Configuring the measuring system, 136
Acknowledgment block, 231 CYCLE832, 89
Acknowledgment step, 347
Acknowledgment-step table, 327

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Index

D H
Data area, 390 Hardware serial number, 54
Service Planner, 227 High Speed Cutting (HSC), 89
Data backup, 390
Data classes, 34
Data set I
Adding, 154
I/O module DIP switch, 83
Drive (DDS), 153
Infeed, 124
Encoder (EDS), 153
Initial data table, 227
Modify, 163
Input Method Editor (IME), 45
Motor (MDS), 153
Intermediate acknowledgment, 338, 339
Removing, 160
IP address, 83
DB1800, 229, 230
ISO Dialect, 88
DB9903, 227
DB9904, 228
Definition files, 36
J
Dictionary
Editing, 46 Job status, 325
Importing, 46
Direct connection, 26
Drive L
Circuitry, 174
Language code, 401
Configuration, 118
License, 50, 54
Parameter, 143
License key, 50, 54
DRIVE-CLiQ, 118
License number, 54
Wiring rules, 166
Loading magazine, 308

E M
Easy Archive, 397
Machine data, 85
Easy Extend, 239
Effectiveness, 87
Options bits, 243
Unit, 86
EE_IFC (DB9905), 241
Macros, 36
End acknowledgment, 338, 339
Magazine, 307, 344
Ethernet interface, 21
Configuration, 368
Example
Magazine list, 308
Change manual tool (1), 356
Maintenance interval, 238
Change manual tool (2), 357
Manual tools, 310
Milling machine, 371
MD10715[0]
Milling part program, 372
M_NO_FCT_CYCLE, 328
Turning machine, 360
MD10716[0]
Turning part program, 361
M_NO_FCT_CYCLE_NAME, 328
MD10717
$MN_T_NO_FCT_CYCLE_NAME, 331
F
MD11210
Feedback signal, 316 $MN_UPLOAD_MD_CHANGES_ONLY, 396
MD12986
PLC_DEACT_IMAGE_LADDR_IN, 81
G MD12987
PLC_DEACT_IMAGE_LADDR_OUT, 81
GUD, 36

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 Index

MD14510 PLC user alarms, 55

$MN_USER_DATA_INT[i], 243, 269 PLC user program, 306
MD14516 Aligning, 349
USER_DATA_PLC_ALARM, 57 PLC-Firmware, 307
MD17500 Probe, 176
MAXNUM_REPLACEMENT_TOOLS, 328 Process data, 142
MD20124 Programming Tool, 13
TOOL_MANAGEMENT_TOOLHOLDER, 328
MD20270
CUTTING_EDGE_DEFAULT, 328 R
MD20310 RTC capacitor, 20
TOOL_MANAGEMENT_MASK, 329
MD22550
TOOL_CHANGE_MODE, 309, 328 S
MD22560
TOOL_CHANGE_MCODE, 328 SD54215
MD22562 TM_FUNCTION_MASK_SET, 332
TOOL_CHANGE_ERROR_MODE, 310, 355, 356 Serial interface, 399
MD51235 Service Planner
ACCESS_RESET_SERV_PLANNER, 238 Configuration mode, 233
MD52270 Standard mode, 234
TM_FUNCTION_MASK, 330 Setting data, 85
Measuring in JOG Setting date/time, 44
Tool call, 335 STARTER drive/commissioning software, 14
With rotating 'spindle, 336 Strategy selection
Message frame type, 142 Interpolation, 191
Message, asynchronous, 338 String functions, 290
Motor data set direct selection, 159 System languages, 45

N T
NC command TCA, 335 TCP/IP, 21
NCK variables, 350 TMMVTL (PI service), 352
Network connection, 26 Tool change, 318, 376
End acknowledgment, 318
Tool list, 308
O Tool management, 305
Optimization objective MD20360/SD54215 dependency, 332
Maximum fault clearance, 185 Toolbox, 13
Moderate fault clearance, 185 Total acknowledgment, 339
Optimal damping, 185 Transfer step, 344
Optimization strategy, 184 Transfer-step table
Option, 50, 54 Constant, 326
Variable, 327
Trigonometric functions, 302
P
Password U
Change, 43
Set, 43 USB FlashDrive, 392
PI service, 352 User example, 397
Pin assignment User interface, 311
Digital inputs/outputs, 172 User views, 87

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Index

V POWER_OFF, 271
PRINT, 272
V24
PROPERTY, 278
Deactivate, 400
REQUEST, 279
Interface, 399
SET_ACTIVE, 257
Parameter, 399
SET_INACTIVE, 257
Variable
SOFTKEY_CANCEL, 279
Location state, 351
SOFTKEY_OK, 279
Location type, 350
START_UP, 257
T number, 351
TEST, 257
TEXT, 280
TYPE_CAST, 280
W
UID, 257
Wiring rules DRIVE-CLiQ, 166 UPDATE_CONTROLS, 281
VERSION, 257
WAITING, 272
X
X122 digital inputs/outputs, 171
X132 digital inputs/outputs, 171
XML
Identifiers, 257
Operators, 256
Special characters, 256
Statements, 287
XML identifier
?up, 273
AGM, 257
BOX, 275
CAPTION, 273
CLOSE, 273
CONTROL, 275
CONTROL_RESET, 258
DATA, 259
DATA_ACCESS, 259
DATA_LIST, 260
DEVICE, 257
DRIVE_VERSION, 261
FILE, 261
FORM, 274
FUNCTION, 263
FUNCTION_BODY, 264
IMG, 277
INCLUDE, 265
INIT, 274
LET, 266
MSGBOX, 267
NAME, 257
OP, 268
OPTION_MD, 269
PAINT, 274
PASSWORD, 270
PLC_INTERFACE, 270

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